WO2010073533A1 - R-t-b系希土類永久磁石用合金材料、r-t-b系希土類永久磁石の製造方法およびモーター - Google Patents
R-t-b系希土類永久磁石用合金材料、r-t-b系希土類永久磁石の製造方法およびモーター Download PDFInfo
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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
- H01F41/0253—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 for manufacturing permanent magnets
- H01F41/0266—Moulding; Pressing
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/05—Mixtures of metal powder with non-metallic 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
- C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
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- 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
- C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
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- 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
- C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/10—Ferrous alloys, e.g. steel alloys containing cobalt
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- 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
- C22C38/16—Ferrous alloys, e.g. steel alloys containing copper
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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
- H01F1/032—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 hard-magnetic materials
- H01F1/04—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 hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
- H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
- H01F1/0575—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together
- H01F1/0577—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together sintered
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C2202/00—Physical properties
- C22C2202/02—Magnetic
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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
- H01F41/0253—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 for manufacturing permanent magnets
- H01F41/0273—Imparting anisotropy
Definitions
- the present invention relates to an alloy material for an RTB-based rare earth permanent magnet, a method for producing an RTB-based rare earth permanent magnet, and a motor, and particularly has excellent magnetic properties and is suitably used for a motor.
- the present invention relates to an alloy material for an RTB-based rare earth permanent magnet from which an RTB-based rare earth permanent magnet can be obtained, a method for producing an RTB-based rare earth permanent magnet using the same, and a motor.
- RTB magnets have been used in various motors, etc. Internal permanent magnets with RTB magnets built into the motor are significantly more powerful than conventional motors. It is known to have high efficiency. In recent years, in addition to the improvement in heat resistance of RTB-based magnets, the demand for energy saving has increased, so the ratio of motor applications including automobiles has increased.
- the RTB-based magnet is mainly composed of Nd, Fe, and B.
- R is a part of Nd substituted with other rare earth elements such as Pr, Dy, and Tb. T is obtained by substituting a part of Fe with another transition metal such as Co or Ni.
- B is boron, and a part thereof can be substituted with C or N.
- the existing capacity ratio of the R 2 Fe 14 B phase (where R represents at least one rare earth element) as the main phase component is 87.5 to 97.5%, an RFeB-based magnet alloy having a rare earth element or rare earth element and transition metal oxide content ratio of 0.1 to 3%, wherein Zr as a main component in the metal structure of the alloy A compound selected from the group consisting of ZrB compound consisting of N and B, NbB compound consisting of Nb and B, and HfB compound consisting of Hf and B are uniformly dispersed, and the average particle size of these compounds is 5 ⁇ m or less.
- the rare earth permanent magnet alloy whose maximum space
- the material used for the R—Fe—B rare earth permanent magnet is R—Fe—Co—B—Al—Cu (where R is one or two of Nd, Pr, Dy, Tb, and Ho).
- R is one or two of Nd, Pr, Dy, Tb, and Ho.
- the above is a rare earth permanent magnet material containing 15 to 33% by mass of Nd, which is an MB compound, an MB-Cu compound, an MC compound (M is Ti, Zr, or Hf).
- a rare earth permanent magnet material in which at least two of one or two or more) and an R oxide are precipitated in the alloy structure has also been proposed (see, for example, Patent Document 2).
- the present inventors investigated the relationship between the RTB-based alloy and the magnetic properties of a rare earth permanent magnet obtained using the alloy. Then, when the rare-earth permanent magnet is manufactured by sintering the RTB-based alloy containing Dy, the present inventors and the RTB-based alloy have a temperature equal to or higher than the sintering temperature (for example, 1080). RTB) by mixing with a high melting point compound having a melting point of °C or higher) to obtain an alloy material for a permanent magnet, and molding and sintering the material to obtain an RTB rare earth permanent magnet.
- a high melting point compound having a melting point of °C or higher
- the present inventors have found that a high coercive force (Hcj) can be obtained without increasing the Dy concentration in a system alloy and that the decrease in magnetization (Br) due to the addition of Dy can be suppressed.
- This effect is obtained when an RTB-based alloy and a high melting point compound having a melting point of 1080 ° C. or higher are mixed to form an alloy material for permanent magnet, which is molded and sintered.
- the compound reacts with a trace amount of metal contained in the magnetic phase or rare earth elements constituting the grain boundary, Al, Ga, B, C, and other alloys to produce a reaction product, a part of which is the main phase particle It may be obtained by covering the surface very thinly and preventing the magnetic domain from moving and improving the coercive force.
- an RTB-based alloy having R, T, and B (wherein R is at least one selected from the group consisting of Nd, Pr, Dy, and Tb, and Dy or Tb is the R— It is essential that 4 to 10% by mass is contained in the TB system alloy, T is a transition metal in which Fe is essential, B is boron, and a part thereof can be replaced with carbon or nitrogen. ) And a high melting point compound having a melting point of 1080 ° C. or higher.
- the high melting point compound includes any one oxide, boride, carbide, nitride, or silicide selected from the group consisting of Al, Ga, Mg, Nb, Si, Ti, and Zr (1 RTB-based alloy material for rare earth permanent magnets.
- the high melting point compound is AlN, Al 2 O 3 , BN, Ga 2 O 3 , LaSi 2 , MgO, NbB 2 , NbO 2 , SiC, TiO 2 , TiB 2 , TiC, TiN, ZrO 2, ZrN. , ZrC, alloy material for R-T-B rare earth permanent magnet according to including one (1) or (2) selected from the group consisting of ZrB 2.
- a method for producing an RTB rare earth permanent magnet comprising molding and sintering the alloy material for an RTB rare earth permanent magnet according to any one of (1) to (5).
- the RTB-based rare earth permanent magnet alloy material of the present invention is an RTB-based alloy having R, T, and B (where R is selected from the group consisting of Nd, Pr, Dy, and Tb) It is essential that at least one kind of Dy or Tb is contained in the RTB-based alloy in an amount of 4 to 10% by mass, T is a transition metal in which Fe is essential, and B is boron. And a high melting point compound having a melting point of 1080 ° C. or higher, and is molded and sintered to obtain an RTB rare earth permanent.
- Hcj coercive force
- Br magnetization
- FIG. 1 is a photograph showing the results of analyzing an RTB rare earth permanent magnet of the present invention with an electron probe microanalyzer.
- FIG. 2 is a photograph showing the results of analyzing the RTB rare earth permanent magnet of the present invention with an electron probe microanalyzer.
- the alloy material for RTB-based rare earth permanent magnets of the present invention (hereinafter abbreviated as “alloy material for permanent magnets”) comprises an RTB-based alloy and a high melting point compound having a melting point of 1080 ° C. or higher. Is included.
- R is at least one selected from the group consisting of Nd, Pr, Dy, and Tb, and Dy or Tb is the R— It is essential that 4 to 10% by mass is contained in the TB system alloy, T is a transition metal in which Fe is essential, B is boron, and a part thereof can be replaced with carbon or nitrogen. .
- R is 27 to 33% by mass, preferably 30 to 32%
- B is 0.85 to 1.3% by mass, preferably 0.87 to 0.98. %
- other components such as T and inevitable impurities are the balance.
- R constituting the RTB-based alloy is less than 27% by mass, the coercive force may be insufficient, and if R exceeds 33% by mass, the magnetization may be insufficient.
- Examples of rare earth elements other than Dy contained in R of the RTB-based alloy include Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Ho, Er, Tm, Yb, Among them, Nd, Pr, and Tb are preferably used, and Nd is the main component.
- Dy contained in the RTB-based alloy is included in the RTB-based alloy in an amount of 4% by mass to 10% by mass, preferably 6% by mass to 9.5% by mass. More preferably, the content is 7 mass% to 9.5 mass%. If Dy contained in the RTB-based alloy exceeds 10% by mass, the magnetization (Br) is remarkably lowered, which is insufficient for motor use. Further, if the Dy contained in the RTB-based alloy is less than 4% by mass, the coercive force of the rare earth permanent magnet produced using this will be insufficient for motor applications.
- T contained in the R—T—B-based alloy is a transition metal in which Fe is essential, and may contain other transition metals such as Co and Ni in addition to Fe.
- Tc Trie temperature
- B constituting the RTB-based alloy is less than 0.85% by mass, the coercive force may be insufficient, and if B exceeds 1.3% by mass, the magnetization decreases, There is a risk that it will be insufficient as a motor application.
- B contained in the RTB-based alloy is boron, but a part thereof can be substituted with C or N.
- the RTB-based alloy preferably contains Al, Cu, and Ga in order to improve the coercive force. More preferably, Ga is contained in an amount of 0.03% by mass to 0.3% by mass. When Ga is contained in an amount of 0.03% by mass or more, the coercive force can be effectively improved, which is preferable. However, if the Ga content exceeds 0.3% by mass, the magnetization decreases, which is not preferable.
- the oxygen concentration of the alloy material for permanent magnets is preferably as low as possible. However, even if 0.03% by mass to 0.5% by mass, specifically 0.05% by mass to 0.2% by mass, Sufficient magnetic properties can be achieved. If the oxygen content exceeds 0.5% by mass, the magnetic properties may be significantly reduced. Further, the carbon concentration of the permanent magnet alloy material is preferably as low as possible. However, even if 0.003% by mass to 0.5% by mass, specifically 0.005% by mass to 0.2% by mass, Sufficient magnetic properties can be achieved. In addition, when carbon content exceeds 0.5 mass%, there exists a possibility that a magnetic characteristic may fall remarkably.
- the alloy material for the permanent magnet is preferably a mixture in which a powder made of an RTB-based alloy and a powder made of a high melting point compound are mixed.
- the average particle size of the powder made of the RTB-based alloy is preferably 3 to 4.5 ⁇ m.
- the particle size distribution (volume cumulative frequency) of the powder composed of the high melting point compound is preferably in the range of d10 of 0.3 to 4.4 ⁇ m, d50 of 1 to 9.5 ⁇ m, and d90 of 2.3 to 15 ⁇ m. .
- the high melting point compound those having a melting point of 1080 ° C. or higher are used, and it is preferable to use a nonmagnetic compound having a melting point of 1800 ° C. or higher.
- the high melting point compound include Group 3 to Group 5 and Group 13 oxides, borides, carbides, nitrides, silicides, solid solutions, and mixtures thereof.
- any one oxide selected from the group consisting of Al, Ga, Mg, Nb, Si, Ti, and Zr, boride, carbide, nitride, silicide, or a solid solution or a mixture thereof is preferable.
- the high melting point compound is preferably contained in the alloy material for permanent magnets in an amount of 0.002% by mass to 2% by mass, more preferably 0.05% by mass to 1.0% by mass, The content is preferably 0.1 to 0.7% by mass.
- the content of the high melting point compound is less than 0.002% by mass, the effect of improving the coercive force (Hcj) by suppressing the oversintering of the RTB-based rare earth permanent magnet cannot be obtained. There is a fear.
- the content of the high melting point compound is more than 2% by mass, the magnetic properties such as magnetization (Br) and maximum energy product (BHmax) are significantly lowered, which is not preferable.
- the alloy material for permanent magnets of the present invention can be produced by mixing an RTB-based alloy and a high-melting point compound, but comprises an RTB-based alloy powder and a high-melting point compound. It is preferably produced by a method of mixing powder.
- the powder made of the RTB-based alloy is produced, for example, by casting a molten alloy by SC (strip casting) method to produce a cast alloy flake, and the obtained cast alloy flake is disintegrated by, for example, a hydrogen crushing method. It is obtained by a method of pulverizing and pulverizing with a pulverizer.
- the cast alloy flakes are occluded at room temperature, heat-treated at a temperature of about 300 ° C., degassed by depressurization, and then heat-treated at a temperature of about 500 ° C.
- a method of removing hydrogen from the inside since the volume of the cast alloy flakes in which hydrogen is occluded expands, a large number of cracks (cracks) are easily generated inside the alloy and crushed.
- a method of pulverizing the hydrogen-crushed cast alloy flakes an average particle size of 3-4. Examples thereof include a method of pulverizing to 5 ⁇ m to obtain a powder.
- an RTB rare earth permanent magnet using the thus obtained permanent magnet alloy material for example, 0.03% by mass of stearin as a lubricant is added to the permanent magnet alloy material.
- stearin as a lubricant
- zinc acid press-molding using a transverse magnetic field molding machine (perpendicular alignment pressing ⁇ ⁇ machine), etc., sintering in vacuum at 1030 ° C to 1080 ° C, and then heat treating at 400 ° C to 800 ° C
- Examples thereof include a method of using an RTB-based rare earth permanent magnet.
- the RTB-based alloy used in the present invention is manufactured using the SC method. It is not limited to things.
- an RTB-based alloy may be cast using a centrifugal casting method, a book mold method, or the like.
- the RTB-based alloy and the high melting point compound may be mixed after the cast alloy flakes are pulverized into a powder composed of the RTB-based alloy.
- the cast alloy flakes and the high melting point compound may be mixed to obtain an alloy material for permanent magnets, and then the alloy material for permanent magnets may be pulverized.
- the high melting point compound is not limited to powder and may be the same size as the cast alloy flake. In this case, the permanent magnet alloy material composed of the cast alloy flake and the high melting point compound is pulverized in the same manner as the cast alloy flake pulverization method, and then molded and sintered in the same manner as described above.
- the mixing of the RTB-based alloy and the high melting point compound may be performed after adding a lubricant such as zinc stearate to the powder made of the RTB-based alloy.
- the high melting point compound in the alloy material for permanent magnets of the present invention may be finely and uniformly distributed, but may not be finely and uniformly distributed.
- the high melting point compound may have a particle size of 1 ⁇ m or more, or exerts an effect even if it aggregates to form an aggregate of 5 ⁇ m or more.
- the effect of improving the coercive force according to the present invention is greater as the Dy concentration is higher, and is even greater when Ga is contained.
- the RTB-based rare earth permanent magnet obtained by molding and sintering the permanent magnet alloy material of the present embodiment has a high coercive force (Hcj) and is sufficiently magnetized (Br). It is suitable as a magnet for high motors. The higher the coercive force (Hcj) of the RTB rare earth permanent magnet, the better. However, when it is used as a magnet for a motor, it is preferably 30 kOe or more. If the coercive force (Hcj) is less than 30 kOe in a motor magnet, the heat resistance of the motor may be insufficient. The higher the magnetization (Br) of the RTB rare earth permanent magnet, the better.
- the motor torque may be insufficient, which is not preferable as a magnet for the motor.
- the permanent magnet alloy material of this embodiment is an RTB-based alloy having R, T, and B (where R is at least one selected from the group consisting of Nd, Pr, Dy, and Tb).
- Dy or Tb must be contained in the RTB-based alloy in an amount of 4 to 10% by mass
- T is a transition metal in which Fe is essential
- B is boron
- a high melting point compound having a melting point of 1080 ° C. or higher and molding and sintering it into an RTB-based rare earth permanent magnet.
- a sufficiently high coercive force (Hcj) can be obtained without increasing the Dy concentration in the RTB-based alloy, and a decrease in magnetic properties such as magnetization (Br) due to the addition of Dy can be suppressed.
- the R-T-B rare earth permanent magnet can be realized that.
- RTB RTyb system rare earth permanent having a coercive force (Hcj) equivalent to that of an RTB system rare earth permanent magnet containing 9.5% by mass of Dy in the Al alloy and having no high melting point compound A magnet is obtained.
- the Dy contained in the RTB-based alloy is 9.5% by mass
- the RTB-based rare earth permanent produced from the one containing and not containing the high melting point compound is used. Comparing the magnets, the magnetization (Br) and maximum energy product (BHmax) of both are equal, but the coercive force (Hcj) of the one containing the high melting point compound is high.
- the alloy material for permanent magnets of the present embodiment is a mixture obtained by mixing a powder made of an RTB-based alloy and a powder made of a high melting point compound, it is easily used for a permanent magnet of uniform quality.
- An alloy material can be obtained, and an RTB rare earth permanent magnet with uniform quality can be easily obtained by molding and sintering the alloy material.
- the manufacturing method of the RTB system rare earth permanent magnet of the present embodiment manufactures the RTB system rare earth permanent magnet by molding and sintering the permanent magnet alloy material of the present embodiment. Since the method is used, an RTB rare earth permanent magnet having excellent magnetic properties that can be suitably used for a motor can be obtained.
- Table 3 or Table 4 shows powders composed of RTB type alloys having the component composition and average particle size shown in Table 1 (alloy A to alloy D), and powders composed of high melting point compounds having the particle sizes shown in Table 2.
- a permanent magnet alloy material was manufactured by adding and mixing at a ratio (concentration (mass%) of a high melting point compound contained in the permanent magnet alloy material).
- the powder made of the RTB-based alloy was produced by the following method. First, cast alloy flakes were produced by casting an alloy melt having the composition shown in Table 1 by the SC (strip cast) method.
- the obtained cast alloy flakes are occluded with hydrogen at room temperature, heat-treated at a temperature of about 300 ° C., depressurized to degas the hydrogen, and then heat-treated at a temperature of about 500 ° C. in the cast alloy flakes.
- the hydrogen was crushed by removing hydrogen.
- the hydrogen-crushed cast alloy flakes were finely pulverized with a jet mill using high pressure nitrogen of 0.6 MPa so as to have an average particle size shown in Table 1 to obtain powder.
- the particle size of the powder composed of the high melting point compound was measured with a laser diffractometer.
- each RTB rare earth permanent magnet obtained using a permanent magnet alloy material containing a high melting point compound or a permanent magnet alloy material not containing a high melting point compound were measured with a BH curve tracer. .
- the results are shown in Tables 3 and 4.
- “Hcj” is the coercive force
- “Br” is the magnetization
- “SR” is the squareness
- “BHmax” is the maximum energy product.
- the values of these magnetic properties are the average of the measured values of five RTB rare earth permanent magnets.
- an RTB-based rare earth permanent magnet obtained by using an alloy material for a permanent magnet containing an RTB-based alloy of alloy A and a high melting point compound includes alloy A.
- the coercive force (Hcj) is higher than that of an RTB-based rare earth permanent magnet obtained using an alloy material for a permanent magnet that does not contain a high melting point compound. This shows that the coercive force can be increased without increasing the amount of Dy added by using an alloy material for a permanent magnet containing a high melting point compound.
- an alloy material for a permanent magnet containing an RTB-based alloy of alloy A to alloy D and 0.2% by mass of TiC as a high melting point compound is provided.
- FIG. 1 and FIG. 1 and 2 are photographs showing the results of analyzing an RTB rare earth permanent magnet with an electron probe microanalyzer. 1 and 2 show detection results of various elements.
- FIG. 1 shows that Ti and B are detected at the same location, and C is not detected. From this result, it was confirmed that TiC contained in the high melting point compound was present as TiB 2 at the grain boundary.
- TiB 2 is considered to be produced by reacting TiC contained in the high melting point compound with B in the material of the RTB-based rare earth permanent magnet during sintering.
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Abstract
Description
本願は、2008年12月26日に、日本に出願された特願2008-334438号に基づき優先権を主張し、その内容をここに援用する。
R-T-B系磁石は、Nd、Fe、Bを主成分とするものである。R-T-B系磁石合金においてRは、Ndの一部をPr、Dy、Tb等の他の希土類元素で置換したものである。TはFeの一部をCo、Ni等の他の遷移金属で置換したものである。Bはホウ素であり、一部をCまたはNで置換できる。
R-T-B系希土類永久磁石の保磁力を向上させる方法としては、R-T-B系合金中のDy濃度を高くする方法が考えられる。R-T-B系合金中におけるDy濃度を高くするほど、焼結後に保磁力(Hcj)の高い希土類永久磁石が得られる。しかし、R-T-B系合金中のDy濃度を高くすると、磁化(Br)が低下してしまうという問題がある。一方、Dyの代わりにTbを使用すると、保磁力を向上させつつ磁化の低下を改善することが可能であるが、Tbが資源的な制約を有し、高価であるため、実用は難しい。
このため、従来の技術では、R-T-B系希土類永久磁石の保磁力などの磁気特性を十分に高くすることは困難であった。
また、上記のR-T-B系希土類永久磁石の製造方法により製造された優れた磁気特性を有するR-T-B系希土類永久磁石を用いたモーターを提供することを目的とする。
この効果は、R-T-B系合金と1080℃以上の融点を有する高融点化合物とを混合して永久磁石用合金材料とし、これを成形して焼結した場合、焼結中に高融点化合物が磁性相あるいは粒界を構成する希土類元素、Al、Ga、B、Cや、その他合金中に含まれる微量の金属と反応して反応生成物を生成し、その一部が主相粒子の表面を極薄く被覆し、磁区の移動が妨げられて保磁力が向上されることによって得られる可能性がある。
(1)R、T、及びBを有するR-T-B系合金(ただし、RはNd、Pr、Dy、Tbからなる群から選ばれる少なくとも1種であって、DyまたはTbを前記R-T-B系合金中に4質量%~10質量%含むことを必須とし、TはFeを必須とする遷移金属であり、Bはホウ素であって、一部が炭素又は窒素で置換可能である)と、融点1080℃以上の高融点化合物とを含むR-T-B系希土類永久磁石用合金材料。
(3)前記高融点化合物が、AlN、Al2O3、BN、Ga2O3、LaSi2、MgO、NbB2、NbO2、SiC、TiO2、TiB2、TiC、TiN、ZrO2、ZrN、ZrC、ZrB2からなる群から選ばれるいずれか1つを含む(1)または(2)に記載のR-T-B系希土類永久磁石用合金材料。
(4)前記高融点化合物が、0.002質量%~2質量%含まれている(1)~(3)のいずれかに記載のR-T-B系希土類永久磁石用合金材料。
(5)前記R-T-B系合金からなる(made of)粉末と前記高融点化合物からなる粉末とが、混合されてなる混合物である(1)~(4)のいずれかに記載のR-T-B系希土類永久磁石用合金材料。
本発明のR-T-B系希土類永久磁石用合金材料(以下、「永久磁石用合金材料」と略記する)は、R-T-B系合金と、融点1080℃以上の高融点化合物とを含むものである。
本実施形態の永久磁石用合金材料を構成するR-T-B系合金において、RはNd、Pr、Dy、Tbからなる群から選ばれる少なくとも1種であって、DyまたはTbを前記R-T-B系合金中に4質量%~10質量%含むことを必須とし、TはFeを必須とする遷移金属であり、Bはホウ素であって、一部が炭素又は窒素で置換可能である。
R-T-B系合金のRに含まれるDy以外の希土類元素としては、Sc、Y、La、Ce、Pr、Nd、Pm、Sm、Eu、Gd、Tb、Ho、Er、Tm、Yb、Luが挙げられ、中でも特に、Nd、Pr、Tbが好ましく用いられ、Ndを主成分とすることが好ましい。
R-T-B系合金に含まれるBは、ホウ素であるが、一部をCまたはNで置換できる。
Gaは0.03質量%~0.3質量%含まれていることがより好ましい。Gaを0.03質量%以上含む場合、保磁力を効果的に向上させることができ、好ましい。しかし、Gaの含有量が0.3質量%を超えると磁化が低下するため好ましくない。
また、永久磁石用合金材料の炭素濃度は低いほど好ましいが、0.003質量%~0.5質量%、具体的には0.005質量%~0.2質量%含まれていても、モーター用として十分な磁気特性を達成できる。なお、炭素の含有量が0.5質量%を超える場合、磁気特性が著しく低下するおそれがある。
R-T-B系合金からなる粉末の平均粒度は、3~4.5μmであることが好ましい。
また、高融点化合物からなる粉末の粒度分布(体積累積頻度)は、d10が0.3~4.4μm、d50が1~9.5μm、d90が2.3~15μmの範囲であることが好ましい。
R-T-B系合金からなる粉末は、例えば、SC(ストリップキャスト)法により合金溶湯を鋳造して鋳造合金薄片を製造し、得られた鋳造合金薄片を、例えば、水素解砕法などにより解砕し、粉砕機により粉砕する方法などによって得られる。
水素解砕法としては、室温で鋳造合金薄片に水素を吸蔵させ、300℃程度の温度で熱処理した後、減圧して水素を脱気し、その後、500℃程度の温度で熱処理して鋳造合金薄片中の水素を除去する方法などが挙げられる。水素解砕法において水素の吸蔵された鋳造合金薄片は、体積が膨張するので、合金内部に容易に多数のひび割れ(クラック)が発生し、解砕される。
また、水素解砕された鋳造合金薄片を粉砕する方法としては、ジェットミルなどの粉砕機により、水素解砕された鋳造合金薄片を例えば0.6MPaの高圧窒素を用いて平均粒度3~4.5μmに微粉砕して粉末とする方法などが挙げられる。
また、R-T-B系合金と高融点化合物との混合は、R-T-B系合金からなる粉末に、ステアリン酸亜鉛などの潤滑剤を添加した後に行ってもよい。
本発明の永久磁石用合金材料中の高融点化合物は、微細で均一に分布していてもよいが、微細で均一に分布していなくてもよい。例えば、高融点化合物は、1μm以上の粒度を有してもよいし、凝集して5μm以上の凝集体となっていても効果を発揮する。また、本発明による保磁力向上の効果は、Dy濃度が高いほど大きく、Gaが含まれているとさらに大きく発現する。
R-T-B系希土類永久磁石の保磁力(Hcj)は、高いほど好ましいが、モーター用の磁石として用いる場合、30kOe以上であることが好ましい。モーター用の磁石において保磁力(Hcj)が30kOe未満であると、モーターとしての耐熱性が不足する場合がある。
また、R-T-B系希土類永久磁石の磁化(Br)も高いほど好ましいが、モーター用の磁石として用いる場合、10.5kG以上であることが好ましい。R-T-B系希土類永久磁石の磁化(Br)が10.5kG未満であると、モーターのトルクが不足する恐れがあり、モーター用の磁石として好ましくない。
また、例えば、R-T-B系合金中に含まれるDyが9.5質量%である場合に、高融点化合物を含むものと含まないものとから製造されたR-T-B系希土類永久磁石を比較すると、両者の磁化(Br)や最大エネルギー積(BHmax)は同等であるのに、高融点化合物を含むものの保磁力(Hcj)は高くなる。
表1に示す成分組成および平均粒度のR-T-B系合金からなる粉末(合金A~合金D)に、表2に示す粒度の高融点化合物からなる粉末を、表3または表4に示す割合(永久磁石用合金材料中に含まれる高融点化合物の濃度(質量%))で添加して混合することにより永久磁石用合金材料を製造した。
なお、R-T-B系合金からなる粉末は、以下に示す方法により製造した。まず、SC(ストリップキャスト)法により表1に示す成分組成の合金溶湯を鋳造して鋳造合金薄片を製造した。次いで、得られた鋳造合金薄片に室温で水素を吸蔵させ、300℃程度の温度で熱処理した後、減圧して水素を脱気し、その後、500℃程度の温度で熱処理して鋳造合金薄片中の水素を除去することにより水素解砕を行なった。続いて、水素解砕された鋳造合金薄片を、ジェットミルにより、0.6MPaの高圧窒素を用いて表1に示す平均粒度となるように微粉砕して、粉末とした。
また、高融点化合物からなる粉末の粒度は、レーザ回析計によって測定した。
なお、表3および表4において「Hcj」とは保磁力であり、「Br」とは磁化であり、「SR」とは角形性であり、「BHmax」とは最大エネルギー積である。また、これらの磁気特性の値は、それぞれ5個のR-T-B系希土類永久磁石の測定値の平均である。
また、表3および表4に示されているように、合金A~合金DのR-T-B系合金と、高融点化合物として0.2質量%のTiCとを含む永久磁石用合金材料を用いて得られたR-T-B系希土類永久磁石の保持力を比較すると、Dy含有量(添加量)が多い程、保磁力の上昇幅が大きくなっていることが分かる。
[実験例2]
実験例1で用いた合金Aに、高融点化合物としてTiCからなる平均粒度d50が1.04μmの粉末を、永久磁石用合金材料中に含まれる高融点化合物の濃度で0.2質量%添加して混合することにより永久磁石用合金材料を製造した。
次に、このようにして得られた永久磁石用合金材料を用いて、実験例1と同様にしてR-T-B系希土類永久磁石を作製した。
図1および図2は、R-T-B系希土類永久磁石を電子プローブマイクロアナライザーで分析した結果を示した写真である。図1および図2には、各種元素の検出結果が示されている。図1にはTiとBが同一の箇所において検出され、Cは検出されなかったことが示されている。この結果から、高融点化合物に含まれていたTiCがTiB2として粒界に存在することが確認できた。TiB2は、高融点化合物に含まれていたTiCが、焼結中にR-T-B系希土類永久磁石の材料中のBと反応して生成したものと考えられる。
Claims (7)
- R、T、及びBを有するR-T-B系合金(ただし、RはNd、Pr、Dy、Tbからなる群から選ばれる少なくとも1種であって、DyまたはTbを前記R-T-B系合金中に4質量%~10質量%含むことを必須とし、TはFeを必須とする遷移金属であり、Bはホウ素であって、一部が炭素又は窒素で置換可能である)と、
1080℃以上の融点を有する高融点化合物とを含むR-T-B系希土類永久磁石用合金材料。 - 前記高融点化合物が、Al、Ga、Mg、Nb、Si、Ti、Zrからなる群から選ばれるいずれか1つの酸化物、ホウ化物、炭化物、窒化物、又はケイ化物を含む請求項1に記載のR-T-B系希土類永久磁石用合金材料。
- 前記高融点化合物が、AlN、Al2O3、BN、Ga2O3、LaSi2、MgO、NbB2、NbO2、SiC、TiO2、TiB2、TiC、TiN、ZrO2、ZrN、ZrC、ZrB2からなる群から選ばれるいずれか1つを含む請求項1に記載のR-T-B系希土類永久磁石用合金材料。
- 前記高融点化合物が、0.002質量%~2質量%含まれている請求項1に記載のR-T-B系希土類永久磁石用合金材料。
- 前記R-T-B系合金からなる粉末と前記高融点化合物からなる粉末とが、混合されてなる混合物である請求項1に記載のR-T-B系希土類永久磁石用合金材料。
- 請求項1~請求項5のいずれかに記載のR-T-B系希土類永久磁石用合金材料を成形して焼結するR-T-B系希土類永久磁石の製造方法。
- 請求項6に記載のR-T-B系希土類永久磁石の製造方法により製造されたR-T-B系希土類永久磁石を備えるモーター。
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WO2012002060A1 (ja) * | 2010-06-29 | 2012-01-05 | 昭和電工株式会社 | R-t-b系希土類永久磁石、モーター、自動車、発電機、風力発電装置 |
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WO2013122256A1 (ja) * | 2012-02-13 | 2013-08-22 | Tdk株式会社 | R-t-b系焼結磁石 |
WO2013122255A1 (ja) * | 2012-02-13 | 2013-08-22 | Tdk株式会社 | R-t-b系焼結磁石 |
US9514869B2 (en) | 2012-02-13 | 2016-12-06 | Tdk Corporation | R-T-B based sintered magnet |
US9773599B2 (en) | 2012-02-13 | 2017-09-26 | Tdk Corporation | R-T-B based sintered magnet |
WO2014156592A1 (ja) * | 2013-03-25 | 2014-10-02 | インターメタリックス株式会社 | 焼結磁石製造方法 |
JP6067841B2 (ja) * | 2013-03-25 | 2017-01-25 | インターメタリックス株式会社 | 焼結磁石製造方法 |
JP2015023242A (ja) * | 2013-07-23 | 2015-02-02 | Tdk株式会社 | 希土類磁石、電動機、及び電動機を備える装置 |
JP2016164958A (ja) * | 2014-09-29 | 2016-09-08 | 日立金属株式会社 | R−t−b系焼結磁石 |
CN113674943A (zh) * | 2021-07-29 | 2021-11-19 | 福建省长汀金龙稀土有限公司 | 一种钕铁硼磁体材料及其制备方法和应用 |
Also Published As
Publication number | Publication date |
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US20110260565A1 (en) | 2011-10-27 |
JPWO2010073533A1 (ja) | 2012-06-07 |
JP5439385B2 (ja) | 2014-03-12 |
DE112009003804T5 (de) | 2012-07-26 |
CN102264932B (zh) | 2013-12-04 |
DE112009003804B4 (de) | 2014-02-13 |
CN102264932A (zh) | 2011-11-30 |
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