WO2011040126A1 - 磁性材料及びそれを用いたモータ - Google Patents

磁性材料及びそれを用いたモータ Download PDF

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WO2011040126A1
WO2011040126A1 PCT/JP2010/063612 JP2010063612W WO2011040126A1 WO 2011040126 A1 WO2011040126 A1 WO 2011040126A1 JP 2010063612 W JP2010063612 W JP 2010063612W WO 2011040126 A1 WO2011040126 A1 WO 2011040126A1
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fluorine
iron
magnetic
phase
powder
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French (fr)
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又洋 小室
祐一 佐通
啓幸 鈴木
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Hitachi Ltd
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/02—Details of the magnetic circuit characterised by the magnetic material
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G49/00—Compounds of iron
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G49/00—Compounds of iron
    • C01G49/009—Compounds containing iron, with or without oxygen or hydrogen, and containing two or more other elements
    • 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
    • H01F1/0572—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 with a protective layer
    • 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
    • H01F1/059—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and Va elements, e.g. Sm2Fe17N2
    • H01F1/0596—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and Va elements, e.g. Sm2Fe17N2 of rhombic or rhombohedral Th2Zn17 structure or hexagonal Th2Ni17 structure
    • 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
    • H01F41/0293—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 diffusion of rare earth elements, e.g. Tb, Dy or Ho, into permanent magnets
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2002/00—Crystal-structural characteristics
    • C01P2002/50—Solid solutions
    • C01P2002/52—Solid solutions containing elements as dopants
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2002/00—Crystal-structural characteristics
    • C01P2002/70—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data
    • C01P2002/72—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data by d-values or two theta-values, e.g. as X-ray diagram
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2002/00—Crystal-structural characteristics
    • C01P2002/70—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data
    • C01P2002/77—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data by unit-cell parameters, atom positions or structure diagrams
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/32—Thermal properties
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/42—Magnetic properties

Definitions

  • the present invention relates to a magnetic material in which the amount of use of heavy rare earth elements is reduced, and a motor using the magnetic material.
  • Patent Documents 1 to 5 disclose rare earth sintered magnets containing conventional fluorine compounds or acid fluorine compounds.
  • Patent Document 6 discloses mixing a fine powder (1 to 20 ⁇ m) of a rare earth fluorine compound with NdFeB powder.
  • Patent Documents 7 and 8 describe an example in which Sm 2 Fe 17 is fluorinated.
  • the above-mentioned conventional invention is a reaction of a compound containing fluorine with a Nd-Fe-B based magnet material or a Sm-Fe based material, and in particular, the reaction of fluorine with Sm 2 Fe 17 to introduce a fluorine atom.
  • the effects of lattice expansion and Curie temperature rise are disclosed.
  • the Curie temperature of the disclosed SmFeF material is as low as 155 ° C., and the value of the magnetization is unknown.
  • the coercive force is increased by using a fluoride containing a heavy rare earth element.
  • the above-mentioned fluoride is not a reaction for fluorinating the main phase, and it is a heavy rare earth element that reacts or diffuses with the main phase. Since such heavy rare earth elements are expensive, the reduction of heavy rare earth elements is an issue.
  • Light rare earth elements which are less expensive than heavy rare earth elements, are elements of Sc, Y and atomic numbers 57 to 62, and some of the elements are used in magnet materials. The most mass-produced material among iron-based magnets other than oxides is the Nd 2 Fe 14 B-based material, but addition of heavy rare earth elements is essential for securing heat resistance.
  • R 2 Fe 17 (R is a earth element) -based alloy has a low Curie temperature (Tc), but a compound in which carbon or nitrogen penetrates is applied to various magnetic circuits because the Curie temperature is high.
  • Tc Curie temperature
  • the main phase volume of the magnet occupying in the volume of magnetic powder is 50%, the Curie temperature (Curie point) of the main phase is 200 ° C. or more, and the saturation magnetic flux density is 1.0 T (Tesla) or more at around 20 ° C.
  • a high-performance magnet can be provided by the coercivity being 10 kOe or more and the crystal structure of the main phase being stable up to 200 ° C., and the grain boundaries other than the main phase or the different phase of the surface stabilize or improve the magnetic characteristics. .
  • ferromagnetism two types, ferromagnetism, a ferromagnetic compound composed of one or more rare earth elements including fluorine, iron, and yttrium, and ferromagnetic iron containing fluorine, carbon, nitrogen, hydrogen or boron
  • a magnetic material which is composed of a phase and in which a fluoride or an acid fluoride is formed in part of the grain boundary or surface of the ferromagnetic phase is used.
  • interstitial elements are arranged at interstitial positions or penetration positions of Fe, and by making the arrangement have anisotropy or directionality, high crystal magnetic anisotropy and high magnetic moment Reconcile.
  • anisotropy of the antiferromagnetic coupling or the orbit of the rare earth element is utilized to make the coercive force high.
  • the residual magnetic flux density is increased by forming Fe n F m (n, m is a positive integer), which is an iron-fluorine binary compound capable of ferromagnetic coupling with the matrix phase, as a second phase other than the matrix phase. .
  • a concentration gradient of fluorine is provided in a magnetic powder or the like, iron or iron is a constituent element, and a parent phase having larger crystal magnetic anisotropy than iron-fluorine binary compound is magnetically
  • the high performance magnet can be realized by bonding to.
  • the fluorine concentration in the iron-fluorine binary alloy is 0.1 to 15 atomic percent, and the fluorine concentration in the matrix is 5 to 13 atomic percent.
  • acid-fluorine compounds containing impurities are formed, but the fluorine concentration in the iron-fluorine binary alloy is smaller than that of the matrix phase having high crystal magnetic anisotropy on average.
  • the fluorine atoms in the iron-fluorine binary alloy easily form a phase containing an impurity element such as an acid fluoride at grain boundaries etc.
  • mass production using a fluorine-containing gas, ion or solution In the process, the average fluorine concentration of each of the grain boundaries and the matrix phase grains and the iron-fluorine binary alloy phase is different.
  • the fluorine concentration at the outermost surface excluding the protective film is different from the fluorine concentration at the central portion, and the fluorine concentration at the surface is lower than that at the central portion.
  • a third element such as a transition metal element or a different intruding element is added or The addition of elements for improving the consistency of the lattice constant to improve the consistency of the element, the formation of the grain boundary phase, and the formation of the ordered phase as the nonferromagnetic heterophase.
  • the fluorine-containing ferromagnetic material uses at least one transition metal element such as iron or manganese. It is divided into two types, substitutional and interstitial, depending on the arrangement of fluorine atoms. Since the ionic radius of the fluorine atom is smaller than the ionic radius of the transition metal element, local distortion occurs because the interatomic distance is expanded and contracted by introduction of the fluorine atom in both the substitution type and the penetration type.
  • the strain accompanying the displacement of the interatomic position affects the wave function of the electron, and various physical properties such as magnetic properties, electrical properties, mechanical properties, thermodynamic properties, specific heat, and superconductivity change.
  • a magnetic material when fluorine is introduced into iron, the iron-iron atomic distance expands and contracts, and the volume per iron atom increases on average. Such volume increase affects the wave function around iron atoms, and the magnetic moment of iron increases.
  • fluorine is introduced into pure iron at the penetration position, the magnetic moment of about 5% iron is increased by the introduction of 4 atomic% of fluorine.
  • the introduction of fluorine at not only the magnetic moment but also the deformation of the lattice changes the magnetocrystalline anisotropic energy.
  • the oxygen content is reduced to make the main phase volume ratio 50% or more, and the oxy-fluorine compound It is necessary to suppress the growth of oxides and oxides to 50% or less of the total volume of magnetic powder. It is effective to use a method of fluorination after hydrogen reduction or nitriding or carbonization of magnetic powder, or reduction with hydrogen gas after fluorination. Further, fluorination at a temperature as low as possible is also necessary to suppress the decomposition of the main phase, and fluorination at 200 to 500 ° C. is desirable.
  • the Curie temperature of the main phase becomes 300 ° C. or more by setting the content to 10% or less, if possible.
  • the fluorine concentration in one particle of the main phase containing fluorine is 0.01 atomic% to 20 atomic%.
  • the volume of the iron-fluorine binary compound is made smaller than the volume of the main phase, and the iron-fluorine binary compound is formed while maintaining the coercive force. It is possible to increase the residual magnetic flux density and the Curie temperature by
  • the saturation magnetic flux density of the main phase in order to set the saturation magnetic flux density of the main phase to 1.0 T (Tesla) or more at around 20 ° C., it is necessary to suppress the growth of fluoride or acid fluoride having a small magnetization value. If the powder surface is oxidized before the fluorination treatment, it is desirable to remove the oxide as much as possible because the acid fluoride tends to grow, and if it is grown as an oxide layer on the surface, the layer thickness is 1 ⁇ m or less is desirable. Further, the introduction of fluorine expands and contracts the distance between iron and iron atoms, between iron and rare earth atoms, and between rare earth and rare earth atoms, and changes the magnetic moment of iron and rare earth elements before and after introduction.
  • the arrangement of iron-iron fluorine atoms increases magnetization by increasing the distance between iron atoms and increasing the magnetic moment of iron. Therefore, it is effective to make the amount of fluorine introduced into the main phase larger than the amount of fluorine introduced into phases other than the main phase, and to make the concentration of intruding fluorine 0.01 to 20 atomic percent in the main phase desirable.
  • To increase the magnetization of the main phase add Co to 0.1 to 20 atomic percent Fe (iron), or place fluorine with carbon, nitrogen, or hydrogen at the penetration position to achieve magnetization of 0.05 T or more An increase is obtained.
  • the concentration of fluorine to be intruded is from 0.001 atomic% to 30 atomic%. It is necessary to increase the directionality energy and reduce the amount of iron that is not magnetically coupled to the main phase, which can be the place of magnetization reversal. Iron or iron-fluorine compounds within 1 ⁇ m can be magnetically bonded to the main phase (mother phase) through grain boundaries or the third phase, but they can be separated from the main phase interface by more than 1 ⁇ m.
  • the volume of iron in which the crystal orientation relationship is not recognized be as small as possible, and 20% or less with respect to the volume of the main phase is desirable, and when it exceeds 20%, it becomes difficult to obtain a coercive force of 10 kOe.
  • it is effective to prevent oxidation, to use a crystal structure stabilizing element, and to form an Fe—F binary compound.
  • the crystal structure of the main phase is rhombohedral, hexagonal such as CaCu 5- type structure, tetragonal such as ThMn 12- type structure, orthorhombic or cubic, and plural crystal structures of these, depending on the type and composition of the constituting elements Have.
  • the fluorine atom concentration should be optimized. , Adding a third element to fix the fluorine at the penetration position, reducing the oxygen concentration, and coating the crystal grain or powder surface with a fluoride, acid fluoride, nitride, carbide or metal to suppress oxidation.
  • rhombohedral crystals hexagonal crystals, tetragonal crystals, orthorhombic crystals or cubic crystals in which a fluorine atom has penetrated by mixing nitrogen, carbon or chlorine, which is an interstitial element other than fluorine, with fluorine, It can be stabilized up to ° C.
  • a phase effective as a phase other than the main phase is iron-fluorine or iron-carbon or iron-carbon having a tetragonal or cubic crystal structure, iron containing iron nitrogen, two or more of these interstitial elements, and the phase with the main phase
  • the residual magnetic flux density is increased by 0.01 T to 0.1 T.
  • Some irons have a specific orientation relationship with the main phase to enhance ferromagnetic coupling and further increase the residual magnetic flux density.
  • the fluorides and acid fluorides that grow on grain boundaries and powder surfaces contain fluorine and oxygen at higher concentrations than the main phase, and have a cubic, hexagonal, orthorhombic, or other structure.
  • the rare earth elements of the main phase improve the magnetic properties as a plurality of types, a concentration gradient of the rare earth element appears in the main phase, and the magnetocrystalline anisotropy of a part of the main phase increases.
  • a plurality of rare earth elements are also diffused in part of the fluoride and acid fluoride. These fluorides and acid fluorides contribute to the oxidation prevention or the coercive force increase of the main phase. Further, by adding a transition metal element to the main phase, it is possible to achieve both stabilization of the crystal structure and improvement of the coercive force. In this case, part of the transition metal element diffuses into fluoride, acid fluoride, iron, and iron-fluorine compound.
  • condition (1) of the following conditions 1) to 6) (1) setting the main phase volume to 50% of the volume of magnetic powder. 2)
  • the Curie temperature (Curie point) of the main phase is 200 ° C. or higher.
  • the saturation magnetic flux density of the main phase should be 1.0 T (Tesla) or more at around 20 ° C. 4)
  • Coercivity should be 10 kOe or more.
  • the crystal structure of the main phase is stable up to 200 ° C. 6) To form another phase at grain boundaries or surfaces other than the main phase to stabilize or improve the magnetic properties.
  • Fluorine-containing magnet material satisfying, as the ferromagnetic material A ⁇ Re l (Fe q M r) m I n ⁇ + B ⁇ Fe x I y ⁇ (1)
  • Re is one or more rare earth elements including Y (yttrium), Fe is iron, M is one or more transition metal elements, I is only fluorine, or fluorine and nitrogen or fluorine and carbon or fluorine or hydrogen , Fluorine and boron
  • l, m, n, q, r, x, y are positive integers, m> n, m> l, x> y, q> r ⁇ 0.
  • At least one of Re, Fe, M and at least one of I other than fluorine represented by the formula (1) other than the ferromagnetic phase represented by the above formula is a fluoride or acid contained for diffusion or reaction It is necessary for fluoride to grow on grain boundaries or part of the surface, and the fluorine concentration of the fluoride or acid fluoride is higher than the fluorine concentration in ferromagnetism.
  • a part of fluorine atoms is disposed at the penetration position of the crystal lattice in any of the two types of ferromagnetic phases, and a part of the fluorine atoms form a fluorine compound other than the formula (1)
  • the fluorine compound contains at least one or more of Re, Fe, and M shown in (1), and the concentration gradient associated with the diffusion of these constituent elements is powder, film or calcined. Seen in the body.
  • Equation (1) A ⁇ LRe l (Fe q M r) m I n ⁇ + B ⁇ Fe x I y ⁇ (2)
  • LRe is a light rare earth element containing one or more yttrium (Y), Fe is iron, M is a transition metal element, I is only fluorine, or fluorine and nitrogen or fluorine and carbon or fluorine and hydrogen, fluorine and boron ,
  • l, m, n, q, r, x, y are positive integers, m> n, m> l, x> y, r ⁇ 0.
  • gas fluorination using gas species containing fluorine As means for fluorination, gas fluorination using gas species containing fluorine, a method using diffusion or reaction using a solution or slurry containing fluoride, a method using plasma, ion implantation, sputtering, vapor deposition, etc.
  • the main phase containing at least one of the rare earth elements containing Y has a higher concentration of fluorine disposed at the penetration position than iron, and n> y in the formulas (1) and (2). It is believed that the inclusion of the rare earth element containing Y makes it easy to trap fluorine atoms in the lattice.
  • the material system is the examples 1, 3, 6, 7, 8, 9, 13, 18, 21 of the Sm-Fe-N-F system, and the examples 2, 20, 23, 29, 30 of the Sm-Fe-F system. , 31, 32, 33, 34, 36, 37, 39, 41, Example 24 of Sm-Fe-Al-F system, Example 25, 26 of Sm-Fe-Ti-F system, Sm-Fe-Mg.
  • Example 27 in the F-F system Example 35 in the Sm-Fe-MnF system, Example 38 in the Sm-Pr-Fe-N-F system, Example 4, 40 in the Nd-Fe-F system, Nd-Fe Examples 5 and 12 of the -F-N system, Examples 10 and 11 of the Nd-Fe-BF system, and Examples 14 and 19 of the Nd-Fe-Ti-F system, Y-Fe-Al-F system
  • Example 15 Ce-Fe-C-F system Example 16 La-Fe-N-F system
  • Example 22 L -Fe-Mn-F systems are described in Example 28.
  • 100 g of ammonium fluoride powder is mixed with 100 g of Sm 2 Fe 17 N 3 magnetic powder which is less oxidizable than Sm 2 Fe 17 having a particle diameter of 1 to 10 ⁇ m.
  • the mixed powder is inserted into a reaction vessel and heated by an external heater.
  • Ammonium fluoride is thermally decomposed by heating to generate NH 3 and a fluorine-containing gas.
  • a part of N atoms in the magnetic powder is replaced with F (fluorine) at 200 to 600 ° C. by this fluorine-containing gas.
  • N At a heating temperature of 400 ° C., a part of N is replaced with F, and Sm 2 Fe 17 (N, F) 3 in which fluorine or nitrogen is disposed at an entry position in the Th 2 Zn 17 or Th 2 Ni 17 structure grows .
  • Sm 2 Fe 17 (N, F) 3 in which fluorine or nitrogen is disposed at an entry position in the Th 2 Zn 17 or Th 2 Ni 17 structure grows .
  • Ar gas is substituted for oxidation prevention.
  • F By replacing F with N, the lattice volume of the compound expands locally, and the magnetic moment of Fe increases.
  • N or F atoms are arranged at a position different from the penetration position before the reaction.
  • the magnetic powder containing such Sm 2 Fe 17 (N, F) 3 contains 0.1 atomic% to 12 atomic% of fluorine, and the main phase in the vicinity of the grain boundary in the magnetic powder and the main phase in the grain are The fluorine concentration differs by about 0.1 to 5%.
  • An oxygen-containing fluoride (SmF 3 , FeF 2 or the like) grows in part of the grain boundary or grain boundary triple point.
  • the basic magnetic properties of such a magnetic powder are a Curie temperature of 400 ° C. to 600 ° C., a saturation magnetic flux density of 1.4 to 1.9 T, and by molding the magnetic powder, a magnet with a residual magnetic flux density of 1.5 T can be created.
  • Magnetic powder whose increase in magnetic moment can be confirmed by the introduction of fluorine is, except for Sm 2 Fe 17 N 3 , Re l Fe m N n (Re is a rare earth element, l, m and n are positive integers), Re l Fe m C n (Re is a rare earth element, l, m, n is a positive integer), Re l Fe m B n (Re is a rare earth element, l, m, n is a positive integer), Re l Fe m (Re is a rare earth element , L and m are positive integers).
  • An acid fluoride containing Re grows as a result of reducing the main phase on the grain boundaries or powder surface of such magnetic powder, and the oxygen concentration in the main phase is reduced.
  • the impurities contain oxygen, carbon, hydrogen and silicon, sulfur and metal elements such as copper, nickel, manganese and cobalt, the magnetic properties do not change significantly.
  • a deposition source in a vacuum vessel to evaporate Fe.
  • the degree of vacuum is 1 ⁇ 10 -4 Torr or less, and Fe is evaporated in a container by resistance heating to produce particles with a particle diameter of 100 nm.
  • An alcohol solution containing the components of SmF 2-3 is applied to the surface of the Fe particles and dried at 200 ° C. to form a fluoride film having an average film thickness of 1 to 10 nm on the surface of the Fe particles.
  • the Fe particles coated with the fluoride film are mixed with ammonium fluoride (NH 4 F) and heated by an external heater.
  • the heating temperature is 800.degree. C., and after heating and holding at 800.degree. C. for 1 hour or more, quenching is performed at 50.degree.
  • a powder having an oxygen concentration of 100 to 2000 ppm is obtained.
  • a part of fluorine atoms is arranged by moving the atomic position of Fe to the tetrahedral or octahedral interstitial position of the unit cell of Fe.
  • nitrogen and hydrogen intrude into the Fe particles or fluoride film because ammonium fluoride is used.
  • carbon and hydrogen in the alcohol solution or oxygen atoms are also mixed into the Fe particles or the fluoride film.
  • the concentration distribution of fluorine atoms is seen from the surface of the quenched powder toward the center, and the fluorine concentration tends to be higher on the outer peripheral side of the quenched powder than the center, such as SmF 3 or SmOF at grain boundaries or part of the powder surface.
  • the compound grows.
  • the growth of the acid fluoride is a result of diffusion of oxygen in the magnetic powder before the fluorination treatment, and the oxygen concentration in the magnetic powder can be reduced.
  • the magnetic properties of the magnet obtained by compression molding or sintering this powder are a residual magnetic flux density of 1.3-1.5 T, a coercive force of 20-30 kOe, and a Curie temperature of 480 ° C. It is applicable to a magnetic circuit.
  • 100 g of an ammonium fluoride powder having an average particle diameter of 0.1 ⁇ m is mixed with 100 g of a Sm 2 Fe 17 N 3 magnetic powder having a particle diameter of 1 to 10 ⁇ m coated with 0.5 wt% of an alcohol solution in which SmF fluoride is swollen.
  • the mixed powder is inserted into a reaction vessel and heated by an external heater.
  • Ammonium fluoride is thermally decomposed by heating to generate NH 3 and a fluorine-containing gas.
  • a part of N atoms in the magnetic powder is replaced with F (fluorine) at 200 to 600 ° C. by this fluorine-containing gas.
  • N At a heating temperature of 300 ° C., part of N is replaced with F, and Sm 2 Fe 17 (N, F) 3 or Sm 2 Fe 17 (N, F) 2 grows with SmOF formation on the powder surface.
  • Sm 2 Fe 17 (N, F) 3 or Sm 2 Fe 17 (N, F) 2 grows with SmOF formation on the powder surface.
  • Ar gas is substituted for oxidation prevention.
  • F By replacing F with N, the lattice volume of the compound expands and the magnetic moment of Fe increases.
  • some N or F atoms are arranged at a position different from the penetration position before the reaction.
  • Such magnetic powder containing Sm 2 Fe 17 (N, F) 3 contains 0.5 atomic percent to 12 atomic percent of fluorine, has a Curie temperature of 400 ° C. to 600 ° C., and a saturation magnetic flux density of 1.4 to 1 It exhibits magnetic properties of 9 T, and by molding magnetic powder in an ammonium fluoride atmosphere at 400 ° C., a magnet with a residual magnetic flux density of 1.5 T can be produced.
  • Re l Fe m N n Re is a rare earth element of CaCu 5 structure and tetragonal, l, m, n are positive integers
  • Re l Co m N n Re is a rare earth element, l, m, n is a positive integer
  • Re l Mn m N n Re is a rare earth element, l, m, n is a positive integer
  • Re l Cr m N n Re is a rare earth element, l, m and n are positive integers
  • Re l Mn m O n Re is a rare earth element and l and m, n are positive integers).
  • a compound in which a part of such fluorine atoms is disposed at the entry position of the lattice can be prepared as a thin film, a thick film, a sintered body, or a foil other than magnetic powder, and grain boundaries inside these fluorine-containing ferromagnetic materials Also, even if oxygen, carbon or a metal element is contained as a growth or impurity of Re-containing acid fluoride on the surface of the magnetic powder, the magnetic characteristics do not change greatly.
  • amorphous Fe powder After hydrogen reduction of amorphous Fe powder with an average particle size of 1 ⁇ m to remove surface oxygen, it is mixed with a fluoride-swelled NdF alcohol solution with a composition close to that of NdF 3.1-3.5 , and amorphous on the surface Form a high quality NdF-based film.
  • the average film thickness after coating and drying is 10 nm.
  • This amorphous fluoride-coated Fe powder is mixed with ammonium fluoride powder, heated at 600 ° C. for 10 hours, and aged at 200 ° C., whereby fluorine and nitrogen atoms diffuse from the surface of the Fe powder, and An anisotropic lattice can be confirmed in the unit cell of the atomic arrangement of nitrogen. Some fluorine and nitrogen atoms are regularly arranged to increase the magnetic moment of Fe. In addition, a part of Nd also diffuses into the Fe powder.
  • a magnetic field is applied to such powder at a temperature of 100 ° C. or less, and a load of 1 t / cm 2 is applied to produce a temporary compact.
  • the powder of the Th 2 Zn 17 structure can be sintered by heat-molding the temporary molded body in ammonium fluoride gas. Before sintering, magnetic powder can be oriented by a magnetic field to produce an anisotropic magnet, and the magnetic properties at 20 ° C. show a residual magnetic flux density of 1.5 T and a coercive force of 25 kOe.
  • Nd 2 Fe 17 F 2 partially contacts the acid fluoride at grain boundaries or surfaces, and cubic or rhombohedral NdOF can be confirmed in the acid fluoride, and some acid fluorine compounds are ordered It was a phase. Also, the Curie temperature is 490 ° C. at a fluorine and nitrogen ratio of approximately 1: 1.
  • the amorphous shaped Fe powder After reducing the hydrogen of the amorphous shaped Fe powder having an average particle diameter of 0.1 ⁇ m to remove oxygen on the surface, it is mixed with an NdF alcohol solution to form an amorphous NdF film on the surface.
  • the average film thickness is 1-10 nm.
  • This amorphous fluoride coated Fe powder is mixed with ammonium fluoride powder, heated at 400 ° C. for 100 hours, kept at 200 ° C. for 10 hours and aged, whereby fluorine and nitrogen atoms diffuse from the surface of Fe powder.
  • Some fluorine and nitrogen atoms are regularly arranged to increase the Fe atom spacing, thereby increasing the magnetic moment of Fe.
  • a part of Fe forms an ordered phase Fe 16 F 2 phase with fluorine.
  • part of Nd also diffuses into the Fe powder, and Nd 2 Fe 17 (N, F) 3 grows.
  • a magnetic field is applied to such powder at a temperature of 100 ° C. or less, and a load of 1 t / cm 2 is applied to produce a temporary compact.
  • a load of 1 t / cm 2 is applied to produce a temporary compact.
  • thermal forming of this temporary formed body by irradiating an electromagnetic wave in ammonium fluoride gas, it is possible to sinter a powder containing a ferromagnetic phase having a Th 2 Zn 17 structure and a tetragonal crystal structure.
  • magnetic powder Before sintering, magnetic powder can be oriented by a magnetic field to produce an anisotropic magnet, and the magnetic properties at 20 ° C. show a residual magnetic flux density of 1.5 T and a coercive force of 25 kOe.
  • NdOF partially grows to reduce the oxygen concentration in the main phase.
  • the Curie temperature is 490 ° C. at a fluorine and nitrogen ratio of approximately 1: 1.
  • amorphous shaped Fe powder After reducing the surface oxygen by hydrogen reduction of amorphous shaped Fe powder having an average particle diameter of 0.1 ⁇ m, the powder is mixed with a SmF-based alcohol solution to form an amorphous SmF-based film on the surface.
  • the average film thickness is 20 nm.
  • This amorphous fluoride coated Fe powder is mixed with ammonium fluoride powder, heated at 400 ° C. for 100 hours, kept at 200 ° C. for 10 hours and aged, whereby fluorine and nitrogen atoms diffuse from the surface of Fe powder.
  • Some fluorine and nitrogen atoms are regularly arranged to increase the Fe atom spacing, thereby increasing the magnetic moment of Fe. Moreover, a part of Sm also diffuses into the Fe powder, and Sm 2 Fe 17 (N, F) 3 grows with the acid fluoride at grain boundaries or on the surface.
  • a magnetic field is applied to such powder at a temperature of 100 ° C. or less, and a load of 1 t / cm 2 is applied to produce a temporary compact.
  • the temporary formed body is impregnated with a SmF-based alcohol solution, the alcohol content is dried and removed, and heat forming is performed by irradiating an electromagnetic wave in an ammonium fluoride gas, thereby obtaining a ferromagnetic structure having a Th 2 Zn 17 structure and a tetragonal crystal structure.
  • the powder containing the phase can be sintered. Before sintering, magnetic powder can be oriented by a magnetic field to produce an anisotropic magnet, and the magnetic properties at 20 ° C.
  • a fluorine-rich phase is formed at grain boundaries, and the matrix contains fluorine and nitrogen.
  • the concentration of fluorine at grain boundaries and near the surface is higher than the concentration of fluorine at grain centers, and the lattice constant also tends to be large. This indicates that the Curie temperature of the grain boundary or surface or the magnetocrystalline anisotropy energy is higher on the outer peripheral side or on the surface than on the grain center.
  • a part of fluorine combines with oxygen to form an acid fluoride, whereby the oxygen concentration inside the Fe powder is reduced.
  • the Curie temperature is 490 ° C. when the ratio of fluorine and nitrogen is about 1: 1, and the Curie temperature tends to be higher as the concentration of fluorine in the matrix is higher.
  • This amorphous Sm fluoride coated Fe powder is mixed with ammonium fluoride powder, heated at 400 ° C. for 100 hours, kept at 200 ° C. for 10 hours and aged, whereby fluorine and nitrogen atoms are removed from the surface of the Fe powder.
  • a magnetic field is applied to such powder at a temperature of 100 ° C. or less, and a load of 1 t / cm 2 is applied to produce a temporary compact.
  • the temporary formed body is impregnated with a SmF-based alcohol solution, the alcohol content is dried and removed, and heat forming is performed by irradiating an electromagnetic wave in an ammonium fluoride gas, thereby obtaining a ferromagnetic structure having a Th 2 Zn 17 structure and a tetragonal crystal structure.
  • the powder containing the phase can be sintered.
  • An anisotropic magnet can be prepared by orienting and sintering magnetic powder with a magnetic field before sintering, and the magnetic properties at 20 ° C.
  • a fluorine rich phase and an Fe rich phase are formed, and the matrix phase contains fluorine and nitrogen.
  • crystal grains having a tetragonal structure ordered phase such as Fe 16 F 2 or Fe 16 (F, N) 2 phase or Fe 16 (F, N, C) 2 phase smaller than main phase grains grow
  • acid fluoride (SmOF) with high fluorine concentration grows.
  • a part of fluorine combines with oxygen or carbon or nitrogen to form an acid fluoride containing carbon or nitrogen.
  • the Curie temperature is 510 ° C.
  • A be the volume ratio of the main phase to the entire bulk
  • B be the phase mainly composed of Fe—F which is ferromagnetic iron.
  • the Fe-F phase contains bcc and bct structures.
  • a and B are determined by mapping of SEM-EDX (energy dispersive X-ray spectroscopy) or TEM-EDX, mapping analysis of EBSP (electron backscattering pattern), X-ray diffraction, or the like.
  • a and B can be controlled by changing parameters such as sintering conditions, fluorination conditions, and temporary forming conditions, and an example thereof is shown in FIG. 6 (1).
  • the Fe--F phase volume fraction B tends to increase as the main phase volume fraction A increases, the Fe--F phase volume fraction B becomes about 5% of the main phase volume fraction A. If the Fe-F phase volume fraction B is less than 20%, the growth of the Fe-F phase contributes to the increase of the residual magnetic flux density Br, but if the Fe-F phase volume fraction B exceeds 50%, the coercivity decreases significantly, Hard to be a magnet material. This is because the Fe-F phase becomes soft and magnetic due to the growth of the Fe-F phase, in which the Fe-F phase volume fraction B increases and the ferromagnetic coupling with the main phase is weak, and the coercivity decreases. It shows.
  • the main phase volume ratio A increases, the residual magnetic flux density Br also tends to increase.
  • the required residual flux density Br is 0.7T.
  • Magnets having a residual magnetic flux density of 0.7 T have already been mass-produced even with NdFeB-based and SmFeN-based magnets, but the mass-produced magnet has not achieved 0.7 T at a main phase volume ratio of 50%.
  • the main phase has a structure similar to the Th 2 Zn 17 structure containing fluorine as in this example
  • the main phase volume is increased as shown in FIG. 6 (2) due to the increase in residual magnetic flux density due to the magnetic moment increase effect.
  • a residual magnetic flux density of 0.75 T can be obtained at a rate of 0.5, which contributes to the reduction in size and weight of various parts and products through weight reduction and size reduction of the magnet.
  • the coercivity shows a low value when the main phase volume ratio is small, and the magnetic powder is separated in the compact, and the magnetically isolated magnetic powder or the oxidized magnetic powder is present because the coercive force is small.
  • a magnetic circuit such as a motor requires a coercive force of 10 kOe because a magnetic field in the direction opposite to the magnetization direction of the magnet is applied.
  • the main phase volume ratio A needs to be 0.5 or more.
  • a coercivity of 10 kOe and a residual magnetic flux density of 0.7 T or more are one of the indicators for production, and in order to satisfy this indicator, it is necessary to set the main phase volume ratio A to 0.5 or more.
  • the characteristics with a coercive force of 10 kOe and a residual magnetic flux density of 0.7 T or more are values necessary for magnetic circuit application also in bulk sintered magnets and thin film magnets. In order to satisfy the above values, not only sintered magnets but also thin-film magnets, bonded magnets, pressure-molded magnets, and magnets prepared by an electrochemical method from solution, the main phases rare earth elements, iron and fluorine It is necessary to make the volume fraction of ferromagnetic phase contained 0.5 or more.
  • Phases other than the main phase include the above-mentioned Fe-F phase, fluoride and acid fluoride.
  • Fe-F phase since the Fe-F phase is a ferromagnetic phase, it greatly affects the magnetic properties of the main phase, and the exchange coupling between the main phase and the Fe-F phase acts to improve the magnetic properties of the magnet.
  • the Fe-F phase increases, the magnetization of the main phase is easily reversed when a magnetic field opposite to the magnetization direction is applied to the magnet, so the Fe-F volume ratio is 0.5 (50%) It is desirable to make it less than.
  • fluoride or acid fluoride or rare earth oxide, iron oxide, iron fluoride grow on the grain boundary or powder surface, and the fluorine concentration is at the grain boundary or surface where the fluorine-containing compound is growing than the grain center. Get higher.
  • a fluorine-containing compound acts to reduce the oxygen concentration in the ferromagnetic phase, thereby enhancing the structural stability of the fluorine-containing ferromagnetic phase and increasing the coercivity.
  • High Curie temperature can be achieved without using heavy rare earth elements.
  • Sinterable by forming a fluorine rich phase at grain boundaries.
  • a bonded magnet in which magnetic powder is fixed in resin can be produced.
  • the nitrogen or fluorine atoms are partially regularly arranged in the main phase or the iron-rich phase.
  • Acid fluoride grows near grain boundaries and suppresses oxidation of the main phase.
  • the size, direction, Curie temperature and magnetic moment of the magnetic anisotropy can be controlled by the ratio (N, C, F) of atoms to the penetration position, and the anisotropic magnetic field reaches 25 MA / m.
  • the degree of order of the parent phase or the Fe rich phase changes depending on the ratio of interstitial atoms, and the magnetic properties change.
  • Various transition metals and rare earth elements can be added as the third element in order to stabilize the structure of the main phase in which fluorine is arranged at the penetration position.
  • Such a magnet can be prepared not only for materials containing Sm, Fe and F but also for all other rare earth elements including yttrium, and at least two phases grow as a ferromagnetic phase.
  • the two ferromagnetic phases are a phase containing a rare earth element containing Y having a large crystal magnetic anisotropy and a ferromagnetic iron rich in iron.
  • oxides containing iron and rare earth elements, fluorides or oxyfluorides grow, but they have magnetization smaller than that of the two types of ferromagnetic phases, and their volume is also Less than the two phases. If the example is arranged including these examples, it can be expressed as follows.
  • the ferromagnetic material is composed of a phase having at least two kinds of compositions, and the main composition of the ferromagnetic material is In correspondence with the two types of phases shown in the following equations, A ⁇ Re l (Fe q M r) m I n ⁇ + B ⁇ Fe x I y ⁇
  • the ferromagnetic phase is constituted by the formula, where A and B are respectively a phase composed of Re, Fe, I for powder, bulk sintered body or whole thin film, and a phase composed of Fe and I Volume fraction, one or more rare earth elements in which Re represents Y, Fe is iron, M is a transition metal element, I is only fluorine, or fluorine and nitrogen or fluorine and carbon or fluorine and hydrogen, fluorine and boron, A ⁇ 0.5 (50% or more of the magnetic material), A>B> 0, l, m, n, q,
  • ferromagnetic iron In such a ferromagnetic material, at least a part of ferromagnetic iron is ferromagnetically coupled to the main phase to increase the residual magnetic flux density.
  • a partial concentration of fluorine is diffused from the fluoride formed on the grain boundary or surface to the main phase, whereby a concentration gradient of fluorine is formed from the grain surface or grain boundary toward the grain center, and the lattice constant and lattice volume are also Change.
  • the lattice volume of the main phase is a lattice containing rare earth elements, iron and fluorine, it is larger than the lattice volume of body-centered cubic system or body-centered tetragonal system of fluorine-containing ferromagnetic iron.
  • the grain surface or the part containing high fluorine concentration at grain boundaries has large crystal magnetic anisotropy
  • the high fluorine concentration part and the low fluorine concentration part at the grain center part have a part of crystal lattice continuous.
  • the integrity of the grid is verified. This indicates that the lattice volume or lattice strain changes in a similar crystal structure in one crystal grain or magnetic powder, and the crystal magnetic anisotropy of the phase having a large lattice volume due to the introduction of fluorine. Higher properties lead to increased coercivity, increased residual magnetic flux density, and increased Curie temperature.
  • part of the fluorine atoms disposed at the entry position has a long-period structure in which they are regularly arranged, which further stabilizes the crystal structure and is less likely to be thermally decomposed, and the transition metal element is added to the main phase to form a Curie temperature.
  • the stability of the crystal structure is confirmed up to 800 ° C. higher than that.
  • N or F atoms are arranged at a position different from the penetration position before the reaction.
  • the magnetic powder containing such Sm 2 Fe 17 (N, F) 3 contains 0.5 atomic percent to 5 atomic percent of fluorine, and has a Curie temperature of 400 ° C. (0.5% fluorine) to 600 ° C. %, And saturation magnetic flux density of 1.4 (0.5% fluorine) to 1.7 T (5% fluorine), and the residual magnetic flux can be obtained by shaping the magnetic powder in an ammonium hydrogen fluoride atmosphere at 400 ° C. A magnet with a density of 1.6 T can be created.
  • Magnetic powder whose increase in magnetic moment can be confirmed by the introduction of fluorine is not limited to Sm 2 Fe 17 N 3 but may be Re l (Fe, Co) m N n (Re is a rare earth element, l, m and n are positive integers), Re l (Fe, Co) m N n (Re is a rare earth element, l, m, n is a positive integer), Re l (Mn, Cr) m N n (Re is a rare earth element, l, m, n is positive Integer), Re l (CrNi) m N n (Re is a rare earth element, l, m, n is a positive integer), Re l (Mn, Cr) m O n (Re is a rare earth element, l and m, n is These fluorine-containing compounds, which are positive integers), are formed together with near nonmagnetic fluorides and acid fluorides.
  • 10 g of ammonium hydrogen fluoride powder is mixed with 200 g of powder grown by mixing Sm 2 Fe 17 N 3 of 5 ⁇ m in particle diameter with 1 volume% of iron in the same powder as a main phase.
  • the mixed powder is inserted into a reaction vessel and heated by an external heater. The heating causes thermal decomposition of ammonium hydrogen fluoride to generate NH 3 and a fluorine-containing gas.
  • the oxidation phase on the surface of the magnetic powder is removed, and the oxygen concentration becomes 70 ppm.
  • a part of N atoms in the magnetic powder is replaced with F (fluorine) at 200 ° C. by a fluorine-containing gas.
  • the heating temperature is 300 ° C.
  • part of N is replaced with F, and Sm 2 Fe 17 (N, F) 3 grows.
  • an ordered phase such as Fe 16 F 2 grows in the Fe-rich phase having the bcc or bct structure.
  • the cooling rate after heating and holding is 1 ° C./min, some of the N and F atoms are regularly arranged, and Fe 16 (F, N) 2 or the like grows.
  • the surface of the magnetic powder is irradiated with fluorine ions, and the fluorine concentration at the penetration position is increased to increase the magnetic moment by about 5%.
  • the irradiation dose is 5 ⁇ 10 16 / cm 2 .
  • the position of the magnetic powder is changed to irradiate 50% or more of the surface of the magnetic powder.
  • Irradiation may be performed several times by changing the irradiation amount and the irradiation energy.
  • the concentration of fluorine after irradiation becomes maximum at a depth of 0.1 to 3 ⁇ m from the surface of the magnetic powder to the center of the magnetic powder than the outermost surface of the magnetic powder.
  • a magnetic field of 1 T may be applied to enhance anisotropy during irradiation.
  • F By replacing F with N, expansion of the c axis of the main phase and the Fe-rich phase expands the lattice volume of the tetragonal system, and the magnetic moment of Fe increases by about 10%.
  • some N or F atoms are arranged at a position different from the penetration position before the reaction.
  • the maximum value of fluorine concentration is at a depth of 1-1.3 ⁇ m from the surface, and nitrogen is higher at the surface.
  • the magnetic powder containing such Sm 2 Fe 17 (N, F) 3 contains 4 atomic percent to 9 atomic percent of fluorine, and the distribution of the lattice constant in the depth direction is as shown in FIG.
  • the lattice constant is large at a depth of more than 1 ⁇ m from the surface layer where the fluorine concentration is high, and the unit cell volume is also large.
  • This magnetic powder exhibits magnetic characteristics with a Curie temperature of 420 ° C. (4% fluorine) to 650 ° C.
  • Such an increase in lattice constant indicates that a fluorine atom is disposed at a tetrahedral or octahedral position entry position, which contributes to an increase in the magnetic moment of iron atoms.
  • magnetic particles can be confirmed an increase in the magnetic moment by the injection of gas or fluorine ions containing fluorine atom in addition to Sm 2 Fe 17 N 3, Re l Co m N n (Re is a rare earth element, l, m, n is a positive integer, Re l Mn m N n (Re is a rare earth element, l, m, n is a positive integer), Re l Cr m N n (Re is a rare earth element, l, m, n is positive (Integer), Re l Mn m O n (Re is a rare earth element, and l and m, n are positive integers).
  • the crystal structure of the magnetic substance in which a part of fluorine atoms is disposed at the penetration position is a metastable phase, and therefore, the phase transition to the stable phase is caused by heating.
  • the phase transition is plural, and at least one phase transition proceeds at 300 ° C to 400 ° C.
  • this phase transition temperature it is possible to form a main phase ordered with an element arranged at another intrusion position, add a plurality of rare earth elements, or a fluoride which is matched with the ordered phase at grain boundaries.
  • 10 g of ammonium hydrogen fluoride powder is mixed with 200 g of powder having Nd 2 Fe 14 B of 5 ⁇ m in particle diameter as the main phase.
  • the mixed powder is inserted into a container which does not react directly with the magnetic powder and heated by an external heater.
  • the heating causes thermal decomposition of ammonium hydrogen fluoride to generate NH 3 and a fluorine-containing gas.
  • the oxidation phase on the surface of the magnetic powder is removed by this gas generation, and the oxygen concentration becomes 120 ppm.
  • a part of B atoms in the magnetic powder is replaced with F (fluorine) at 400 ° C. by a fluorine-containing gas.
  • the surface of the magnetic powder is irradiated with fluorine ions, and the fluorine concentration at the penetration position is increased to increase the magnetic moment by about 3%.
  • the irradiation dose is 1 ⁇ 10 16 / cm 2 .
  • the position of the magnetic powder is changed to irradiate 50% or more of the surface of the magnetic powder. Irradiation may be performed several times by changing the irradiation amount and the irradiation energy.
  • the concentration of fluorine after irradiation becomes maximum at a depth of 0.1 to 3 ⁇ m from the surface of the magnetic powder to the center of the magnetic powder than the outermost surface of the magnetic powder.
  • a magnetic field of 1 T may be applied to enhance anisotropy during irradiation.
  • F By replacing F with B, expansion of the c-axis of the main phase and the Fe-rich phase expands the lattice volume of tetragonal crystal and increases the magnetic moment of Fe by about 5%.
  • N or F atoms are arranged at a position different from the penetration position before the reaction.
  • Such magnetic powder containing Nd 2 Fe 14 (B, F) contains 1 atomic% to 5 atomic% of fluorine and has a Curie temperature of 320 ° C. (1% fluorine) to 380 ° C. (5% fluorine), saturated It exhibits magnetic characteristics with a magnetic flux density of 1.61 (1% fluorine) to 1.72 T (5% fluorine), and magnetic particles are molded in an ammonium hydrogen fluoride atmosphere at 400 ° C. to form a magnet with a residual magnetic flux density of 1.7 T. It can be created.
  • the magnetic powder is Nd 2 Fe 14 (B, F ) which increase can be confirmed in the magnetic moment by the injection of gas or fluorine ions containing fluorine atom in addition, Re l Co m B n ( Re is a rare earth element, l , M, n are positive integers, Re l Mn m B n (Re is a rare earth element, l, m, n is a positive integer), Re l Cr m B n (Re is a rare earth element, l, m, n Is a positive integer), Re l (Mn, Al) m B n (Re is a rare earth element, l and m, n are positive integers).
  • the magnetic properties of such magnetic powder do not change significantly even if oxygen, carbon or metal elements are contained as acid fluoride growth or impurities at grain boundaries inside the powder or on the surface of the magnetic powder, and the magnetic properties of some Fe atoms are not changed.
  • the following effects can be confirmed as the moment increases. 1) increase of internal magnetic field, 2) increase of crystal magnetic anisotropy, 3) change of direction of magnetic anisotropy, 4) increase of electric resistance, 5) change of temperature coefficient of saturation magnetic flux density, 6) magnetostriction 7) change in heat quantity associated with phase transition, 8) phase transition related to movement of fluorine atom position when heated above the Curie temperature, etc.
  • a magnet made of Nd 2 Fe 14 (B, F) structure as a main phase and having a bcc or bct structure containing fluorine and having a ferromagnetic iron grown thereon is used as a laminated electromagnetic steel sheet, laminated amorphous or compacted iron When making it adhere
  • FIG. 5 shows a schematic view of a cross section perpendicular to the axial direction of the motor.
  • the motor is composed of a rotor 100 and a stator 2.
  • the stator is composed of a core back 5 and teeth 4.
  • coils 8a, 8b and 8c (three-phase winding U
  • a coil group of the phase winding 8a, the V-phase winding 8b, and the W-phase winding 8c) is inserted.
  • a rotor insertion portion 10 into which the rotor is inserted is secured at the center of the shaft from the tip 9 of the teeth 4, and the rotor 100 is inserted at this position.
  • a fluorine-containing magnet subjected to surface treatment such as plating is inserted on the outer peripheral side of the rotor 100, and a portion with less iron fluoride (less than 5% of average fluorine atom concentration in iron) 200 and a lot of iron fluoride (The average fluorine concentration in iron is 5% to 10%) 201 and 202.
  • the areas of portions 201 and 202 where the fluorine concentration in the iron phase constituting the magnet is 5 to 10 atomic% are different, and the larger the area of the magnetic field strength to which the reverse magnetic field is applied by the magnetic field design Increase the magnetic force and residual magnetic flux density.
  • the amount of rare earth elements used can be reduced by increasing the amount of iron fluoride on the outer peripheral side of the sintered magnet as described above.
  • the above-mentioned fluorine treatment can also be applied to the soft magnetic part of the magnetic circuit, and it is possible to increase the saturation magnetic flux density to 2.4-2.6 T, various motors and magnetic heads for hard disks, MRI, electron microscope, superconductivity It is applicable to measuring instruments, such as an instrument.
  • 10 g of ammonium hydrogen fluoride powder is mixed with 200 g of powder having Nd 2 Fe 19 B with a particle diameter of 1 ⁇ m as a main phase.
  • the mixed powder is inserted into a container which does not react directly with the magnetic powder and heated by an external heater.
  • the heating causes thermal decomposition of ammonium hydrogen fluoride to generate NH 3 and a fluorine-containing gas.
  • the oxidation phase on the surface of the magnetic powder is removed by this gas generation, and the oxygen concentration becomes 120 ppm.
  • a part of B atoms in the magnetic powder is replaced with F (fluorine) at 400 ° C. by a fluorine-containing gas.
  • a phase in which at least two elements of fluorine, oxygen, nitrogen and boron are regularly arranged is formed in part of the main phase or the grain boundary phase.
  • the growth of such a regular phase contributes to the increase of residual magnetic flux density and the increase of coercivity, and it is analyzed from diffraction experiments that it has about twice the lattice constant of iron of bcc structure, and the value of the lattice constant is It has been found to be in the range of 0.57 nm to 0.65 nm.
  • the surface of the magnetic powder is irradiated with fluorine ions in a low oxygen atmosphere, and the fluorine concentration at the penetration position is increased to increase the magnetic moment by about 3%.
  • the irradiation dose is 5 ⁇ 10 16 / cm 2 .
  • the lattice constant is different between the inside (central portion) of the magnetic powder and the surface by changing the position of the magnetic powder to irradiate 20% or more of the surface area to the whole surface of the magnetic powder, and the lattice constant becomes smaller inside. That is, the lattice volume is large near the surface of the magnetic powder or grain boundary, and the lattice volume inside tends to be smaller than the vicinity of the grain boundary or the surface.
  • the lattice volume of the parent phase and the ferromagnetic iron tends to be smaller in the magnetic powder interior with lower fluorine concentration.
  • Irradiation may be performed several times by changing the irradiation amount and the irradiation energy.
  • the concentration of fluorine after irradiation becomes maximum at a depth of 0.1 to 3 ⁇ m from the surface of the magnetic powder to the center of the magnetic powder than the outermost surface of the magnetic powder.
  • a magnetic field of 5 T may be applied to enhance the anisotropy during irradiation.
  • F By replacing F with B, the c-axis of the main phase and the Fe-rich phase is elongated, the lattice volume of tetragonal crystals is expanded, and the magnetic moment of Fe is increased by about 5%.
  • N or F atoms are arranged at a position different from the penetration position before the reaction.
  • the fluorine atom disposed at the entry position has a larger number of atoms than the fluorine atom disposed at an atom position other than the entry position, and the atom configuration other than the entry position forms a compound with a rare earth element different from the main phase or iron.
  • Such magnetic powder containing Nd 2 Fe 19 (B, F) contains 1 atomic% to 3 atomic% of fluorine, and the Curie temperature is 480 ° C. (1% fluorine) to 530 ° C.
  • the increase in residual magnetic flux density is due to the increase in the magnetic moment of iron due to the regular arrangement of the elements arranged at the above-mentioned entry position, and the fluorine atoms located at the entry position of octahedron position or tetrahedron position are interatomic atoms of ferromagnetic iron Since the crystal magnetic anisotropy is increased due to the anisotropic arrangement of the penetration positions while the distance is extended, a magnet having a high energy product of 45 MGOe to 65 MGOe can be obtained. In order to enhance the corrosion resistance and thermal stability of these fluorine-containing magnets, they are applied to various magnetic circuits after plating, painting, resin coating treatment and the like. Such an increase in the magnetocrystalline anisotropy and the Curie temperature and the magnetization can also be achieved by introducing chlorine into the penetration position.
  • ammonium hydrogen fluoride powder 100 g is mixed with 200 g of powder having Nd 1 Fe 19 having a particle diameter of 1 ⁇ m as a main phase.
  • the mixed powder is inserted into a container which does not react directly with the magnetic powder and heated by an external heater.
  • the heating causes thermal decomposition of ammonium hydrogen fluoride to generate NH 3 and a fluorine-containing gas.
  • F fluorine
  • the oxidation phase on the surface of the magnetic powder is removed, and the oxygen concentration becomes 50 ppm.
  • F fluorine
  • the heating temperature is 600 ° C., part of Fe is replaced with F, and FeF 2 or FeF 3 grows.
  • the lattice volume of Fe 16 F 2 , Fe 16 (F, C) 2 , Fe 16 (F, N) 2 etc. is in the order of 0.15 to 0.25 nm 3
  • the phase grows, and part of the fluoride becomes an acid fluoride of fcc structure.
  • a phase in which at least two elements of fluorine, oxygen, nitrogen and carbon are regularly arranged is formed in part of the main phase or the grain boundary phase.
  • the growth of such a regular phase contributes to an increase in residual magnetic flux density and an increase in coercivity.
  • F By arranging F at the penetration position, the axes of the main phases Nd 1 Fe 19 F 1-3 and the Fe-rich phase are anisotropically stretched, and the lattice volume of tetragonal crystal and hexagonal crystal expands, and the magnetism of Fe The moment is increased by about 5%.
  • some N or F atoms are arranged at a position different from the penetration position before the reaction.
  • the fluorine atom disposed at the entry position has a larger number of atoms than the fluorine atom disposed at an atom position other than the entry position, and the atom configuration other than the entry position forms a compound with iron different from the main phase.
  • Such Nd 1 Fe 19 (N, F ) 1-3 or magnetic powder containing Nd 1 Fe 19 F 1-3 is a Curie temperature of 530 ° C., shows the magnetic characteristics of the saturation magnetic flux density 1.8 T, the magnetic powder By heating at 1000 ° C. in an ammonium hydrogen fluoride atmosphere, it can be made by sintering a magnet with a residual magnetic flux density of 1.7 T.
  • the increase of the residual magnetic flux density is due to the increase of the magnetic moment of iron due to the regular arrangement of the elements arranged at the above-mentioned entry position, and the fluorine atom located at the entry position of octahedron position or tetrahedron position As it extends, the anisotropic alignment of the penetration sites increases the magnetocrystalline anisotropy.
  • a part of fluoride in which fluorine in the vicinity of the grain boundary is not intruded and aligned contributes to high coercivity by antiferromagnetic coupling with the parent phase, so that a magnet with high energy product of 55 MGOe to 70 MGOe can be obtained.
  • antiferromagnetic coupling depends on the application direction of the magnetic field during heat treatment or magnetization, and a left-right asymmetry component can be seen in the demagnetization curve. This asymmetrical component disappears by heating below the Curie point.
  • 200 g of powder consisting mainly of Sm 2 Fe 17 N 3 with a particle size of 5 ⁇ m is mixed with 200 cc of an alcohol solution of PrF 3 in composition, placed in a stainless steel container, and mechanically alloyed with stainless steel balls to use Sm 2 Fe 17 N 3 Incorporate fluorine into the main phase. It was confirmed by mass spectrometry that fluorine was incorporated into the main phase after 30 hours of mechanical aloinizing. The fluorine concentration was different at the center and outside of the powder, being higher at the outside, and the average fluorine concentration of the whole powder was 5-10 atomic%. This concentration depends on the concentration of PrF 3 in alcohol and mechanical alloying conditions, such as ball diameter, ball to powder volume ratio, rotational speed, type of solvent, and impurities in the solvent.
  • the fluorine atom forms not only a penetration position but also a substitution position or an acid fluoride, and by introducing fluorine at a concentration of 0.1 atomic% or more, one of the following effects can be confirmed. 1) increase of internal magnetic field, 2) increase of magnetocrystalline anisotropy, 3) change of direction of magnetic anisotropy, 4) increase of electrical resistance, 5) change of temperature coefficient of saturation magnetic flux density, 6) magnetic Changes in resistance, 7) change in heat quantity accompanying phase transition, 8) phase transition related to movement of fluorine atom position when heated above the Curie temperature, etc.
  • the crystal structure of the magnetic substance in which a part of fluorine atoms is disposed at the penetration position is a metastable phase, and therefore, the phase transition to the stable phase is caused by heating.
  • the number of phase transitions is multiple, and at least one phase transition proceeds at 300 ° C. to 600 ° C.
  • this phase transition temperature it is possible to form a main phase ordered with an element arranged at another intrusion position, add a plurality of rare earth elements, or a fluoride which is matched with the ordered phase at grain boundaries.
  • it is effective to form an acid fluoride and these techniques make it possible to make the phase transition temperature and the Curie temperature approximately the same.
  • iron of bcc or bct structure is grown on Sm 2 Fe 17 N 3 powder as the main phase by vacuum heat treatment at 500 ° C., and then mechanical alling is performed using a solvent in which the above fluoride is swollen.
  • Fe 8 F, Fe 16 F 2 , Fe 4 F, Fe 3 F, Fe 2 F and fluorides in which nitrogen, carbon or oxygen is disposed in part of them are formed.
  • Fe 8 F and Fe 16 F 2 have a bct structure, and in Fe 16 F 2 , a period about twice that of Fe 8 F is observed in electron diffraction or an X-ray diffraction pattern.
  • this approximately double period has a lattice constant in the range of 0.57 nm to 0.65 nm analyzed from diffraction experiments.
  • Fe 4 F has a structure close to fcc, and these three compounds exhibit ferromagnetism, and the magnetic moment at 20 ° C. has a value exceeding 2.5 Bohr magneton, and the magnetic flux density is increased.
  • fluorides in which impurities such as oxygen are mixed with Fe 3 F and Fe 2 F, which are a trace amount grow.
  • the coercivity increase effect due to the change in coupling can be realized, and it is possible to achieve both high residual magnetic flux density and high coercivity.
  • the average composition was adjusted to NdFe 11 TiF 0.1, and the concentration of NdF 3 in alcohol, the ball diameter which is mechanical alloying conditions, the volume ratio of balls to powder, the rotation speed, the type of solvent, and the impurities in the solvent were adjusted.
  • Fluorine atoms form not only penetration positions but also substitution positions and acid fluorides, but the lattice constant of body-centered tetragonal crystals tends to increase.
  • the lattice constants and Curie points of body-centered tetragonal crystals of the main phase are shown in Nos. 1 and 2 of Table 1.
  • the lattice constant is represented by the a-axis and c-axis for body-centered tetragonal crystals, and the unit is angstrom.
  • the Curie point is represented by Tc and the unit is K (Kelvin).
  • the introduction of fluorine increases the length of the c-axis from 4.91 to 4.95 A (angstrom), and the unit cell volume increases. Along with this, Tc rises from 547K to 558K.
  • NdFe 11 TiF 0.2 produced with a mechanical alloying time of 200 hours further extends the c-axis and raises Tc.
  • the phases formed other than body-centered tetragonal crystals of the main phase have cubic or rhombohedral fluorides or acid fluorides and structures other than tetragonal crystals such as Nd 3 Fe 29, and the volume of the phases other than the main phase Is less than 20% by volume with respect to the main phase, and phases other than some of the main phases have consistency at the interface with the main phase and stabilize the crystal structure of the main phase, and the residual magnetic flux density is 1. This ratio is necessary to achieve 2 T or more and a coercive force of 10 kOe or more.
  • the values of the lattice constant and Tc for material systems other than NdFe 11 Ti are shown in Table 1 numbers 9 to 59.
  • the introduction of fluorine raises Tc in comparison with the lattice constant and Tc of the main phase not containing fluorine.
  • the c-axis also increases for any major phase.
  • the reason why the c-axis extends can be presumed to be that part of the fluorine atoms intrude into the gaps of the structure composed of rare earth elements or iron atoms, and the extension of the c-axis increases the crystal magnetic anisotropy energy.
  • the magnetic force can also be increased.
  • the alignment of fluorine is observed, and in SmFe 15 MnF 1.1 (No. 17)
  • the fluorine is arranged in a part between Sm-Fe, between Fe-Fe, and between atoms between Fe-Mn, and local lattice distortion occurs, resulting in an increase of the Curie temperature. Expansion of the lattice due to the introduction of similar lattice strain is observed in the fluorine-containing compounds of the material composition of No. 18 to No. 59.
  • the axial length of at least one of the lattice constants of the main phase fluorine compound shown in Table 1 is longer than the longest axial length of the lattice constant of ferromagnetic iron containing fluorine.
  • the lattice volume of the main phase is larger than 250 cubic angstroms, and larger than 23.6 to 220 cubic angstroms which is the lattice volume of ferromagnetic iron containing fluorine.
  • the lattice volume expands unidirectionally or isotropically by the penetration of fluorine, and the change in the density of states of electrons due to the high electronegativity of fluorine atoms increases the magnetocrystalline anisotropy and the Curie temperature And it is considered that the increase in magnetization is realized.
  • 100 g of powder containing YFe 6 Al 6 as the main phase with a particle size of 0.1 ⁇ m is mixed with 200 cc of alcohol solution containing YF 2 crystalline fluoride with a composition of 0.01 ⁇ m in particle diameter, and applied to a stainless steel container coated with YF 2 Then, a metastable compound is grown by diffusion or reaction in the vicinity of the surface of YF 2 fluorine from the surface of YFe 6 Al 6 main phase by mechanical alloying using stainless steel balls coated with YF 2 having a diameter of about 100 ⁇ m.
  • the amount of fluorine atoms constituting the fluoride or acid fluoride is smaller than the amount of fluorine atoms disposed at the entry position
  • a powder is used in which the oxygen concentration is 500 ppm or less and Fe is increased by 0.1 to 5 atomic% from the composition of YFe 6 Al 6 .
  • heat treatment at 500 ° C. for 10 hours was attempted using an atmosphere containing 1% of fluorine.
  • YFe 6 Al 6 F grew, and elongation of the a-axis and c-axis could be confirmed.
  • Tc Curie temperature
  • 100 g of powder consisting mainly of Ce 2 Fe 17 C with a particle size of 1 ⁇ m is mixed with 200 cc of an amorphous fluoride alcohol solution of CeF 2 composition, and placed in a fluoride coated stainless steel container.
  • the metastable compound is grown by diffusion or reaction in the vicinity of the surface of fluorine of CeF 2 from the surface of the Ce 2 Fe 17 C main phase by mechanical alloying using a stainless steel ball coated with.
  • the amount of fluorine atoms constituting the fluoride or acid fluoride is smaller than the amount of fluorine atoms disposed at the entry position
  • a powder is used in which the oxygen concentration is 1000 ppm or less and the amount of Fe is increased by 0.1 to 5 atomic%.
  • heat treatment at 400 ° C. for 10 hours was attempted using an atmosphere containing 1% of fluorine.
  • Ce 2 Fe 17 CF 0.1 was grown, and elongation of the lattice constant was confirmed.
  • the Curie temperature (Tc) of Ce 2 Fe 17 CF 0.1 obtained from the temperature dependency of the magnetization was increased from a temperature (297 K) where no fluorine was introduced to 412 K.
  • the axial length increase of the lattice constant and the increase of the Curie point due to the introduction of fluorine can be confirmed also for other rare earth iron materials, and the results are shown in Table 3.
  • a sintered magnet or a bonded magnet to a magnet applied product (a rotating machine, a hard disk, a magnetic resonance device, etc.) which is required to have heat resistance.
  • 100 g of powder consisting mainly of La 2 Fe 17 N with a particle size of 100 nm is mixed with 100 cc of an amorphous fluoride alcohol solution having a composition of LaF 2 and placed in a fluoride coated stainless steel container.
  • a metastable compound is grown by diffusion or reaction in the vicinity of the surface of fluorine of LaF 2 from the surface of the La 2 Fe 17 N main phase by mechanical alloying using a stainless ball coated with.
  • the concentration of fluorine atoms constituting the above-mentioned fluoride or acid fluoride is determined by the concentration of fluorine atoms arranged at the entry position of the matrix. Also high.
  • the phase in which the fluorine atom is at the penetration position is the main phase, and the main phase volume is larger than that of the other fluorine-substituted phase or acid fluoride.
  • a sintered magnet a fluorine compound having a crystal structure different from that of the main phase grows in part of grain boundaries.
  • An oxygen-containing oxy-fluorine compound grows at part of the grain boundary triple point.
  • oxides, fluorides or acid fluorides other than organic materials can be used as the binder, and the heat resistance of the magnet is improved by using the inorganic binder.
  • a Sm-F based solution is applied to a 100 nm thick iron foil and then heat treated.
  • the purity of the iron foil is 99.8%.
  • the Sm—F-based solution exhibits an amorphous structure, so the X-ray diffraction pattern differs from the crystalline pattern, and contains one or more peaks with a half-width of 1 degree or more.
  • After applying a 0.1 wt% solution to the iron foil it is heated and maintained at 600 ° C. for 10 hours in an atmosphere in which ammonium fluoride is evaporated, and then quenched.
  • the iron foil and the fluoride react with each other to obtain an iron foil containing Sm and fluorine.
  • fluorine When heat-treated at a temperature higher than 600 ° C., fluorine hardly forms an iron rare earth fluorine ternary compound, stable fluorides and acid fluorides grow, and improvement of magnetic properties becomes difficult.
  • 100 g of powder consisting mainly of NdFe 11 Ti with a particle size of 100 nm is mixed with 100 cc of an alcohol solution containing 10 wt% of ground powder of NdF 3 and placed in a stainless steel container in which fluoride is coated and diffused.
  • Fluorine is incorporated into the NdFe 11 Ti main phase by mechanical alloying using a stainless steel ball having fluoride formed on the surface by fluoride surface treatment. After 200 hours of mechanical alloying, it was confirmed by mass spectrometry that fluorine was taken in the main phase.
  • the fluorine concentration was different at the center and the outside of the powder, and tended to be higher at the outside.
  • the average composition was adjusted to be NdFe 11 TiF 1, and the concentration of NdF 3 in alcohol, the ball diameter which is mechanical alloying conditions, the volume ratio of balls to powder, the rotation speed, the type of solvent, and the impurities in the solvent were adjusted.
  • Fluorine atoms form not only entry positions but also substitution positions of hexagonal crystals and acid fluorides, but the lattice constant of body-centered tetragonal crystals tends to increase.
  • fluorination proceeds further, NdFe 11 TiF 2 and NdFe 11 TiF 3 grow, and the fluorine concentration is higher than the concentration of the rare earth element. It has a high concentration, and part of the fluorine forms rare earth fluorides other than the mother phase, rare earth acid fluorides, iron fluorides, and iron fluorides.
  • the mechanical alloying conditions and the crystal grain size are adjusted so that the phase other than the main phase is in the range of 0.1 to 20% by volume.
  • the growth of the ferromagnetic tetragonal Fe-F binary alloy phase makes it possible to increase the residual magnetic flux density.
  • the content of the ferromagnetic iron-fluorine alloy and the fluorine-containing phase other than the main phase is preferably 0.1 to 10% by volume.
  • a powder containing the fluorine-containing phase other than the main phase can be heat-formed after magnetic orientation to obtain a compact with a density of 95-98% It becomes an anisotropic magnet with a magnetic flux density of 1.0 to 1.8 T and a coercive force of 15 to 40 kOe.
  • a powder having Sm 2 Fe 17 having a particle diameter of 5 ⁇ m as a main phase is temporarily formed in a magnetic field of 10 kOe, and then the formed body is inserted into a vacuum heating device and heat sintered at 1200 ° C. for 5 hours. After sintering, ammonium fluoride gas is introduced into an aging chamber adjacent to the heating chamber at around 1000 ° C. to diffuse fluorine from the outside of the sintered body.
  • the fluorine concentration is different at the center and the outside of the sintered body, and is higher at the outside, and the average fluorine concentration of the whole sintered body is It was 1-15 atomic percent.
  • This concentration depends on the partial pressure of the gas obtained by the thermal decomposition of ammonium fluoride (NH 4 F) and the aging fluorination temperature. It also depends on the particle size of the powder and the density of the sintered body.
  • the fluorine atom forms not only a penetration position but also a substitution position or an acid fluoride, and by introducing fluorine at a concentration of 0.1 atomic% or more, one of the following effects can be confirmed. 1) increase of internal magnetic field, 2) increase of magnetocrystalline anisotropy, 3) change of direction of magnetic anisotropy, 4) increase of electrical resistance, 5) change of temperature coefficient of saturation magnetic flux density, 6) magnetic Changes in resistance, 7) change in heat quantity accompanying phase transition, 8) phase transition related to movement of fluorine atom position when heated above the Curie temperature, etc.
  • the crystal structure of the magnetic substance in which a part of fluorine atoms is disposed at the penetration position is a metastable phase, and therefore, the phase transition to the stable phase is caused by heating.
  • the number of phase transitions is multiple, and at least one phase transition proceeds at 400 ° C. to 900 ° C.
  • Fe 8 F, Fe 16 F 2 , Fe 4 F, Fe 3 F, Fe are obtained by the fluorination treatment as described above. 2 F and fluorides in which nitrogen, carbon or oxygen is disposed in part of these are formed.
  • Fe 8 F and Fe 16 F 2 have a bct structure, and in Fe 16 F 2 , a period about twice that of Fe 8 F is observed in electron diffraction or an X-ray diffraction pattern. It has been found that this approximately double period has a lattice constant in the range of 0.57 nm to 0.65 nm analyzed from diffraction experiments.
  • Fe 4 F has a structure close to fcc, and these three compounds exhibit ferromagnetism, and the magnetic moment at 20 ° C. has a value exceeding 2.5 Bohr magneton, and the magnetic flux density is increased. Furthermore, fluorides in which impurities such as oxygen are mixed with Fe 3 F and Fe 2 F, although in a small amount, grow.
  • Fe 8 F, Fe 16 F 2 and Fe 4 F in a high coercivity magnetic material, it is possible to increase the residual magnetic flux density in the magnet material by exchange coupling with the matrix phase. In soft magnetic materials it is possible to increase the saturation flux density.
  • these fluorides are mixed with impurities such as carbon, oxygen, hydrogen and nitrogen, the magnetic properties can be secured, so there is no practical problem.
  • a powder having Sm 2 Fe 19 as a main phase with a particle diameter of 1 ⁇ m is temporarily molded in a magnetic field of 10 kOe, and then a temporary compact is inserted into a vacuum heating device, and after hydrogen reduction, heat sintering is performed at 1100 ° C. for 5 hours. After sintering, in order to inject ammonium fluoride gas at around 900 ° C., it moves to the aging chamber adjacent to the heating chamber without being exposed to the air to diffuse fluorine from the outside of the sintered body.
  • the fluorine concentration differs between the center and the outside of the sintered body, and the outside is higher, and the whole sintered body
  • the average fluorine concentration of H 2 was 1-12 atomic%, and it was confirmed that nitrogen and hydrogen contained at a concentration lower than the fluorine concentration.
  • the concentration of these elements depends on the partial pressure of the gas obtained by thermal decomposition of ammonium fluoride (NH 4 F) and the aging fluorination temperature. It also depends on the particle size of the powder and the density of the sintered body.
  • the fluorine atom forms not only a penetration position but also a substitution position or an acid fluoride, and by introducing fluorine at a concentration of 0.01 atomic% or more, it is possible to confirm one of the following effects.
  • the phase transition to the stable phase is caused by heating.
  • the number of phase transitions is multiple, and at least one phase transition proceeds at 400 ° C. to 900 ° C.
  • Fe 8 (F, N), Fe 16 (F, N) 2 Fe is obtained by the fluorination treatment as described above. 4 (F, N), Fe 3 (F, N), Fe 2 (F, N), or a fluoride in which nitrogen, carbon or oxygen is disposed in part of these is formed.
  • Fe 8 (F, N) and Fe 16 (F, N) 2 have a bct structure, and in Fe 16 (F, N) 2 , the period is about twice that of Fe 8 (F, N) Are observed by electron beam diffraction or X-ray diffraction pattern. It has been found that this approximately double period has a lattice constant in the range of 0.57 nm to 0.65 nm analyzed from diffraction experiments. Further, Fe 4 (F, N) has a structure close to fcc, and these three compounds exhibit ferromagnetism, and the magnetic moment at 20 ° C. has a value exceeding 2.5 Bohr magneton, and the magnetic flux density increases.
  • Fe 8 (F, N), Fe 16 (F, N) 2 , Fe 4 (F, N) into a high coercivity magnetic material, the magnetic material and the parent phase It is possible to increase the residual magnetic flux density by exchange coupling, and it is possible to increase the saturation magnetic flux density in the soft magnetic material.
  • the Fe n F m N l compounds (n, m and l are positive integers) whose unit cell volume is expanded compared to bcc Fe are not only strong in magnetic moment but also due to increase in anisotropic energy and ferromagnetism.
  • the coercivity increase effect due to the change of exchange coupling to magnetism can be realized, and it is possible to achieve both a high remanent magnetic flux density and a high coercivity, and similar improvement of the magnetic properties is realized by Re n Fe m , Re n Co m (Re
  • the rare earth elements n and m are integers, and a plurality of metals other than Fe and Co or metalloid elements (Cu, Al, Zr, Ti, Mn, Cr, Mo, Ca, Bi, Ta, Mg, Si , B, C), and the fluorination treatment of the sintered body or temporary formed body).
  • the fluorination treatment of the sintered body or temporary formed body even if these fluorides are mixed with impurities such as carbon, oxygen, hydrogen and the like, the magnetic characteristics can be secured, and there is no problem in practical use.
  • 100 g of powder consisting mainly of La (Fe 0.9 Si 0.1 Al 0.01 ) 13 with a particle diameter of 100 nm is mixed with 100 cc of an alcohol solution containing 10 wt% of ground powder of LaF 3 and put in a stainless steel container coated with fluoride After the heat reduction in a hydrogen atmosphere, fluorine is introduced into the La (Fe 0.9 Si 0.1 Al 0.01 ) 13 main phase by mechanical alloying using stainless steel balls having fluorides formed on the surface by fluoride surface treatment. After 200 hours of mechanical alloying, it was confirmed by mass spectrometry that fluorine was taken in the main phase.
  • the fluorine concentration was different at the center and the outside of the powder, and tended to be higher at the outside.
  • the average composition is La (Fe 0.9 Si 0.1 Al 0.01 ) 13 F so that the concentration of LaF 3 in the alcohol, the ball diameter which is the mechanical alloying conditions, the ball to powder volume ratio, the rotational speed, the type of solvent, The impurities in the solvent were adjusted.
  • the fluorine atom forms not only the position of penetration but also the substitution position of the main phase and the acid fluoride.
  • fluorination proceeds further, and La (Fe 0.9 Si 0.1 Al 0.01 ) 13 F 2 and La (Fe 0.9 Si 0.1 Al 0.01 ) 13 F 3 grows, the fluorine concentration is higher than the concentration of rare earth elements, and some fluorine forms rare earth fluorides or rare earth acid fluorides or iron fluorides or iron fluorides other than the mother phase doing.
  • the mechanical alloying conditions and the crystal grain size were adjusted so that the phase other than the main phase was in the range of 0.1 to 20% by volume, and it was confirmed that the change in magnetic entropy was increased by the introduction of fluorine.
  • the fluorine-containing phase and the hard magnetic material can be combined to form a magnetic material having a magnetic cooling effect.
  • the powder of Sm 2 Fe 17.2 is heated in a hydrogen stream using a heat treatment furnace to hydrogenate a part of the powder.
  • the powder is pulverized utilizing the embrittlement of the powder due to hydrogen content to obtain a powder having an average powder diameter of 5 ⁇ m.
  • Hydrogen disproportionation recombination may be used to add anisotropy to the powder.
  • 100 g of this powder is heated and held in a gas atmosphere in which ammonium fluoride NH 4 F is sublimed without being exposed to the atmosphere. After heating and holding, acid fluorides and oxides formed on the powder surface etc. are reduced by the addition of CaH 2 .
  • the heating temperature is in the range of 150 ° C. to 1000 ° C., and the optimum temperature is 300 ° C. to 700 ° C.
  • This treatment causes Sm 2 Fe 17.1 F 1-3 to grow with the fluorine-containing iron and the acid fluoride.
  • the matrix is Sm 2 Fe 17.1 F 1-3 , and the fluorine concentration is higher on the outer peripheral side in the matrix than the center of the powder on average.
  • a phase different from the oxide or acid fluoride or fluoride main phase containing fluorine is grown on the powder surface, and in the above Sm 2 Fe 17.1 F 1-3 , Fe of bcc structure, bct structure Ferromagnetic phase with a crystal structure different from the main phase such as Fe-F phase, SmOF, SmF 3 , Fe 2 O 3 , Fe 3 O 4 , Sm 2 O 3, etc.
  • a phase thought to be a nonmagnetic phase grows.
  • the volume of the Sm 2 Fe 17.1 F 1-3 with respect to the whole powder was 70 to 90%, and the ferromagnetic phase was 95%.
  • these magnetic properties are different in composition from fluorine concentration gradient, composition of additives, impurities, etc., fluorine atom position and order, crystal structure including lattice constant, and crystal structure different from the main phase having an interface with the main phase. It has been confirmed that it changes depending on the phase of the loss.
  • the increase of the saturation magnetic flux density and the Curie temperature can be confirmed also by the measurement of the temperature dependency of the magnetization even in the composition of Sm 2 Fe 17.1 F 0.1 , and the increase of the lattice constant by the fluorine atom can also be confirmed by the X-ray diffraction pattern measurement.
  • the magnetocrystalline anisotropy energy obtained from a single crystal of Sm 2 Fe 17.1 F 0.1 is also confirmed increasing effect due to introduction of fluorine.
  • Materials in which any one of such magnetization increase, Curie temperature (Tc) increase and crystal magnetic anisotropy energy increase can be observed are CeFeF, PrFeF, NdFeF, PmFeF, EuFeF, GdFeF, TbFeF other than the above-mentioned SmFeF system. , DyFeF, HoFeF, ErFeF, TmFeF, YbFeF, LuFeF, YFeF, etc.
  • Re 2 Fe 17 (represents Re as a rare earth element containing Y) (Re 2 Fe 17 F 0.1-3 ) or ReFe 12 (ReFe 12 F 0.1) -3 ), ReFe 15-19 (ReFe 15-19 F 0.1-3 ) system, Re 3 Fe 29 (Re 3 Fe 29 F 0.1-3 ) system, and among these series, some of Fe atoms are Composition replaced with transition metal elements including Co, Ti, Al, Mn, Mg, Si, and Cu other than Fe and part of fluorine atoms replaced with H, C, B, N, O, Cl It is.
  • 100 g of SmFe 11 Al powder with a particle size of about 1 ⁇ m is mixed with 10 g of ammonium fluoride (NHF 4 ) powder and evacuated and heated. During heating, CaH 2 is added to suppress the progress of oxidation on the surface of SmFe 11 Al powder.
  • the heat treatment temperature is 300 ° C., and the holding time is 5 hours. After heating, quenching and fluoridated SmFe 11 Al powder are taken out from the heat treatment furnace. By this heat treatment, fluorine-containing reactive gas is generated from ammonium fluoride (NHF 4 ), and SmFe 11 AlF 0.1-3 powder can be prepared.
  • a fluorine such as SmF 3 , SmOF, AlF 2 , Al 2 O 3 , SmO 2 , Fe 2 O 3 , Fe 3 O 4 , SmH 2 Oxides or acid fluorides, oxides, and hydrides grow.
  • the bcc structure includes a deformed bcc structure due to a lattice strain, etc., and the a-axis and c-axis lattice constants differ by 0.01-1%, and a bcc structure that is difficult to judge as bct from diffraction experiments is included.
  • the fluorine concentration of the matrix is higher on the outer peripheral side than the powder center, and a part of the powder surface is in contact with a fluoride or acid fluoride containing a higher concentration of fluorine than the matrix.
  • This magnet can be applied to embedded magnet type motor and surface magnet motor, and voice coil motor, stepping motor, AC servo motor, linear motor, power steering, drive motor for electric car, spindle motor, actuator, undulator for synchrotron radiation, polarized magnet It can be applied to fan motors, permanent magnet type MRIs, electroencephalographs, etc.
  • a part or all of Al instead of Al is used in addition to SmFe 11 Al powder.
  • the fluorine introduction effect is also confirmed in a fluorine compound of SmFe 11.1-30 or a fluorine compound containing a transition element, which has a higher Fe content than SmFe 11 Al.
  • the particle size of SmFe 11 Al powder is 20 ⁇ m or less, and the gas used for fluorination can use various gases containing fluorine, and the reducing agent during heating is other than CaH 2 Hydride can be used.
  • 100 g of SmFe 11 Ti powder with a particle size of about 0.5 ⁇ m is mixed with 10 g of ammonium fluoride (NHF 4 ) powder and evacuated and heated. During heating, CaH 2 is added to suppress the progress of oxidation on the surface of SmFe 11 Ti powder.
  • the heat treatment temperature is 200 ° C., and the holding time is 10 hours. After heating, quenching and fluorination SmFe 11 Ti powder are taken out from the heat treatment furnace. By this heat treatment, fluorine-containing reactive gas is generated from ammonium fluoride (NHF 4 ), and SmFe 11 TiF 0.1-3 powder can be prepared.
  • the fluorine concentration is different between the central portion and the outer peripheral portion of the crystal grain or powder, and the outer peripheral portion has a higher fluorine concentration than the central portion. This is because fluorine diffuses from the outer peripheral portion. Even if it is SmFe 11 TiF 0.1 in the central part, it is possible to use SmFe 11 TiF 3 in the outer peripheral part. When the holding time of the heat treatment is set to 20 hours, the difference in fluorine concentration between the central portion and the outer peripheral side becomes small, and SmFe 11 TiF 0.3 at the central portion and SmFe 11 TiF 3 at the outer peripheral portion can be obtained.
  • the fluorine concentration and concentration gradient can be adjusted according to the retention time, gas partial pressure, gas species and the like according to the characteristics.
  • Fluoride such as SmF 3 , SmOF, TiF 2 , Ti 2 O 3 , SmO 2 , Fe 2 O 3 , Fe 3 O 4 , TiN, etc.
  • acid fluorides, oxides and nitrides grow.
  • the lattice volume is larger at the outer peripheral side or the surface of the particle containing the high concentration of fluorine or near the interface, and the anisotropic energy tends to be larger than the particle center.
  • the saturation magnetization increased by 35%
  • the Curie temperature increased by 250 ° C.
  • the uniaxial magnetic anisotropy energy (Ku) increased by 20%. This powder was inserted into a mold and compression-molded at a temperature of 400 ° C.
  • a partially sintered molded body composed of SmFe 11 TiF 0.1-3 crystal grains.
  • the magnetic properties of this molded body were a residual magnetic flux density of 1.6 T, a coercive force of 35 kOe, and a Curie temperature of 835 K.
  • various heat molding processes such as impact compression molding, electric current molding, rapid heat molding, and heat molding by electromagnetic waves can be adopted for producing a molded body.
  • a CF-based or HF-based gas or solution containing hot water may be used as the fluorination treatment.
  • the magnet exhibiting the above magnetic characteristics can be applied to various motors such as home electric appliances / industrial magnet motors, railway magnet motors, electric car drive motors, HDD spindles, VCM motors, etc., and magnetic circuits such as medical devices and measuring devices. Contributes to reducing the size and weight of the magnetic circuit or improving the efficiency.
  • Iron powder with a particle size of 100 nm was produced by vacuum evaporation.
  • An iron powder prepared in a deposition chamber is mixed with an alcohol solution in which a composition close to SmF 3 is swelled and Ti is added at 1% by weight without being exposed to the atmosphere, SmF containing Ti with a coverage of 90% on the powder surface
  • Three films are formed with a thickness of 1 to 10 nm.
  • the fluoride-coated iron powder is heated and held at 500 ° C. with CaH 2 and then cooled at an average cooling rate of 10 ° C./min or more. After cooling, it was subjected to aging treatment at 200 ° C. for 10 hours, and cooled at an average cooling rate of 20 ° C./min.
  • Sm, Fe, F, and Ti diffused and reacted to grow SmFe 11 TiF 0.01-2 having a tetragonal crystal structure.
  • a concentration gradient is observed for fluorine, Sm, and Ti in the powder, and the concentration gradient of fluorine is the largest, and at the atomic concentration ratio where Sm is 1, the fluorine is 0.01 at the central portion and 2 at the outer peripheral portion there were.
  • the concentration gradient tended to decrease as the aging time was further lengthened.
  • acid fluorides are higher than SmFe 11 TiF 0.01-2 but the magnetic properties are determined by the interface with SmFe 11 TiF 0.01-2 and this SmFe 11 TiF 0.01-2 , the growth phase near the interface There, the SmF 3 fluorides, acid fluorides or oxides such SmOF such, some of the carbides to form an interface having consistent with the crystal lattice of the matrix phase.
  • the SmFe 11 TiF 0.01-2 powder containing the coated portion grew 55% of the SmFe 11 TiF 0.01-2 with respect to the entire volume, and the near iron nonmagnetic non-magnetic portion of the coated portion When removed, it exhibits magnetic characteristics with a saturation magnetic flux density of 190 emu / g, a coercive force of 35 kOe, and a Curie temperature of 825 K, and the magnetic anisotropy tends to be larger on the surface or on the outer peripheral side of the grain than in the grain center.
  • the magnetic powder was mixed with a resin material, oriented in a magnetic field, and compression molded to form a bonded magnet.
  • the volume of the magnetic powder occupied in the bonded magnet was 80%, and a bonded magnet with a residual magnetic flux density of 1.25 T and a coercive force of 34 kOe was obtained.
  • the bonded magnet was applied to an embedded magnet motor, and as a result of measuring the induced voltage waveform after magnetization, it showed a higher induced voltage than other NdFeB-based or SmFeN-based rare earth bonded magnets.
  • Re n Fe m F l (Re is a rare earth element containing Y, Fe is iron, F is fluorine, n, m and l are positive integers) or other transition elements (M) are added to Re n Fe, M)
  • m F 1 is a magnet material which has a lower rare earth content and improved magnetic properties than conventional bonded magnets, and can be applied to various magnetic circuits.
  • a magnet material having a residual magnetic flux density of more than 1.2 T and a coercive force of 25 kOe or more is a main phase represented by Re n (Fe, M) m F l as described above, and is a fluorine compound of the main phase
  • the concentration of the transition element M to be added is smaller than that of iron (Fe), with the fluoride or acid fluoride necessary for forming H.
  • the composition close to SmF 3.5 is swelled without exposing the iron foil to the atmosphere, and an alcohol solution to which 1 wt% of Mg is added And an Mg-containing SmF 3.1 film with a coverage of 95% on the powder surface to a thickness of 1 to 10 nm.
  • the fluoride-coated iron powder is heated and held at 400 ° C. with CaH 2 and then cooled at an average cooling rate of 20 ° C./min or more. After cooling, it was subjected to aging treatment at 300 ° C. for 10 hours, and cooled at an average cooling rate of 30 ° C./min.
  • the contained fluorine concentration can be increased, but the number of fluorine atoms that do not enter the tetragonal lattice increases, and Sm 2 Fe 17 F 3 or Sm Fe 5 F 1 -4 etc. also grow.
  • SmFe 11 MgF 0.1-4 foils prepared at a heating temperature of 400 ° C fluorides such as SmF 3 not having tetragonal structure, acid fluorides or oxides such as SmOF, carbides, etc. and iron having a bcc or bct structure grow Do.
  • the lattice volume of iron of bcc and bct structures is smaller than the main phase SmFe 11 MgF 0.1-4 lattice volume.
  • Interface fluorine concentration is more of these fluorides and acid fluorides higher than SmFe 11 MgF 0.1-4, the determines the magnetic properties and SmFe 11 MgF 0.1-4 and the SmFe 11 MgF 0.1-4 , Growth phase near the interface, and iron of bcc and bct structures.
  • the SmFe 11 MgF 0.1-4 foil including coated portion grew 65% with respect to the total volume of SmFe 11 MgF 0.1-4, close to the non-magnetic low iron concentration of the coated portion When the portion was removed, magnetic characteristics of a saturation magnetic flux density of 200 emu / g, a coercive force of 30 kOe, and a Curie temperature of 815 K were exhibited.
  • Iron 50% manganese powder (Fe-50% Mn powder) with a particle size of 100 nm was prepared by vacuum evaporation.
  • the Fe-50% Mn powder prepared in the deposition chamber swells the composition close to LaF 3 and is mixed with an alcohol solution to which 1 wt% of Co is added without being exposed to the atmosphere, and the coverage is 90% Co on the powder surface.
  • the fluoride-coated Fe-50% Mn powder is heated and held at 300 ° C. together with CaH 2 and cooled at an average cooling rate of 10 ° C./min or more. After cooling, it was subjected to aging treatment at 200 ° C.
  • the thus prepared La (Fe, Co) 11 MnF 0.01-2 powder grows with fluorides such as LaF 3 not having a tetragonal crystal structure, acid fluorides such as LaOF, oxides, carbides, hydrides, etc.
  • the fluorine concentration of these fluorides and acid fluorides is higher than that of La (Fe, Co) 11 MnF 0.01-2 .
  • What determines the magnetic properties are La (Fe, Co) 11 MnF 0.01-2 and the La (Fe, Co) 11 interface with the MnF 0.01-2, growth phase near the interface.
  • La (Fe, Co) 11 MnF 0.01-2 Including coated portion La (Fe, Co) 11 MnF 0.01-2 the powdered La (Fe, Co) 11 MnF 0.01-2 grew 51% relative to the total volume, further LaMn 11 F and La 2 Mn 17 F 2 grows as a ferromagnetic phase.
  • a compound composed of such a rare earth element, Mn and fluorine most of the magnetic moment of Mn is ferromagnetically coupled and has high magnetic anisotropy energy.
  • magnetic characteristics of a saturation magnetic flux density of 170 emu / g, a coercive force of 31 kOe, and a Curie temperature of 754 K were exhibited.
  • the magnetic powder is mixed with a nonmagnetic fluoride material, oriented in a magnetic field, and subjected to heat compression molding so that the fluoride is plastically deformed and a high electric resistance bonded magnet in which the fluoride is a binder can be formed.
  • the volume of the magnetic powder in the bonded magnet of the fluoride binder (MgF 2 ) was 90%, and a bonded magnet having a residual magnetic flux density of 1.21 T and a coercive force of 30 kOe was obtained.
  • the bonded magnet was applied to an embedded magnet motor, and as a result of measuring the induced voltage waveform after magnetization, it showed a higher induced voltage than that of a bonded magnet consisting of a main phase containing a rare earth element such as other NdFeB or SmFeN. .
  • Re n (Fe, M) m F l (where n, m is a positive integer and l is a positive number) to which a transition element (M) is added is composed of the element M, Re and fluorine (F) It can be applied to various magnetic circuits as a magnet material which has less rare earth content and improved magnetic properties than conventional bonded magnets, with the growth of a ferromagnetic compound different from the main phase.
  • the ferromagnetic compound different from the main phase is Re x M y F z (Re is a rare earth element, M is a transition metal element, F is fluorine, x, y and z are positive numbers, 0 ⁇ x ⁇ y, z ⁇ y) It is a fluoride represented, and one part has mother phase ferromagnetic coupling.
  • Iron and SmF 3 and Sm are mixed to make a target having a composition of Sm 2.3 Fe 17 F 4 .
  • the target is placed in a sputtering apparatus, and the surface of the target is sputtered with Ar ions to form a SmFeF-based thin film on the substrate.
  • the composition of the film formed by sputtering was Sm 2 Fe 17 F 2 .
  • Ta was selected as the base and capped with Ta for preventing oxidation.
  • the film formed on the substrate is heat-treated in ammonium fluoride (NH 4 F) decomposition gas.
  • the heat treatment temperature is 300 ° C., and the holding time is 1 hour.
  • the composition of the thin film after the heat treatment was changed from Sm 2 Fe 17 F 2 to Sm 2 Fe 17 F 3 and it was confirmed that the magnetic characteristics were improved as the fluorine concentration increased.
  • the magnetic properties of the Sm 2 Fe 17 F 3 film are a residual magnetic flux density of 1.5 T, a coercive force of 35 kOe, and a Curie temperature of 770 K, which have magnetic properties applicable to magnetic recording media.
  • a fluoride such as SmF 3 , SmF 2 , or FeF 2 having a structure different from that of the main phase at grain boundaries or interfaces, or an acid fluoride such as SmOF or iron oxide is grown to an electron beam with a diameter of 2 nm. It is confirmed from the analysis of the electron beam diffraction image used.
  • a film having a residual magnetic flux density of more than 1.4 T and a Curie temperature of more than 700 K is Re n (Fe, M) m F l as described above (where Re is a rare earth element containing Y, Fe is iron) , M is a transition element, F is fluorine, n, m and l are positive numbers), and is a main phase having a crystal structure such as hexagonal, rhombohedral, tetragonal, orthorhombic, etc.
  • the concentration of the transition element M to be added contributes to the improvement of the stability of the crystal structure and is less than iron (Fe) Is desirable for securing the residual magnetic flux density, and the underlayer and the capping layer can obtain substantially the same characteristics even if metals other than Ta, or fluorides, nitrides, carbides, and oxides are used.
  • the Re n (Fe, M) m F l, oxygen, hydrogen, nitrogen, carbon, boron or trace metal impurities no characteristic problem also contain as impurities.
  • Iron and SmF 3 and Sm are mixed, and two kinds of targets of Sm 2.3 Fe 17 F 6 composition and Sm 2 Fe 17 are created.
  • the two targets are placed in a sputtering apparatus, and the surfaces of the two targets are alternately sputtered with Ar ions to form a thin film in which SmFeF-based thin films and SmFe-based films are multi-layered on the substrate.
  • the film thickness of the SmFeF-based thin film was 2 nm, and the film thickness of the SmFe-based film was 3 nm.
  • the multilayer film was heat treated at 200 ° C., and optimization of the film forming conditions and the heat treatment conditions was advanced so that the composition of the entire film became Sm 2 Fe 17 F 2 .
  • the composition of the thin film after heat treatment becomes a composition of Sm 2 Fe 17 F 2 to Sm 2 Fe 17 F 2.5 , and as the fluorine concentration increases, coercivity increase, residual magnetic flux density increase, saturation magnetic flux density increase, coercivity temperature coefficient It was confirmed that the magnetic characteristics such as decrease, residual magnetic flux density decrease, and Curie temperature rise were improved.
  • the magnetic properties of the Sm 2 Fe 17 F 2.5 film are a residual magnetic flux density of 1.45 T, a coercive force of 32 kOe, and a Curie temperature of 750 K, and has magnetic properties applicable to magnetic recording media. Fluoride such as SmF 3 , SmF 2 , FeF 2 etc.
  • iron oxide is confirmed from the analysis of electron beam diffraction images using an electron beam with a diameter of 1 nm.
  • a film having a residual magnetic flux density of more than 1.4 T and a Curie temperature of more than 700 K is Re n (Fe, M) m F l as described above (where Re is a rare earth element containing Y, Fe is iron) , M is a transition element, F is fluorine, n, m and l are positive numbers), and is a main phase having a crystal structure such as hexagonal, rhombohedral, tetragonal, orthorhombic or cubic.
  • the film forms fluorides or acid fluorides and oxides that grow when forming the main phase fluorine compound, and Ti, Al, Ga, Ge, Bi, Ta, Cr, Mn, Zr, Mo to be added.
  • the concentrations of transition elements M such as Hf, Cu, Pd, Mg, Si, Co, Ni, Nb, etc. contribute to the improvement of the stability of the crystal structure, and less than iron (Fe) to secure the residual magnetic flux density.
  • the underlayer or capping layer is a metal other than W or a fluoride or nitride Carbides, almost the same characteristics can be obtained even if an oxide.
  • the Re n (Fe, M) m F 1 contains oxygen, hydrogen, nitrogen, carbon, boron or a trace metal impurity as an impurity. You may use chlorine.
  • a solution obtained by swelling a composition near SmF 3 with ethanol as a solvent and a solution containing iron ions are alternately applied on a substrate.
  • the coating film thickness per layer is 1 to 2 nm.
  • the crystal structure of the monolayer film immediately after application is nearly amorphous.
  • the substrate used an iron plate.
  • the total thickness of the film in which the Sm-rich layer and the Fe-rich layer are stacked is about 1 mm.
  • the film is heated at 350 ° C. for 1 hour while applying a magnetic field in one direction to crystallize.
  • Sm 2 Fe 17 F 2 is a fluoride such as SmOF, Fe 2 O 3 , FeF 2 , FeF 3 , acid Grows with fluoride or oxide / carbide. Stabilize Sm 2 Fe 17 F 2 to grow more Sm 2 Fe 17 F 2 , Al, Ga, Ge, Co, Ti, Mg, Co, Mn, Nb, Cu, Bi, Pd, Pt, etc.
  • a transition element is added as an ion in a solvent to 0.01 to 1 wt% of any of the above two solutions.
  • the Sm 2 Fe 17 F 2 has a rhombohedral Th 2 Zn 17 or hexagonal Th 2 Ni 17 structure, and the fluorine atom has a 9e site of the rhombohedral Th 2 Zn 17 or a hexagonal Th 2 Ni 17 structure It is arranged at 6 h site, and either a-axis length or c-axis length expands by introducing fluorine atom, and increase of lattice volume by fluorine introduction is 0.1 to 5%, or increase of lattice strain is 0.1 to We can confirm 15%.
  • An Sm 2 Fe 17 F 2 film exhibits anisotropy by an applied magnetic field, and its magnetic properties are a residual magnetic flux density of 1.65 T, a coercive force of 32 kOe, a Curie temperature of 780 K, and a small magnetic circuit including a magnetic recording medium and a motor.
  • a film having a residual magnetic flux density of more than 1.5 T and a Curie temperature of more than 600 K is Re n (Fe, M) m F l as described above (where Re is a rare earth element containing Y and Fe is iron) , M is a transition element, F is fluorine, n, m and l are positive numbers), crystal structure such as hexagonal, rhombohedral, tetragonal, orthorhombic, cubic or Laves phase (Laves Phase)
  • the main phase has a fluoride or acid fluoride, an oxide is formed on the film, which is grown when the main phase fluorine compound is formed, and a fluorine atom and iron-iron arranged between iron and iron atoms.
  • a fluorine atom which forms a compound with a rare earth element or oxygen without being arranged between atoms is recognized, and Ti, Al, Ga, Ge, Bi, Ta, Cr, Mn, Zr, Mo, Hf, Cu, Pd, Mg to be added
  • the concentration of the transition element M such as, Si, Co, Ni, Nb, has a crystal structure Contributing to improve stability, it is desirable for the residual magnetic flux density ensuring less than iron (Fe).
  • the Re n (Fe, M) m F 1 contains oxygen, hydrogen, nitrogen, carbon, boron or a trace metal impurity as an element to be located at an impurity or an entry position. And F may be substituted for chlorine.
  • SmF 3 and Sm 2 Fe 17 chips were disposed on an iron target, and the number of chips was adjusted to obtain a Sm 2 Fe 24 F film.
  • a Sm-Fe-F based film was formed with a thickness of 1 ⁇ m on a glass substrate by Ar gas. During sputtering, a magnetic field was applied to the substrate to add magnetic anisotropy to the film. After film formation, heat diffusion was performed at 400 ° C. to form a hard magnetic film. In this film, a ferromagnetic phase having a crystal structure of a ThMn 12 type structure is grown, and some fluorine atoms are arranged at the penetration position.
  • fluorides such as SmOF, Fe 2 O 3 , FeF 2 , FeF 3 , acid fluorides or oxides, and carbides are grown with a particle diameter of 1 to 100 nm.
  • a transition element such as, Sr, W, Ca, etc. is disposed on a target as an alloy tip with iron, and added to the Sm—Fe—F film in the range of 0.001 to 1 at%.
  • the magnetic properties of the formed film are a residual magnetic flux density of 1.6 T, a coercive force of 35 kOe, and a Curie temperature of 790 K, and has magnetic properties applicable to a magnetic recording medium, a magnetic film of a magnetic head, and a small magnetic circuit including a motor.
  • a sputtering film having a residual magnetic flux density of more than 1.5 T and a Curie temperature of more than 700 K is Re n (Fe, M) m F l as described above (where Re is a rare earth element containing Y, Fe is Iron, M is a main phase having a crystal structure such as hexagonal, rhombohedral, tetragonal, orthorhombic, cubic, etc.
  • F is fluorine
  • n, m and l are positive numbers
  • a fluoride or acid fluoride, an oxide, and an iron or iron fluorine binary alloy phase having a bcc or bct structure, which grow when forming a main phase fluorine compound, are formed on the film,
  • a fluorine atom to be arranged and a fluorine atom forming a compound with a rare earth element or oxygen without being arranged between iron and iron atoms are recognized, and fluorine is used for both exchange coupling in a ferromagnetic substance and superexchange interaction in a ferrimagnetic substance.
  • the introduction effect is recognized.
  • the concentration of the transition element M to be added such as Al, Ga, Ge, Co, Ti, Mg, Co, Mn, Cr, Nb, Cu, Bi, Pd, Pt, Bi, Sr, W, Ca, has a crystal structure It is desirable for the residual magnetic flux density to be secured that it contributes to the improvement of the stability of Fe and is less than iron (Fe). There is no problem with the characteristics even if the Re n (Fe, M) m F 1 contains oxygen, hydrogen, nitrogen, carbon, boron, or a trace metal impurity as an impurity. Chlorine, phosphorus, sulfur, or a mixture of these elements with fluorine.
  • a solution obtained by swelling a composition near SmF 4 with ethanol as a solvent and a solution containing iron ions are alternately applied on a substrate.
  • the coating thickness per layer is 10 to 20 nm.
  • the crystal structure of the monolayer film immediately after application is near amorphous and partially crystalline.
  • the substrate was a glass plate.
  • the total thickness of the film in which the layer rich in Sm and fluorine and the layer rich in Fe are stacked is about 1 mm.
  • the film is heated at 400 ° C. for 1 hour with application of a magnetic field in one direction of magnitude of 10 kOe to crystallize the amorphous or metastable phase.
  • Sm 2 Fe 17 F 3 is a fluoride such as SmOF, Fe 2 O 3 , FeF 2 , FeF 3, and so on. Grow with oxides, oxides and carbides. Stabilize Sm 2 Fe 17 F 3 in order to grow Sm 2 Fe 17 F 3 a lot, Ti, V, Co, Cr, Mn, Cu, Zn, Ga, Ge, As, etc. Transition elements in the solvent 0.1 to 1 wt% as an ion is added to any of the above two solutions.
  • the above Sm 2 Fe 17 F 3 has a rhombohedral Th 2 Zn 17 or hexagonal Th 2 Ni 17 structure, and part of fluorine atoms is a rhombohedral Th 2 Zn 17 9 e site or a hexagonal Th 2 Ni It is disposed at the 6h site of the 17 structure, and introduction of a fluorine atom causes expansion of either the a-axis length or the c-axis length, and an increase in lattice volume by fluorine introduction can be confirmed by 0.1 to 7%.
  • Such an increase in lattice volume increases the magnetic moment of iron atoms on average by 5 to 10%, increases the magnetocrystalline anisotropy energy by about 50%, and increases the Curie temperature (Curie point) by 200.degree.
  • An Sm 2 Fe 17 F 3 film exhibits anisotropy due to an applied magnetic field, and its magnetic properties are 298 K, residual magnetic flux density 1.63 T, coercive force 35 kOe, Curie temperature 795 K, small size including magnetic recording medium and motor It has magnetic properties applicable to magnetic circuits.
  • a film prepared using a solution having a residual magnetic flux density of more than 1.5 T and a Curie temperature of more than 750 K as described above has Re n (Fe, M) m F 1 (where Re contains Y) as described above
  • Rare earth elements Fe is iron, M is a transition element, F is fluorine, n, m and l are positive numbers and n ⁇ l ⁇ m) hexagonal, rhombohedral, tetragonal, orthorhombic, cubic
  • the main phase has a crystal structure such as crystal phase, and the film forms a regular phase or irregular phase fluoride or acid fluoride, an oxide which is grown when forming the main phase fluorine compound, iron-
  • the arrangement between fluorine atoms and iron-iron atoms which are not arranged between iron atoms and fluorine atoms which form a compound with rare earth elements or oxygen or between rare earth atoms and iron atoms is recognized, and the interface of some main phases
  • the concentration of transition elements M such as Ti, V, Co, Cr, Mn, Cu, Zn, Ga, Ge, As which are added contributes to the improvement of the stability of the crystal structure and is less than iron (Fe). Is desirable for securing residual magnetic flux density. There is no problem with the characteristics even if the Re n (Fe, M) m F 1 contains oxygen, hydrogen, nitrogen, carbon or trace metal impurities as impurities, and chlorine instead of fluorine of F is used. Or you may use phosphorus and sulfur.
  • a target in which SmF 3 and Sm 2 Fe 17 chips were disposed on an iron target was placed in a sputtering apparatus.
  • a mixed gas of Ar and fluorine was injected into the apparatus to try reactive sputtering.
  • fluorides such as SmOF, Sm (O, F, C), Fe 2 O 3 , FeF 2 , FeF 3 , acid fluorides or oxides, carbides, hydrides have a particle size of 0. .1 to 100 nm were grown.
  • Al, Ga, Ge, Co, Ti, Mg, Co, Mn, Cr, Nb, Cu, Bi, Pd, Pt, Sr, W stabilize SmFe 24 F 3 in order to grow Sm Fe 24 F 3 a lot
  • one or more kinds of transition elements such as Fe, Ca, etc. are arranged on the target as an alloy chip with iron, and added to the Sm—Fe—F film in the range of 0.001 to 1 at%.
  • the resulting film is heat-treated at 300 ° C. to grow crystal grains to an average crystal grain size of 10 to 100 nm.
  • heat treatment is performed at a temperature higher than 500 ° C., the structure of SmFe 24 F 3 changes, and fluorides and acid fluorides in the vicinity of the grain boundaries grow to lower the coercive force.
  • the substrate material it is possible to form a film whose magnetization direction is oriented in the substrate plane or in the direction perpendicular to the substrate.
  • the magnetic properties of SmFe 24 F 3 have a residual magnetic flux density of 1.7 T, a coercive force of 35 kOe, and a Curie temperature of 820 K, and is applied to magnetic recording media, magnetic memories such as MRAM, magnetic films of magnetic heads, and small magnetic circuits including motors and motors. Have magnetic properties.
  • a sputtering film having a residual magnetic flux density of more than 1.6 T and a Curie temperature of more than 700 K can be obtained by adding Re n (Fe, M) m F 1 (where Re is a rare earth element containing Y, Fe as described above).
  • the Fe-rich compound or alloy phase is a main phase having a crystal structure such as hexagonal crystal, rhombohedral crystal, tetragonal crystal, orthorhombic crystal or cubic crystal as the alloy phase, which depends on the fluorine concentration.
  • Iron and iron fluoride binary alloy phases of bcc or bct structure are formed in the film, which has different crystal structure, and the film grows when forming the main phase fluorine compound.
  • the fluorine atom which forms a compound with a rare earth element or oxygen is recognized, and either of the fluorine introduction effect is recognized in both the exchange coupling in the ferromagnetic material and the superexchange interaction in the ferrimagnetic material.
  • concentration of transition element M such as Al, Ga, Ge, Co, Ti, Mg, Co, Mn, Cr, Nb, Cu, Bi, Pd, Pt, Sr, W, Ca, etc., stabilizes the crystal structure.
  • Re n (Fe, M) m F 1 contains oxygen, hydrogen, nitrogen, carbon, boron, or a trace metal impurity as an impurity. Chlorine, phosphorus, sulfur, or a mixture of these elements with fluorine.
  • SmFe 11 MnF and SmFeMn 11 F 2 grow, and a composite magnetic material in which the former is ferromagnetic and the latter is ferrimagnetic is obtained.
  • fluorides and acids having different lattice constants and crystal structures from SmFe 11 MnF and SmFeMn 11 F 2 such as SmF 3 , SmOF, MnF 2 and FeF 2 at grain boundaries or interfaces. Fluoride grows.
  • a part of the fluorine atoms contained in SmFe 11 MnF and SmFeMn 11 F 2 are arranged at the penetration position to expand the crystal lattice, and in the former, the magnetic moment increases and the Curie temperature rises by about 250 ° C. due to the introduction of fluorine. In the latter, the difference in magnetic moment depending on the atomic site of Mn is increased, and the magnetization is increased by 20%.
  • the magnetic property of the magnetic film of the SmFe 11 Mn 5 F 2 composition is that the demagnetization curve depends on the direction of the magnetic field during cooling due to the occurrence of exchange coupling between the two phases due to cooling in a magnetic field. It had a high coercive force characteristic of a magnetic force of 35 kOe.
  • the magnetic phase is composed of at least two phases of Re u Fe v M w F a and Re x Fe y M z F b ,
  • Re is a rare earth element including Y
  • Fe is iron
  • M is transition such as Mn or Cr.
  • F is fluorine
  • u, v, w, a, x, y, z, b are positive numbers
  • magnetic coupling can be confirmed by the fact that there is a difference of 0.5 kOe or more in coercive force comparing the case of employing cooling in the magnetic field and the case of cooling without magnetic field, and in the growth of the two phases.
  • Re u Fe v of the magnetic phase M w F a or Re x Fe y M z F major phase only any one phase of b represents the hard magnetic properties even when made, various magnetic circuits as a magnet material Applicable to In these main phases, the magnetoresistive effect, the magnetostrictive effect, the thermoelectric effect, and the magnetism are accompanied by the large change of the electronic state by controlling u, v, w, a, x, y, z, b. The effects of refrigeration, magnetic heating, magnetic field induced structural phase transition or superconductivity are shown.
  • a 2 ⁇ m thick iron foil is thermally reduced in hydrogen gas to remove surface oxides. Fluorine ions are implanted into this iron foil at a temperature of 150.degree. The injection amount is 1 ⁇ 10 16 / cm 2 .
  • a bcc or bct structure with a lattice constant of 0.2865-0.295 was confirmed in iron after injection, and the concentration of fluorine was higher in the center or inside of the foil than in the outermost surface, and the lattice volume also tended to be large. This injection increases the saturation magnetization of the iron foil by about 5%.
  • This increase in saturation magnetization is due to the fluorine atoms penetrating into tetrahedral or octahedral sites of the body-centered cubic lattice.
  • an alcohol solution in which the SmF 3 composition is swelled is coated and dried to a film thickness of 10 nm on this fluorine-injected iron foil, and then heat treated at 400 ° C. for 5 hours to diffuse Sm and fluorine. Sm and fluorine diffuse to the center of the iron foil to increase anisotropy.
  • Bcc iron, bct iron and Sm 2 Fe 17 F grow on the iron foil, and fluorine is placed at the interstitial or substitutional position of iron and Sm 2 Fe 17 , resulting in an increase in lattice distortion, It was confirmed from the peak position and peak width of the X-ray diffraction pattern that the interplanar spacing increased.
  • the Sm 2 Fe 17 powder is ground to a particle size of about 1 ⁇ m and reduced at 500 ° C. in a hydrogen stream.
  • a pressure of 0.5 t / cm 2 is applied to the oxide-removed Sm 2 Fe 17 powder in a magnetic field of 10 kOe to form a preform.
  • the interstices of the preform are impregnated with an alcohol solution in which the SmF 3.1 composition swells.
  • a SmF-based amorphous film is formed on the surface of the Sm 2 Fe 17 powder. This is heated and dried in a hydrogen stream to crystallize a part of the amorphous film while suppressing oxidation.
  • the surface of the Sm 2 Fe 17 powder is fluorinated by irradiating an electromagnetic wave in a hydrogen gas flow to generate heat in the fluoride.
  • Pressure can be applied during fluorination to form a high density compact, and the magnetic properties are: residual magnetic flux density 1.6 T, coercivity 25 kOe, Curie temperature 720 K, magnetic recording medium, magnetic film of magnetic head, motor
  • magnetic properties are: residual magnetic flux density 1.6 T, coercivity 25 kOe, Curie temperature 720 K, magnetic recording medium, magnetic film of magnetic head, motor
  • a molded product having a residual magnetic flux density of 1.6 T and a Curie temperature of 700 K as described above is Re n (Fe, M) m F l as described above (where Re is a rare earth element containing Y, Fe is iron, M is a transition element, F is fluorine, n, m and l are positive numbers, n ⁇ 0.11 (n + m), and the Re content is less than 11 atomic% based on 100% of Re, Fe and M And the Fe-rich compound is a main phase having a crystal structure such as hexagonal, rhombohedral, tetragonal, orthorhombic, cubic, etc.
  • Fluoride or acid fluoride, oxide, and iron or iron fluorine binary alloy phase of bcc or bct structure which has different crystal structure depending on concentration and grows in forming a main phase fluorine compound in the compact Are formed and arranged between iron and iron atoms, and fluorine atoms and iron-iron A fluorine atom which forms a compound with a rare earth element or oxygen without being disposed between the atoms is recognized, and either of the fluorine introduction effect is recognized in both the exchange coupling in the ferromagnetic substance and the superexchange interaction in the ferrimagnetic substance.
  • the fluorine concentration tends to be higher on the particle outer peripheral side on average than the particle center, and the lattice volume also tends to be larger on the outer peripheral side of the particles than in the central portion. Since the magnetic anisotropy is large on the grain outer peripheral side, a difference is observed in the domain wall width of the magnetic domain structure. When the main phase fluoride is heated to over 600 ° C., some grains change in structure to become a more stable fluoride and iron alloy phase.
  • the concentration of the transition element M is the stability of the crystal structure Contribute to improvement.
  • the Re n (Fe, M) m F 1 contains oxygen, hydrogen, nitrogen, carbon, boron, or trace metal impurities as impurities, and there is no problem with M and Re elements. Some of them may be localized at grain boundaries or surfaces, and may be chlorine, phosphorus, sulfur, or a mixture of these elements and fluorine instead of fluorine in F.
  • Re n (Co, M) m F 1 (where Re is Y, a rare earth element containing Y, Co is cobalt, M is one or more types) using Co instead of iron used in the above-mentioned ferromagnetic fluoride Transition elements, F is fluorine, n, m and l are positive numbers n ⁇ 0.11 (n + m), and the Re content is less than 11 atomic% when the sum of Re, Co and M is 100%)
  • the effect of increasing the coercivity, increasing the magnetization or increasing the Curie temperature can be obtained by the introduction of fluorine.
  • the Sm 2 Fe 17 powder is ground to a particle size of about 0.5 ⁇ m and reduced at 500 ° C. in a stream of ammonia.
  • the oxide is removed, and a partially nitrided Sm 2 Fe 17 powder is subjected to a pressure of 0.5 t / cm 2 in a magnetic field of 10 kOe to form a preform.
  • the interstices of the preform are impregnated with an alcohol solution in which the PrF 3.1 composition has swelled. By this impregnation treatment, a PrF-based amorphous film is formed on the surface of the Sm 2 Fe 17 N 1-3 powder.
  • the surface of the Sm 2 Fe 17 powder is fluorinated by irradiating an electromagnetic wave in a hydrogen gas flow to generate heat in the fluoride.
  • pressure can be applied to form a high density compact, and a part of Pr and Sm exchange reaction proceeds by diffusion.
  • PrF 3 , PrOF, and Pr 2 O 3 grow on the magnetic powder surface, and (Sm, Pr) 2 Fe 17 (N, F) 1-3 grows on the outer peripheral portion of the crystal grain in the magnetic powder.
  • the central portion of the crystal grain has a lower fluorine concentration and Pr concentration than the outer peripheral portion and a smaller lattice constant, and the unit cell or lattice volume tends to be smaller on the inner peripheral portion on average than the outer peripheral portion of the crystal grain.
  • fluorides, acid fluorides, and oxides containing the above-mentioned rare earth elements, Fe, Fe-F of bcc, fcc structure, or iron-based alloys thereof may be added to grain boundaries or part of the surface.
  • the phase containing the rare earth elements and nitrogen, carbon, oxygen, etc. grows.
  • the lattice constant of these Fe-based alloys is smaller than (Sm, Pr) 2 Fe 17 (N, F) 1-3 of the matrix, and the lattice volume of the Fe-based alloy is smaller than that of the matrix.
  • the magnetic properties of magnetic powder are residual magnetic flux density 190 emu / g, coercivity 25 kOe, Curie temperature 730 K, and it has magnetic properties applicable to small magnetic circuits including motors, so surface magnet motors, embedded magnet motors, polar anisotropy
  • the present invention can be applied to magnet motors such as magnet motors, radial ring magnet motors, axial gap magnet motors, and linear magnet motors.
  • magnetic particles having a residual magnetic flux density of 190 emu / g and a Curie temperature exceeding 700 K are Re n (Fe, M) m (N, F) l as described above (where Re is a rare earth element containing Y, Fe Is iron, M is a transition element, N is nitrogen, F is fluorine, n, m and l are positive numbers n ⁇ 0.11 (n + m), Re content is Re, and the sum of Fe and M is 100%. (Less than 11 at.%)), And the alloy phase has a crystal structure such as hexagonal crystal, rhombohedral crystal, tetragonal crystal, orthorhombic crystal, or cubic crystal.
  • a main phase which has a different crystal structure and an ordered / irregular structure depending on the fluorine concentration, and the formed body has a fluoride or acid fluoride, an oxide, and an oxide or fluoride which grow when forming the main phase fluorine compound.
  • Iron or iron-fluorine binary alloy with bcc or bct or fcc structure Fluorine atoms which are arranged between iron and iron atoms and fluorine atoms which are not arranged between iron and iron atoms and which form a compound with rare earth elements or oxygen are recognized, and the distribution change of the density of electronic states in the ferromagnetic material
  • fluorine concentration tends to be higher on the grain outer peripheral side on average than the grain center, and the lattice volume also tends to be larger on the outer circumference side of the grain than the central part.
  • n ⁇ 0.11 the concentration of the rare earth element becomes high, the cost of the raw material for the material becomes expensive, and the residual magnetic flux density is lowered.
  • the optimum n is 0.01 ⁇ n ⁇ 0.11.
  • n ⁇ 0.01 the coercivity decreases and the residual magnetic flux density also decreases.
  • the nitrogen-containing fluoride of the main phase is heated to 650 ° C. or higher, some of the crystal grains change their structure to become a more stable fluoride or nitride and iron alloy phase.
  • transition elements M such as Al, Ga, Ge, Co, Ti, Mg, Co, Mn, Cr, Nb, Cu, Bi, Sr, W, Ca, etc.
  • M transition elements
  • the M element is localized at grain boundaries and surfaces. Instead of fluorine in F, chlorine, phosphorus, sulfur, or a mixture of these elements and fluorine may be used.
  • An alloy of Sm 2.1 Fe 17 is prepared by vacuum melting and subjected to hydrogen grinding to obtain Sm 2 Fe 17 powder with a particle size of about 10 ⁇ m.
  • the powder is heated to 300 ° C. in a gas decomposed CaH 2 and NH 4 F and held for 5 hours. By this heat treatment, Sm 2 Fe 17 F 0.1-3 is grown.
  • the Sm 2 Fe 17 F 0.1-3 is inserted into a mold of a thermoforming apparatus and extruded at 400 ° C. under a load of 3 t / cm 2 . By plastic deformation of the powder during heat forming, the orientation direction of Sm 2 Fe 17 F 0.1-3 is aligned, and a highly anisotropic magnetic material or magnetic powder is obtained.
  • Sm 2 Fe 17 F 0.1 is surfaced from Sm 2.1 Fe 17 surface by mechanical alloying using a mixed slurry of powder of SmF 3 with an average diameter of 10 nm and alcohol. -3 can grow.
  • a compression molded bonded magnet having a residual magnetic flux density of 1.3 T and a coercive force of 25 kOe can be obtained at 20 volume% of resin.
  • the volume of the binder material can be further reduced by converting the resin binder to a fluoride such as MgF 2 which is an inorganic binder, and the residual magnetic flux density and energy product increase.
  • the main phase composition of the magnetic powder satisfying the magnetic properties of the bonded magnet is RexFeyFz (Re is a rare earth element containing Y, Fe is iron, F is fluorine, x, y and z are positive numbers and y> (x + z)) Or a fluorine-containing iron having a bcc or bct structure in which part of the fluorine atom is located at the penetration position of the main phase and a grain boundary or part of the surface, and an acid fluoride such as SmOF, a fluoride such as SmF 3 or FeF 2 Alternatively, nonmagnetic or ferrimagnetic oxides or hydrides such as Fe 2 O 3 and SmO 2 are grown, the fluorine concentration is the highest for the acid fluoride or fluoride, and the lattice volume of the main phase is bcc or bct.
  • the crystal grains or magnetic particles that make up the magnet have orientation in the a-axis or c-axis direction, and the volume of the main phase is 30% or more of the entire bonded magnet, preferably 50% to 9%. By setting it to 0%, a high residual magnetic flux density can be realized, and various gases containing fluorine can be used in addition to ammonium fluoride in the fluorination.
  • the main phase constituting the magnetic powder for bonded magnet is RexMyFz (Re is a rare earth element including Y, M is Co, an alloy of Fe and Co, F is fluorine, fluorine and carbon and nitrogen, oxygen, oxygen), in addition to the basic composition of RexFeyFz. Boron, chlorine, phosphorus, sulfur, a mixture with chlorine or chlorine, x, y and z may be positive numbers and y> (x + z)).
  • a sintered magnet containing Nd 2 Fe 14 B as a main phase is pulverized to form magnetic powder of 3 to 10 ⁇ m in diameter, mixed with a slurry in which FeF 2 powder of 0.5 ⁇ m in average diameter is mixed with alcohol,
  • the mechanical alloying is carried out with a hydride coated stainless steel ball. After mechanical alloying, part of the surface of Nd 2 Fe 14 B powder is fluorinated, and heat treatment at 300 ° C. further grows Nd 2 Fe 17 F phase and bcc or bct iron, and the Curie temperature is higher than immediately after mechanical alloying Rises, and the residual magnetic flux density increases.
  • the increase in the magnetic flux density is due to the growth of the N- 2 Fe 17 F phase with a high Curie point with iron by the above-mentioned mechanical alloy (mechanical alloying) and subsequent heat treatment.
  • fluorides such as FeF 3 , NdF 3 , NdF 2
  • acid fluorides such as NdOF, (Nd, Fe) OF or Nd 2 O 3 , Fe 2 O 3 on the powder surface , Oxides such as Fe 3 O 4 grow.
  • the fluorine concentration of Nd 2 Fe 17 F is increased by exposing the powder to a gas containing fluorine such as ammonium fluoride, fluorine and hydrogen fluoride during heat treatment after mechanical alloying, and Nd 2 Fe 17 F 2-3 is a powder. It grows on the surface and the Curie temperature rises to 710K.
  • a gas containing fluorine such as ammonium fluoride, fluorine and hydrogen fluoride during heat treatment after mechanical alloying
  • Curie temperature to grow high and anisotropy is large hard magnetic phase than Nd 2 Fe 14 magnetically coupled to the B Nd 2 Fe 14 B, inhibit the magnetization reversal of the Nd 2 Fe 14 B, It contributes to the reduction of thermal demagnetization, and it is possible to improve heat resistance without adding heavy rare earth elements, and the powder center is an iron-rich phase with soft magnetic characteristics, and the magnetic anisotropy is high on the outer circumference side and the Curie temperature
  • By growing a high hard magnetic material and adding magnetic coupling between the iron-rich phase and the hard magnetic material it is possible to make a hard magnetic material capable of reducing the amount of rare earth elements used.
  • light rare earth fluoride is grown by solution treatment on the surface of a fluorine-containing iron-fluorine alloy powder having a magnetic flux density higher than that of pure iron, and fluorine and light rare earth elements are diffused by heat treatment in hydrogen or fluorine containing gas.
  • RexFeyFz Re is a light rare earth element, Fe is iron, F is fluorine, x, y and z are positive numbers and y> (x + z)
  • acid fluoride can be grown on the outer peripheral side of the powder, residual magnetic flux A magnet material with a density of 1.8 T is obtained.
  • ferromagnetic coupling can be provided between a plurality of ferromagnetic phases different in crystal structure and composition to improve the magnetic properties, and fluorine is contained in at least one ferromagnetic phase, and the fluorine concentration is in the crystal grains.
  • fluorine is contained in at least one ferromagnetic phase, and the fluorine concentration is in the crystal grains.
  • There is a concentration gradient and some fluorine atoms form a compound of rare earth element and iron, some fluorine atoms are arranged in iron, and the electron's state density because of the high electronegativity of fluorine
  • the distribution and the electric field gradient are biased, and the physical property values such as the magnetic property and the electric property are changed to improve the magnetic property, and the residual magnetic flux density of 1.8 T is realized.
  • the effect of introducing fluorine appears in magnetic transformation at an internal magnetic field or at a low temperature, the magnetoresistance effect, the magnetic heat generation effect, the magnetic heat absorption effect, and the superconducting characteristics.
  • An alloy target of Sm 2 Fe 17 is prepared at a purity of 99.9%, one side of the target is water-cooled, and one side is sputtered.
  • the film was formed at ° C. Before sputtering, the substrate surface is cleaned by cleaning and reverse sputtering.
  • the composition of the formed film was Sm 2 Fe 17 F 2 , and the lattice constant increased compared to the Sm 2 Fe 17 film, and the increase of the Curie temperature, the saturation magnetic flux density, and the magnetic anisotropy energy was observed.
  • the orientation of the Sm 2 Fe 17 F 2 film depends on the substrate temperature and the film formation rate, a film of c-axis orientation is obtained under the above conditions, and has an easy magnetization axis in the plane.
  • the Sm 2 Fe 17 F 2 is epitaxially grown on the MgO substrate, but when this film is heated at 400 ° C. for 1 hour, it was confirmed by the XRD pattern that Smc 3 and fluorine-containing bcc or bct structure iron grow. .
  • the iron of the bcc or bct structure containing fluorine is 1 to 20% higher than the saturation magnetization of pure iron, so that ferromagnetic coupling is provided between these fluorine-containing ferromagnetic iron and the fluorine compound as the main phase. It is possible to increase the residual magnetic flux density.
  • Such fluorine-containing iron is a metastable phase and changes to FeF 2 when heated, but in order to stabilize the metastable phase up to a high frequency, it contacts an acid fluoride having a lattice constant of 5.4 to 5.9 nm. Stabilizing the structure, stabilizing by adding carbon and nitrogen, and growing with bcc are effective means. By such means, fluorine-containing iron is less likely to undergo structural change at 400 ° C.
  • the Sm 2 Fe 17 F 2 film grown on the MgO substrate is heat-treated at 400 ° C. for 1 hour, and its magnetic properties are a residual magnetic flux density of 1.55 T and a coercive force of 26 kOe.
  • a material having a residual magnetic flux density of 1.4 T or more and a coercive force of 20 kOe or more is confirmed by the following similar materials other than the above Sm 2 Fe 17 F 2 . That is, it is a composition in which the ferromagnetic phase of the main phase is at least one RexFeyFz (Re is a rare earth element containing Y, Fe is iron, F is fluorine, x, y and z are positive numbers and y> (x + z)) Fluoride-containing iron having bcc or bct structure, which is formed in magnetic powder or crystal grains, part of fluorine atoms is disposed at the penetration position of the main phase, and part of grain boundary or surface, and acid fluoride such as SmOF Fluorides such as SmF 3 and FeF 2 or oxides such as nonmagnetic or ferrimagnetic and antiferromagnetic such as Fe 2 O 3 and SmO 2 are grown, and the fluorine concentration is the highest with the above
  • the lattice volume of the main phase is larger than that of bcc or bct iron-fluorine alloy, and the above magnetic characteristics can be realized with a material having orientation in the a-axis or c-axis direction in crystal grains or magnetic powder constituting the magnet.
  • F may be fluorine or a mixture of fluorine and fluorine with carbon, nitrogen, oxygen, boron, chlorine, phosphorus, sulfur, hydrogen, or chlorine, and various gas species containing fluorine or chlorine can be used.

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