WO2008093430A1 - 高圧縮性鉄粉、およびそれを用いた圧粉磁芯用鉄粉と圧粉磁芯 - Google Patents
高圧縮性鉄粉、およびそれを用いた圧粉磁芯用鉄粉と圧粉磁芯 Download PDFInfo
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- WO2008093430A1 WO2008093430A1 PCT/JP2007/051879 JP2007051879W WO2008093430A1 WO 2008093430 A1 WO2008093430 A1 WO 2008093430A1 JP 2007051879 W JP2007051879 W JP 2007051879W WO 2008093430 A1 WO2008093430 A1 WO 2008093430A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
- C22C33/0264—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements the maximum content of each alloying element not exceeding 5%
- C22C33/0271—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements the maximum content of each alloying element not exceeding 5% with only C, Mn, Si, P, S, As as alloying elements, e.g. carbon steel
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
- H01F1/26—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
- Y10T428/2991—Coated
Definitions
- the present invention relates to an iron powder for powder metal lug), and is particularly suitable for parts that require high magnetic properties or parts that require high density.
- Motoaki also uses iron powder for dust cores and dust cores using them.
- metal powder is mixed with lubricant powder or alloying powder as needed, and then pressed with a mold (pres sure forming).
- the molded body is sintered and further subjected to heat treatment to obtain a sintered part having a desired shape, dimensions and characteristics.
- a binder such as a resin is mixed with metal powder, and then pressed with a mold to form a compact, which may be directly used as a dust core.
- a higher-density molded body can be obtained when compression molding is performed at a constant molding pressure. Is required.
- the metal powder (iron powder) used for these applications is required to have high compressibility.
- Japanese Patent Publication No. 8-921 (or Japanese Patent Application Laid-Open No. 6-2007) has an impurity content of • C: 0.005% or less, Si: 0.010% or less, Mn: 0.050% or less, P: 0.010% or less, S: 0.010% or less, O: 0.10% or less, N: 0.0020% or less, and the balance is substantially Fe and Consisting of inevitable impurities,
- the particle size distribution is a weight percent by sieve classification, and 60 + 83 mesh (mesh) is 4% or less, 1 83no + 100 mesh is 4% or more and 10% or less, 1 100 / + 140 mesh is 10% or more and 25% or less, 330 mesh passing portion is 10% or more and 30% or less,
- the average grain size of one ⁇ no + 200 mesh is a coarse grain with a grain size number of 6.0 or less according to the ferrite grain size measurement method specified in JIS G 00 ⁇ 2.
- the particle size distribution of the iron powder is the mass percentage of the sieve using the sieve specified in JIS Z 8801, the particle size that passes through a sieve with a nominal size of 1 mm and does not pass through a sieve with a nominal size of 250 ⁇ m.
- the upper limit of the microphone mouth Vickers hardness of iron powder of a particle size that does not pass through a sieve with a nominal size of 150 ⁇ m is 110 or less ⁇
- Compressible iron powder has been proposed.
- the impurity content in mass% is C: 0.005% or less, Si: 0.01% or less, Mn: 0.05% or less, P: 0.01% or less, S: 0.01% or less, 0 : 0.10% or less, N: 0.003% or less are preferred.
- Japanese Patent Laid-Open No. 2002-275505 proposes a method for producing a soft magnetic molded body using metal powder particles made of a single crystal of a soft magnetic metal.
- a low temperature preferably 1100 to 1350 ° C. in a reducing atmosphere.
- the maximum permeability of the molded body is improved. Disclosure of the invention
- the density of the green compact obtained is up to about 7.12 g / cm 3 (7.12 Mg / m 3 ), and the compressibility is insufficient. For this reason, when used for magnetic parts such as magnetic cores, the desired magnetic properties such as magnetic flux density and magnetic permeability may not be obtained.
- the iron powder described in JP-A-2002-317204 has a large iron powder particle size, and there is a concern that the strength may be reduced when sintered, and the purity of the iron powder is high. ⁇ The cost increases. Furthermore, since the particle size distribution is very different from the iron powder used for general powder metallurgy, etc., the cost also increases in that mass production effects cannot be obtained. Furthermore, the technology described in Japanese Patent Publication No. 8-921 and Japanese Patent Application Laid-Open No. 2002-317204 is a load on the component adjustment in the refinement process as a normal iron powder that reduces Si to 0.010% by mass or less. The composition which hangs is proposed. Further, in the technique described in Japanese Patent Laid-Open No.
- the number of crystal grains in one metal powder particle is small, but in order to reduce it to 5 or less, it is non-oxidizing. It is necessary to carry out the treatment at a high heating temperature of 1000 ° C or more in the atmosphere. Further, in the technique described in Japanese Patent Application Laid-Open No. 2002-275505, it is necessary to perform treatment at a heating temperature of 1100 ° C. or higher in a reducing atmosphere in order to crystallize metal powder particles. In other words, the techniques described in Japanese Patent Application Laid-Open Nos. 2002-121601 and 2 & 02-275505 require a heating furnace in a non-oxidizing atmosphere that can be heated to a high temperature, resulting in increased production costs.
- the present invention advantageously solves the problems of the prior art, and is an iron powder having high compressibility suitable for use in parts having excellent magnetic properties and high-density sintered parts.
- the purpose is to provide iron powder that also includes low cost.
- Another object of the present invention is to provide an iron powder for a dust core and a dust core using the iron powder.
- the iron powder production process (for example, reduction conditions and re-annealing after reduction) is optimized.
- N the number of crystal grains in iron powder particles
- the gist of the present invention is as follows.
- the particles may contain inclusions containing Si in a size of 50 nm or more in a ratio of 70% or more to the total number of inclusions containing Si.
- Characteristic ⁇ compressible iron powder Characteristic ⁇ compressible iron powder.
- Figure 1 is an explanatory diagram that schematically shows the microstructure of iron powder particles.
- the highly compressible iron powder of the present invention has an iron powder particle number of 4 or less on average and a micro Vickers hardness Hv of 80 or less, preferably 75 or less on average. It is powder.
- compressibility is defined as follows. Add 0.75% by mass of zinc stearate as a lubricant to 1000 g of iron powder, and mix for 15 minutes with a V-type mixer. After that, it is molded into a cylindrical shape of l lmin ⁇ X height of 10 mm in one molding at room temperature and molding pressure: 686 MPa. The case where a molded body having a molding density of 7.24 MgZ m 3 or more is obtained by the above process is called “high compressibility”.
- the iron powder of this invention does not have a restriction
- the sieving mass% it is preferable to use 30% or less of the sieving mass% using a sieve defined in JIS Z 8801 and having a particle size that does not pass through a sieve having a nominal size (nominal opening) force S l50 zm. More preferably, it is 15% or less.
- the nominal size of the particle size that does not pass through a 180 ⁇ m sieve (+180 m) is more than 0% and less than 5%.
- a particle size that passes through a sieve with a nominal size of 75 ⁇ m and does not pass through a sieve with a nominal size of 63 m is 10% or more and 20% or less.
- the particle size configuration is as follows. This particle size composition is equivalent to that of commercially available atomized iron powder for powder metallurgy shown in Table 1 (described later).
- the number of crystals in the iron powder particles is limited to 4 or less on average. By reducing the number of crystals in the iron powder particles to 4 or less, the compressibility of the iron powder is improved. When the number of crystals in the iron powder particles exceeds 4, the compressibility of the iron powder decreases. This is due to the following reasons.
- An increase in the number of crystals in the iron powder particles means an increase in grain boundaries.
- a grain boundary is a collection field of dislocations, and thus a kind of lattice defect.
- An increase in grain boundaries leads to an increase in the hardness of iron powder particles and a decrease in iron powder compressibility. For this reason, in the present invention, the number of iron powder particles is limited to 4 or less on average.
- the “number of crystal grains of iron powder particles” in the present invention refers to the number of crystal grains in the cross section of the iron powder particles, and is a value measured and calculated as follows.
- iron powder which is the object to be measured, is mixed with thermoplastic resin powder to make a mixed powder, and then the mixed powder is charged into an appropriate mold, heated to melt the resin, and then cooled and solidified. It should be a cured resin containing iron powder.
- the iron powder-containing resin solid material is cut in an appropriate cross section, the cut surface is polished and corroded, and then the cross section of the iron powder particles is obtained using an optical microscope or a scanning electron microscope (400 times). Observe and Z or image the tissue and measure the number of crystals in the iron powder particles.
- the number of crystal grains is preferably measured using an image analysis device based on the taken tissue photograph. The average number of crystal grains is calculated by measuring as follows.
- the number of iron powder particles to be observed or imaged by the above method is 30 , the number of target iron powder particles is averaged, and the average value is the average number of iron powder particles.
- the crystal grains in iron powder particles are schematically shown in Fig. 1.
- Fig. 1 there are two types of iron powder particles: crystal grain 1 surrounded only by grain boundaries and crystal grain 2 surrounded by grain boundaries and the surface of iron powder particles.
- the number of crystal grains of iron particles is the sum of crystal grains 1 and 2, which is 6 in the example of Fig.1.
- the particles of the iron powder of the present invention have an average hardness of 80 or less in terms of microphone mouth Vickers hardness HV. If the hardness of the iron powder particles exceeds 80 in terms of micro Vickers hardness H v, the compressibility of the iron powder will decrease, and the target compressibility of the present application (Zinc stearate as the lubricant is 0.75). It is impossible to obtain a molded body having a compact density of 7.24 MSZ m 3 or more after one molding at room temperature at a molding pressure of 686 MPa. For this reason, the strength in the case of a sintered body is reduced, and the magnetic properties in the case of a dust core are reduced.
- the microphone mouth Vickers hardness Hv is preferably 75 or less.
- the chemical composition and the production conditions may be controlled based on the requirements described later.
- the hardness of the iron powder particles is the same as in the measurement of “the number of crystal grains of iron powder particles”.
- the iron powder-containing resinous solids are cut, the iron powder-containing resin solids are cut in an appropriate cross section.
- the cut surface was polished, and the particle cross section was measured using a micro Vickers hardness meter (load 25 gf (0.245N)).
- load 25 gf (0.245N) Each particle was measured at one point near the center of the cross section, the number of measured particles was 10 or more, and the average value of the measured values of each particle was used as the hardness of the iron powder particles.
- the circularity of the iron powder is preferably set to 0.7 or more.
- the iron powder having such a shape can be produced by a gas atomization method, but can also be produced by a low pressure water atomization method.
- the circularity of the iron powder can be controlled by adjusting the water pressure and cooling rate of the customization.
- the iron powder of this shape is mechanically struck with irregular iron powder obtained by powder reduction method, oxide reduction method, or normal high-pressure water atomization. It can be manufactured by the method of eliminating. However, iron powder produced by such a method is work-hardened, so it is necessary to perform strain relief annealing. From the viewpoint of productivity (including manufacturing costs), it is optimal to use the low-pressure water atomization method.
- the circularity of the iron powder is 0.9 or more.
- a gas atomization method is usually required, which is disadvantageous from the viewpoint of productivity.
- Circularity A sufficiently good compressibility can be obtained even at about 0.7 to 0.8, and can be produced by a water atomization method. Therefore, it is also preferable that the iron powder having excellent productivity has a circularity of about 0.7 to 0.8. 'Note that the "circularity" of iron powder in the present invention is expressed by the following formula (1)
- Circularity (peripheral length of equivalent circle) / (actual outer perimeter of particle) The roundness of the iron powder is calculated as follows.
- iron powder which is the object to be measured, is mixed with thermoplastic rosin powder to form a mixed powder, and then the mixed powder is charged into an appropriate mold, heated to melt the resin, and then cooled and solidified. Let it be a contained resin solid. Next, the iron powder-containing resin solid material is obtained with an appropriate cross section. After cutting and polishing the cut surface, an optical microscope or a scanning electron microscope
- the degree of circularity is calculated using the above equation (1).
- the number of particles to be measured shall be 10 or more, and the average value of the circularity of these particles shall be used as the circularity of the iron powder.
- the particle whose long side is 50 / m or more is selected as the particle for which circularity is to be obtained.
- the highly compressible iron powder of the present invention contains impurities as mass%, C: 0.005% or less, Si: more than 0.01%, 0.03% or less, Mn: 0.03% or more, 0.07% or less, P: 0.01% or less, S: 0.01 It is an iron powder having a composition that is limited to not more than%, O: not more than 0.10%, N: not more than 0.001%, and the balance Fe is an inevitable impurity.
- impurities as mass%, C: 0.005% or less, Si: more than 0.01%, 0.03% or less, Mn: 0.03% or more, 0.07% or less, P: 0.01% or less, S: 0.01
- each component will be described.
- C When C is contained in a large amount exceeding 0.005% by mass, the hardness of the iron powder increases and the compressibility of the iron powder decreases. For this reason, C was limited to 0.005 mass% or less.
- the industrially reasonable lower limit of C content is about 0.0005% by mass.
- Si is usually reduced to 0.010 mass% or less in order to reduce the hardness of the iron powder particles and ensure high compressibility.
- Si content is 0.01% by mass or less, refractory melts are liable to cause nozzle clogging at the time of atomization and increase the precision cost. Meanwhile, 0.03 mass. If the content exceeds 0 , the hardness of the iron powder increases and the compressibility of the iron powder decreases.
- Si is more than 0.01 mass% and 0.03 mass%.
- the requirements were limited to the following, and new requirements for ensuring high compressibility in the Si range were also found and defined.
- Mn 0.03 mass% or more 0.07 mass% or less
- Mn is less than 0.03 mass%, refractory melts easily cause nozzle clogging at the time of atomization and increase the cost of refining.
- the content exceeds 0.07% by mass, the iron powder hardness is increased by about 3% and the compressibility of the iron powder is lowered. For this reason, Mn was limited to 0.03 mass% or more and 0.07 mass% or less.
- N is reduced especially to N: 0.001% or less. If N is contained in an amount exceeding 0.001% by mass, the iron powder hardness increases and the iron powder compressibility decreases. Therefore, N is limited to 0.001% by mass or less.
- the reduction of N can be easily realized by performing the reduction treatment described later with a drought load or by performing re-annealing after the reduction for denitrification. Therefore, denitrification to the extent that is normally performed is sufficient at the sperm stage. (It is not forbidden to perform denitrification to the limit). Although this slightly increases manufacturing costs, the burden on productivity is lighter than reducing Si to 0.010% by mass or less in the refinement process.
- the present invention has one technical feature in that the molten metal composition obtained by scouring in the normal range can be applied.
- N is preferably 0.0010% by mass or less.
- the industrially reasonable lower limit of N content is about 0.0003 mass%.
- the above-mentioned range of the amount of impurities is the same as the content of impurities contained in general pure iron powder for powder metallurgy, except that it is low N. There is no particular problem that secondary impurities other than those mentioned above exist in a range that does not affect the properties of the iron powder. .
- the highly compressible iron powder of the present invention does not add any other alloy element to the iron powder particle body.
- alloying elements such as Ni, Cu, and Mo can be partially alloyed on the surface of the iron powder, and alloying element powders such as Ni, Cu, and Mo can be adhered to the surface of the iron powder via a binder. There is no problem.
- the iron powder of the present invention is produced especially for a dust core, the inclusions contained in the iron powder, including Si: size of 50 nm or more, are included in the total number of inclusions containing Si. The number ratio is preferably adjusted to 70% or more.
- the thickness of the magnetic wall of the iron powder particle is considered to be about 40 nm (Nakaku Yasunobu: Physics of Ferromagnetic Material (below) I Magnetic Properties and Applications I, p. 174, Jinhuabo, 1987). If the size of the inclusions is less than 50 nm, the movement of the domain wall in the iron powder particles will be hindered when a magnetic field is applied. For this reason, in the present invention, among inclusions containing Si contained in the iron powder particles, those having a small influence on the magnetic properties: those having a size of 50 nm or more are included in the number ratio with respect to the total number of inclusions containing Si. It is preferable to adjust so as to be present as many as 70% or more.
- the size of inclusions containing Si is more preferably 100 nm or more. That is, it is preferable that inclusions having a size including Si: 100 ⁇ m or more are 70% or more in terms of the number ratio with respect to the total number of inclusions containing Si.
- the method for measuring the size of inclusions containing Si is as follows.
- Ji DX Euthy Dispersive X-ray tluorescence spectroscopy
- For inclusions containing Si measure the maximum diameter (major axis) with a scanning electron microscope, etc., to determine the size of the inclusions.
- the number of inclusions containing Si to be measured was 20 pieces.
- any of the generally known iron powder production methods such as reduction method and atomization method can be applied, and there is no particular limitation.
- the molten metal is particularly preferable.
- a preferred production method will be described by taking as an example the case of producing an atomized iron powder by applying the water atomization method, but it goes without saying that the present invention is not limited thereto.
- the pressure of the high-pressure water is preferably reduced to, for example, about 60 to 80% of the conventional one.
- the reduction treatment is preferably a high load treatment in a reducing atmosphere containing hydrogen.
- a reducing atmosphere containing hydrogen For example, 700 or more 1000 ° less than C in a reducing atmosphere containing hydrogen, heat treatment preferably at a temperature of less than 800 e C than 1000 ° C, the holding time l ⁇ 7 h, to good Mashiku is. 3 to 5 h Is preferably applied in one or more stages.
- a preferable heat retention time is 800 ° C. or more and 950 ° C. or less, and a more preferable retention time is 3.5 to 5 hours.
- the flow rate of reducing gas (hydrogen) is preferably 0.5 NL / min / kg or more for iron powder.
- the dew point in the atmosphere can be selected according to the amount of C in the raw flour, and it is not necessary to specify it.
- the upper limit of the reduction treatment temperature is set because the particles of iron powder heated at a high temperature exceeding 950 ° C., particularly at a high temperature exceeding 1000 ° C., are easily bonded to each other. That is, in order to break up the powder combined at high temperature, a strong mechanical particle separation operation is required. Therefore, excessive stress is applied to the particles, and the stress remaining in the particles is hardened in reverse. As a result of this adverse effect, sufficient compressibility cannot be obtained even if the heat treatment is performed unnecessarily.
- annealing is performed in a dry hydrogen atmosphere for the purpose of further reducing nitrogen, reducing grain growth and hardness. Needless to say, re-annealing is optional if sufficient composition, number of grains and hardness are already achieved after reduction.
- processing such as crushing and classification may be included as appropriate.
- the above-described reduction treatment of soot load is effective in adjusting the inclusions including Si to a size of 50 nm or more, preferably 100 nm or more to 70% or more of the inclusions including all Si. It is.
- high load treatment allows Si to be diffused and discharged out of the iron powder particles through the grain boundary, thereby reducing the amount of Si inside the iron powder particles and reducing the amount of inclusions containing Si. At the same time, the size can be increased.
- an insulating coating is applied to the iron powder to form an insulating layer having a coating structure that covers the surface of the iron powder particles in layers. It is preferable.
- the material for the insulation coating is not particularly limited as long as it can maintain the required insulation even after the iron powder is pressed and formed into a desired shape.
- oxides such as Al, Si, Mg, Ca, Mn, Zn, Ni, Fe, Ti, V, Bi, B, Mo, W, Na, and K.
- oxides include magnetic oxides such as spinel type ferrite.
- An amorphous material typified by water glass can also be used.
- the insulating coating material examples include a phosphate chemical conversion film and a chromate chemical conversion film.
- the phosphate chemical conversion coating can also contain boric acid and Mg. .
- phosphate compounds such as aluminum phosphate, zinc phosphate, calcium phosphate and iron phosphate can be used.
- an organic resin such as an epoxy resin, a phenol resin, a silicon resin, or a polyimide resin may be used. Further, there is no problem even if a coating material containing a silicone resin and a pigment disclosed in Japanese Patent Application Laid-Open No. 2003-303711 is used as an insulating coating material.
- a surfactant or a silane force pulling agent may be added.
- the addition amount of the surfactant silane coupling agent is preferably in the range of 0.001 to 1% by mass with respect to the total amount of the insulating layer.
- the thickness of the insulating layer to be formed is preferably about 10 to about LOOOO nm. If the thickness is less than 10 nm, the insulation effect is not sufficient, and if it exceeds lOOOO nm, the density of the magnetic component decreases, and a high magnetic flux density cannot be obtained.
- any conventionally known film forming method can be suitably applied as the method for forming the insulating layer on the surface of the iron powder particles.
- the coating method examples include a fluidized bed method, a dipping method, and a spray method. In either method, since the insulating material is applied after being dissolved or dispersed in a solvent, a step of drying the solvent is necessary after the coating step or simultaneously with the coating step.
- a reaction layer may be formed between the insulating layer and the surface of the iron powder particles in order to adhere the insulating layer to the iron powder particles and prevent the insulating layer from peeling off during pressure molding.
- the reaction layer is preferably formed by chemical conversion treatment. It is possible to obtain a dust core by press-molding iron powder (insulation-coated iron powder) having an insulating layer formed on the surface of the iron powder particles by performing the above-described insulation coating treatment.
- any conventionally known method can be applied to the pressure forming method.
- a mold forming method in which pressure is formed at room temperature using a uniaxial press a warm forming method in which pressure is formed warm, a mold lubrication method in which a mold is lubricated and pressed, These include a warm mold lubrication method performed at a warm temperature, a high pressure molding method for forming at a high pressure, and a hydrostatic pressure press method.
- the iron powder Prior to pressure forming, the iron powder can be blended with a lubricant such as metal exploration or amide-based wax as necessary.
- the blending amount of the lubricant is preferably 0.5 parts by mass or less with respect to 100 parts by mass of the iron powder. This is preferable because the density of the dust core can be further increased.
- the dust core can be annealed for the purpose of removing strain as necessary.
- Preferred density of the dust core is 7. 2 ⁇ 7. 7Mg / ni 3, high magnetic flux density, in applications where ⁇ permeability is required in 7. 5 ⁇ 7. 7 Mg / m 3 is there. ⁇ Example ⁇
- the molten metal (iron) melted in an electric furnace was subjected to water atomization treatment to obtain atomized powder.
- the molten metal was normally used without any special treatment.
- the hydrotomizing process was carried out by adjusting the spraying pressure.
- the obtained water atomized iron powder was dehydrated and dried, further subjected to reduction treatment and pulverization, and was bound with water atomized pure iron powder.
- the reducing treatment conditions were changed in a reducing atmosphere (hydrogen concentration: 100%, dew point: 10 to 40 ° C) within a temperature range of 800 to 990 ° C and a holding time of 3 to 5 hours. Furthermore, it was held at 830 ° C for 2 hours in a dry hydrogen atmosphere, and was subjected to strain relief annealing that also reduced denitrification '.
- the particle size composition of the iron powder was measured by sieving using a sieve defined in JIS Z 8801. As shown in Table 1, all the pure iron powders were iron powders having a particle size composition in the normal range.
- the amount of impurities in the particles, hardness, the number of crystal grains, the number of inclusions containing Si of 50 nm or more and 100 nm or more, and the circularity of the particles were measured.
- the amount of impurities in the iron powder particles is as follows: for C, O, S and N, For Si, Mn, and P, high frequency inductively coupled plasma (ICP) emission spectrometry was used.
- ICP inductively coupled plasma
- the hardness of the iron powder particles, the number of inclusions containing Si, and the circularity of the iron powder particles were measured in the same manner as described above. The results obtained are shown in Table 2 and Table 3.
- the obtained pure iron powder (1000 g) was mixed with 0.75% by mass of zinc stearate powder and mixed for 15 minutes with a V-type mixer to obtain a mixed powder. These mixed powders were placed in a mold and molded at room temperature (about 25 ° C) at a molding pressure of 686 MPa to obtain a cylindrical ( ⁇ X lOmm) shaped compact. The density (molding density) of the obtained compact was measured by the Archimedes method, and the compressibility of each iron powder was evaluated.
- the molding density of the compacts is also shown in Table 3.
- Each of the inventive examples is a molded body having a high molding density of YJAMgZin 3 or more, and it can be seen that it is a highly compressible iron powder.
- the molding density is less than 7.
- SA MgZ m 3 and the compressibility of the iron powder is reduced.
- the iron powder shown in Tables 2 and 3 was further subjected to an insulating coating treatment by spraying to form an insulating layer made of aluminum phosphate on the surface of the iron powder particles.
- the insulating coating process was performed as follows. Orthophosphoric acid and aluminum chloride were blended so that P: A1 was in a molar ratio of 2: 1 to obtain an aqueous solution (insulating coating treatment liquid) having a total solid concentration of 5% by mass.
- the insulating coating treatment liquid was sprayed and dried to a solid content of 0.25% by mass with respect to the total amount of the iron powder and the solids of the treatment liquid to form an insulating layer.
- the obtained insulating coated iron powder was coated with a 5% by weight alcohol suspension of zinc stearate in the mold and lubricated with the mold, and then charged into the mold and placed at room temperature (about 25 ° C).
- the molding pressure was 980 MPa to form a ring-shaped molded body (outer diameter 38 mm ⁇ X inner diameter 20 mm ⁇ X height 6 mm).
- the resulting compact was annealed in air at 200 ° C x 1 h to obtain a dust core.
- the density was determined by measuring the mass and the dimensions (outer diameter, inner diameter and height) of the dust core.
- the magnetic properties to be measured are the magnetic flux density and the maximum magnetic permeability (the maximum value in terms of the ratio to the magnetic permeability in a vacuum (permeability)), and a coil is wound around the dust core for 100 turns.
- the primary side coil was wound with 20 turns on the same dust core, and the secondary side coil was measured with a DC magnetometer under the maximum applied magnetic field of 10 kA / m.
- Each of the examples of the present invention is a dust core having a high molding density, a high magnetic flux density, and a high maximum magnetic permeability.
- a dust core having excellent magnetic properties can be produced. It is understood that is possible.
- the molding density is lowered, and either or both of the magnetic flux density and the maximum magnetic permeability are lowered. (Example 3)
- Iron powder AH to AR AH to AN varied the reduction temperature, AO to AQ varied the spray water pressure, and other conditions were constant between these iron powders.
- the water pressure was AO> AP> AQ.
- particles were formed using the gas atomization method, and the subsequent processing conditions were the same as for AO.
- Iron powder AT During re-annealing after reduction treatment, mix Ni powder with an average particle size of 8 / z niNi powder and oxidized Mo powder with an average particle size of 3 ⁇ m to diffuse and adhere Ni powder and Mo powder to the surface of the iron powder. I let you. Here, the amounts of Ni and Mo were 2% by mass and 1% by mass, respectively, with respect to the total amount of these and iron powder. In the compression test, graphite powder (average particle size: 3 Am) and zinc stearate powder (average particle size: 12 ⁇ ) were mixed. However, for the purpose of excluding the effect of graphite on the forming density, the results of forming without mixing graphite are also shown.
- Ni the amount of Mo and graphite, with respect to the total amount of these and iron powder, respectively 2.0 wt% and 1.0 wt% and 0.6 wt%.
- the amount of zinc stearate powder was 0.75% by mass with respect to the mixed powder. Since iron powder AT is mainly used for machine parts, no investigation was made on the characteristics of making a dust core.
- 'Magnetic cores 31-47 The insulation coating was made of an iron phosphate coating, and the coating process was carried out to an average film thickness of 80 nm. In the coating treatment, heat treatment was performed at 400 ° C. for 60 minutes. (Insulation coating A) 'Magnetic core 48: The insulation coating was made of epoxy resin, and the coating process was performed so that the average film thickness was 90 nm. In the coating treatment, a baking treatment at 200 ° C. for 60 minutes was performed.
- Magnetic core 49 The insulation coating was made of silicone resin, and the coating was processed to an average film thickness of 70 nm. In the coating process, baking was performed at 500 ° C for 60 minutes.
- 'Magnetic core 50 Polyimide resin was used as the insulation coating, and coating treatment was carried out to an average film thickness of 80 nm. In the coating process, a baking process was performed at 400 ° C. for 60 minutes. (Insulation coating D)
- A iron phosphate (average thickness 80n m)
- B an epoxy resin (average film thickness 90 nm)
- the compressibility is further improved by optimizing the circularity.
- the compressibility circularity is excellent at a circularity of 0.9 or more, and that a sufficiently good compressibility can be obtained even at about 0.7 to 08, which can be achieved by water customization.
- the highly compressible iron powder of the present invention is an iron powder obtained from a molten metal having a purity equivalent to the content of impurities contained in a general pure iron powder for powder metallurgy. There is also the effect that there is virtually no need to worry about a rise in production costs, without the need for additional training.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Metallurgy (AREA)
- Power Engineering (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Organic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Dispersion Chemistry (AREA)
- Powder Metallurgy (AREA)
- Soft Magnetic Materials (AREA)
- Manufacture Of Metal Powder And Suspensions Thereof (AREA)
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA2667843A CA2667843C (en) | 2007-01-30 | 2007-01-30 | High compressibility iron powder, and iron powder for dust core and dust core using the same |
EP07708007A EP2108472A4 (en) | 2007-01-30 | 2007-01-30 | HIGH COMPRESSIBILITY IRON POWDER, IRON POWDER COMPRISING THE SAME FOR AN IRON POWDER CORE, AND IRON POWDER CORE |
CN200780040912XA CN101534979B (zh) | 2007-01-30 | 2007-01-30 | 高压缩性铁粉及使用该高压缩性铁粉的压粉磁芯用铁粉和压粉磁芯 |
PCT/JP2007/051879 WO2008093430A1 (ja) | 2007-01-30 | 2007-01-30 | 高圧縮性鉄粉、およびそれを用いた圧粉磁芯用鉄粉と圧粉磁芯 |
US12/443,993 US20120048063A1 (en) | 2007-01-30 | 2007-01-30 | High compressibility iron powder, and iron powder for dust core and dust core using the same |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/JP2007/051879 WO2008093430A1 (ja) | 2007-01-30 | 2007-01-30 | 高圧縮性鉄粉、およびそれを用いた圧粉磁芯用鉄粉と圧粉磁芯 |
Publications (1)
Publication Number | Publication Date |
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WO2008093430A1 true WO2008093430A1 (ja) | 2008-08-07 |
Family
ID=39673749
Family Applications (1)
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PCT/JP2007/051879 WO2008093430A1 (ja) | 2007-01-30 | 2007-01-30 | 高圧縮性鉄粉、およびそれを用いた圧粉磁芯用鉄粉と圧粉磁芯 |
Country Status (5)
Country | Link |
---|---|
US (1) | US20120048063A1 (ja) |
EP (1) | EP2108472A4 (ja) |
CN (1) | CN101534979B (ja) |
CA (1) | CA2667843C (ja) |
WO (1) | WO2008093430A1 (ja) |
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JP2010010673A (ja) * | 2008-05-30 | 2010-01-14 | Hitachi Ltd | 圧粉磁性体用軟磁性粉末およびそれを用いた圧粉磁性体 |
JP2011216745A (ja) * | 2010-03-31 | 2011-10-27 | Hitachi Powdered Metals Co Ltd | 圧粉磁心およびその製造方法 |
US20120001719A1 (en) * | 2009-12-25 | 2012-01-05 | Yasuo Oshima | Dust core and method for manufacturing the same |
JP2012138494A (ja) * | 2010-12-27 | 2012-07-19 | Tdk Corp | 圧粉コア |
US20130236349A1 (en) * | 2010-11-23 | 2013-09-12 | University Of Science And Technology Beijing | Industrial method for producing dispersion-strengthened iron-based materials at low cost and in large-scale |
WO2014097556A1 (ja) * | 2012-12-19 | 2014-06-26 | Jfeスチール株式会社 | 圧粉磁芯用鉄粉 |
JP6056862B2 (ja) * | 2013-04-19 | 2017-01-11 | Jfeスチール株式会社 | 圧粉磁芯用鉄粉および圧粉磁芯用絶縁被覆鉄粉 |
JP2019021906A (ja) * | 2017-07-06 | 2019-02-07 | パナソニックIpマネジメント株式会社 | 圧粉磁心 |
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JP6052960B2 (ja) * | 2012-01-12 | 2016-12-27 | 株式会社神戸製鋼所 | 軟磁性鉄基粉末の製造方法 |
JP5929819B2 (ja) * | 2013-04-19 | 2016-06-08 | Jfeスチール株式会社 | 圧粉磁芯用鉄粉 |
US20170018344A1 (en) * | 2014-04-02 | 2017-01-19 | Jfe Steel Corporation | Iron powder for iron powder cores and method for selecting iron powder for iron powder cores |
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WO2018131536A1 (ja) * | 2017-01-12 | 2018-07-19 | 株式会社村田製作所 | 磁性体粒子、圧粉磁心、およびコイル部品 |
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US20190013129A1 (en) * | 2017-07-06 | 2019-01-10 | Panasonic Intellectual Property Management Co., Ltd. | Dust core |
KR102528358B1 (ko) * | 2019-03-06 | 2023-05-02 | 제이에프이 스틸 가부시키가이샤 | 압분 자심용 철기 분말 및 압분 자심 |
CN113840674B (zh) | 2019-05-24 | 2023-12-01 | 杰富意钢铁株式会社 | 铁基合金烧结体和粉末冶金用铁基混合粉 |
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- 2007-01-30 US US12/443,993 patent/US20120048063A1/en not_active Abandoned
- 2007-01-30 CA CA2667843A patent/CA2667843C/en not_active Expired - Fee Related
- 2007-01-30 CN CN200780040912XA patent/CN101534979B/zh not_active Expired - Fee Related
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JP2011216745A (ja) * | 2010-03-31 | 2011-10-27 | Hitachi Powdered Metals Co Ltd | 圧粉磁心およびその製造方法 |
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JP2012138494A (ja) * | 2010-12-27 | 2012-07-19 | Tdk Corp | 圧粉コア |
JP2014118630A (ja) * | 2012-12-19 | 2014-06-30 | Jfe Steel Corp | 圧粉磁芯用鉄粉 |
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US10109406B2 (en) | 2013-04-19 | 2018-10-23 | Jfe Steel Corporation | Iron powder for dust core and insulation-coated iron powder for dust core |
JP2019021906A (ja) * | 2017-07-06 | 2019-02-07 | パナソニックIpマネジメント株式会社 | 圧粉磁心 |
JP6998552B2 (ja) | 2017-07-06 | 2022-02-04 | パナソニックIpマネジメント株式会社 | 圧粉磁心 |
Also Published As
Publication number | Publication date |
---|---|
EP2108472A4 (en) | 2011-05-18 |
CA2667843A1 (en) | 2008-08-07 |
EP2108472A1 (en) | 2009-10-14 |
CN101534979A (zh) | 2009-09-16 |
CN101534979B (zh) | 2011-03-09 |
US20120048063A1 (en) | 2012-03-01 |
CA2667843C (en) | 2012-04-10 |
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