WO2015046140A1 - Fe基ナノ結晶合金の製造方法及びFe基ナノ結晶合金磁心の製造方法 - Google Patents
Fe基ナノ結晶合金の製造方法及びFe基ナノ結晶合金磁心の製造方法 Download PDFInfo
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- WO2015046140A1 WO2015046140A1 PCT/JP2014/075070 JP2014075070W WO2015046140A1 WO 2015046140 A1 WO2015046140 A1 WO 2015046140A1 JP 2014075070 W JP2014075070 W JP 2014075070W WO 2015046140 A1 WO2015046140 A1 WO 2015046140A1
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D6/00—Heat treatment of ferrous alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C45/00—Amorphous alloys
- C22C45/02—Amorphous alloys with iron as the major constituent
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/06—Surface hardening
- C21D1/09—Surface hardening by direct application of electrical or wave energy; by particle radiation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
- H01F1/153—Amorphous metallic alloys, e.g. glassy metals
- H01F1/15333—Amorphous metallic alloys, e.g. glassy metals containing nanocrystallites, e.g. obtained by annealing
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/34—Methods of heating
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D2201/00—Treatment for obtaining particular effects
- C21D2201/03—Amorphous or microcrystalline structure
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
- C21D8/12—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of articles with special electromagnetic properties
Definitions
- the present invention relates to an Fe-based nanocrystalline alloy and a method for manufacturing a magnetic core in which an Fe-based nanocrystalline alloy is wound or laminated.
- Fe-based nanocrystalline alloys have excellent soft magnetic properties that can achieve both high saturation magnetic flux density and high relative magnetic permeability ⁇ , and are therefore used in magnetic cores such as common mode choke coils and high frequency transformers.
- a typical Fe-based nanocrystalline alloy composition system is the Fe—Cu—Nb—Si—B system described in Patent Document 1.
- An Fe-based nanocrystalline alloy is produced by microcrystalline (nanocrystallizing) an amorphous alloy obtained by rapid solidification of a liquid phase alloy heated to a temperature equal to or higher than the melting point. .
- a method for rapid solidification from the liquid phase for example, a single roll method excellent in productivity is adopted.
- the Fe-based nanocrystalline alloy has different magnetic properties such as relative permeability ⁇ and squareness ratio by applying a temperature profile during heat treatment and applying a magnetic field in a specific direction during heat treatment.
- Patent Document 2 in order to obtain an Fe-based nanocrystalline alloy having an initial relative permeability of 70,000 or more and a squareness ratio of 30% or less, a magnetic field is applied in the ribbon width direction (magnetic core height direction). It has been proposed to heat-treat while. Although there are various patterns as specific examples of the heat treatment in Patent Document 2, it is roughly divided to hold while applying a magnetic field in the highest temperature range of the heat treatment, cooling process from the temperature rising process to the highest temperature range And holding while applying a magnetic field, and holding while applying a magnetic field from the highest temperature range to the cooling process.
- Patent Document 2 The heat treatment method disclosed in Patent Document 2 is considered effective as a means for reducing the squareness ratio.
- the frequency band used as a common mode choke or the like has become a high frequency band near 100 kHz, and there is an increasing demand for miniaturization of magnetic components in such a high frequency band. That is, a nanocrystalline alloy having a high relative permeability ⁇ in a high frequency range is desired.
- the present inventor conducted various studies in order to obtain a high relative permeability ⁇ at a high frequency near 100 kHz. As a result, it has been recognized that it may be difficult to obtain a high relative permeability ⁇ in the high frequency region in the heat treatment patterns described in Patent Document 1 and Patent Document 2.
- the present invention has been made in view of the above, and provides a method for producing an Fe-based nanocrystalline alloy and a method for producing an Fe-based nanocrystalline alloy magnetic core in which a high relative permeability ⁇ can be easily obtained in the vicinity of a frequency of 100 kHz. For the purpose.
- a method for producing an Fe-based nanocrystalline alloy according to an embodiment of the present invention comprises heating a nanocrystallizable Fe-based amorphous alloy ribbon to a crystallization temperature region and cooling it. And includes at least part of a temperature range from a low crystallization start temperature of 50 ° C. to a high crystallization start temperature of 20 ° C. in the differential scanning calorimeter.
- a magnetic field is selectively applied in the width direction of the alloy ribbon in a temperature range during a temperature rising period not exceeding 50 ° C. of the temperature, that is, in a temperature range during the temperature rising period.
- a magnetic field having a magnetic field strength of 50 kA / m to 300 kA / m is applied in the width direction of the alloy ribbon.
- the magnetic field is not applied when the maximum temperature in the heat treatment step is reached.
- a method for producing an Fe-based nanocrystalline alloy ribbon includes a step of preparing a nano-crystallizable Fe-based amorphous alloy ribbon, and the Fe-based amorphous alloy ribbon in a crystallization temperature range.
- a predetermined intensity for example, 50 kA / m
- a predetermined intensity for example, 50 kA / m
- a magnetic field of the predetermined strength or higher is not applied during a part of the temperature raising period.
- a magnetic field of the predetermined strength or higher is not applied during a temperature rising period exceeding the crystallization start temperature of 50 ° C. or higher. Further, it is not necessary to apply a magnetic field having the predetermined strength or more even during a temperature rising period below the crystallization start temperature of 50 ° C.
- the method for producing a magnetic core includes heating or laminating a nano-crystallizable Fe-based amorphous alloy ribbon to a crystallization temperature region.
- a magnetic core comprising an Fe-based nanocrystalline alloy ribbon wound or laminated by a heat treatment step for cooling, wherein in the heat treatment step, a crystallization start temperature of a differential scanning calorimeter is measured.
- the temperature range includes at least a part of the temperature range from a low temperature of 50 ° C. to a high temperature of 20 ° C. of the crystallization start temperature and does not exceed the high temperature of 50 ° C. of the crystallization start temperature.
- a magnetic field is selectively applied in the height direction of the magnetic core in a temperature range during the warm period.
- a magnetic field having a magnetic field strength of 50 kA / m or more and 300 kA / m or less is applied in the height direction of the magnetic core.
- the Fe-based nanocrystalline alloy ribbon has a thickness of 15 ⁇ m or less and a width of 250 mm or less.
- a high relative permeability ⁇ can be easily realized at a high frequency in the vicinity of a frequency of 100 kHz. Therefore, it is possible to provide an Fe-based nanocrystalline alloy or an Fe-based nanocrystalline alloy magnetic core that is suitably used for a common mode choke or the like in which high-frequency characteristics are important.
- One of the features of the method for manufacturing an Fe-based nanocrystalline alloy and a magnetic core according to an embodiment of the present invention is that when an Fe-based nanocrystalline alloy is obtained by performing a heat treatment while applying a magnetic field to an amorphous alloy. Unlike the case, it is possible to selectively apply a magnetic field in a specific temperature range during the temperature rising period. The magnetic field is applied along the width direction of the ribbon and the height direction as the magnetic core.
- At least a part of the temperature range from a low crystallization start temperature specified by using a differential scanning calorimeter to a high crystallization start temperature of 50 ° C. to a high crystallization start temperature of 20 ° C.
- a magnetic field is selectively applied along the width direction of the alloy ribbon during the heat treatment in a temperature rising period that includes a period and does not exceed the 50 ° C. crystallization start temperature.
- the magnetic field is applied in the period during the temperature rising period without applying the magnetic field in the vicinity of the highest temperature of the heat treatment or in the cooling process after the highest temperature is reached.
- the present inventor confirmed that the relative permeability ⁇ at a frequency of 100 kHz does not substantially decrease even if the magnetic field is relatively weak (for example, less than 50 kA / m) even when applied near the maximum temperature of heat treatment. Has been. Therefore, in the embodiment of the present invention, a relatively weak magnetic field may be applied temporarily or continuously in any period of the heat treatment step.
- application of a weak magnetic field of less than 50 kA / m may be regarded as not applying a magnetic field.
- application of a magnetic field having a magnitude typically 50 kA / m or more and 300 kA / m or less
- the amorphous alloy before heat treatment has a Curie temperature lower than the crystallization start temperature.
- the Curie temperature greatly exceeds the crystallization start temperature. In other words, if a magnetic field is applied during the crystallization period, the magnetic domain is fixed with the crystallization, and it is estimated that the same effect as that obtained by cooling from the Curie temperature or higher is obtained.
- the magnetic field is applied during a temperature rising period that does not exceed 50 ° C., which is the crystallization start temperature.
- the temperature range in which the magnetic field is applied includes at least a part of the temperature range from a low crystallization start temperature of 20 ° C. to a high crystallization start temperature of 10 ° C. in the differential scanning calorimeter.
- the upper limit of the temperature at which the magnetic field is applied is 50 ° C. higher than the crystallization start temperature. More preferably, the upper limit of the temperature at which the magnetic field is applied is a temperature 40 ° C. higher than the crystallization start temperature.
- an effective magnetic field of a predetermined intensity or higher (for example, 50 kA / m or higher) is performed during a part of the temperature rising period. It does not take place over the entire period. That is, there is a period during which no effective magnetic field is applied during the temperature raising period.
- an effective magnetic field is selectively applied in a temperature range near the crystallization start temperature. For example, a temperature range of 50 ° C. and a temperature range higher than 50 ° C.
- the “temperature increase period” means a period before the maximum temperature is reached, and before reaching the maximum temperature, the temperature is increased, the temperature is decreased, and a certain temperature is reached. It may be in a holding state.
- the crystallization start temperature is determined by a differential scanning calorimeter. It is difficult to accurately measure the true crystallization start temperature, and identification by a differential scanning calorimeter (DSC) is effective.
- the temperature at which an exothermic reaction due to the start of nanocrystallization was detected during the temperature rise was defined as the crystallization start temperature.
- the measurement conditions of the differential scanning calorimeter in the present invention are set at a heating rate of 10 ° C./min.
- the heat treatment temperature is controlled by taking into consideration the capacity of the heat treatment furnace and the amount of heat generated by the crystallization of the amorphous alloy ribbon to be heat treated while the actual temperature distribution in the heat treatment furnace is positive. It is preferable to control so that it may become minus 5 degrees C or less. By performing such control, the magnetic properties of the alloy after heat treatment can be stabilized.
- the strength of the applied magnetic field is preferably 50 kA / m or more and 300 kA / m or less. If the applied magnetic field is too weak, it is difficult to impart induced magnetic anisotropy under actual working conditions. If it is too high, induced magnetic anisotropy tends to be imparted too much.
- a more preferable range is 60 kA / m or more and 240 kA / m.
- the time for applying the magnetic field is not particularly limited as long as it is in the first half temperature range, but about 1 to 180 minutes is practical.
- the nano-crystallizable Fe-based amorphous alloy for example, the general formula: (Fe 1-a M a ) 100-xyz- ⁇ - ⁇ - ⁇ Cu x Si y B z M ' ⁇ M ′′ ⁇ X ⁇ (atomic%) (where M is Co and / or Ni, and M ′ is at least selected from the group consisting of Nb, Mo, Ta, Ti, Zr, Hf, V, Cr, Mn and W)
- M ′′ is at least one element selected from the group consisting of Al, platinum group elements, Sc, rare earth elements, Zn, Sn, Re, X is C, Ge, P, Ga, Sb, In , Be, As, and at least one element selected from the group consisting of a, x, y, z, ⁇ , ⁇ , and ⁇ is 0 ⁇ a ⁇ 0.5, 0.1 ⁇ x ⁇ 3, respectively.
- a long amorphous alloy ribbon can be obtained by melting an alloy having the above composition to a melting point or higher and rapidly solidifying it by a single roll method.
- the thickness of the amorphous alloy ribbon is preferably 10 to 30 ⁇ m. If it is less than 10 ⁇ m, the mechanical strength of the ribbon is insufficient and the ribbon is easily broken during handling. When it exceeds 30 ⁇ m, it is difficult to stably obtain an amorphous state.
- the amorphous alloy ribbon is nanocrystallized and used as a magnetic core for high-frequency applications, an eddy current is generated in the ribbon, but the loss due to the eddy current increases as the ribbon becomes thicker. Therefore, a more preferable thickness is 10 to 20 ⁇ m.
- the relative permeability ⁇ at a high frequency in the vicinity of 100 kHz can obtain a larger value as the thickness is thinner, and therefore a thickness of 15 ⁇ m or less is more preferable.
- the width of the amorphous alloy ribbon is preferably 10 mm or more in consideration of a practical magnetic core shape. Since it is possible to reduce the cost by slitting a wide alloy ribbon, it is preferably wide at the stage after quenching, but is preferably 250 mm or less for stable production of the alloy ribbon. In order to manufacture more stably, 70 mm width or less is more preferable.
- the heat treatment for nanocrystallization is preferably performed in an inert gas such as nitrogen, and the maximum temperature reached is preferably set to 550 to 600 ° C.
- the temperature is less than 550 ° C. or exceeds 600 ° C., the magnetostriction is increased, which is not preferable. Even if the holding time at the highest temperature is not specifically set and is 0 minute (no holding time), nanocrystallization can be performed.
- the alloy may be held at the maximum temperature for more than 0 minutes and not more than 3 hours.
- the temperature profile in the heat treatment is, for example, that the temperature rises relatively rapidly at a temperature rise rate of 2 to 4 ° C./min from room temperature to around the temperature at which nanocrystallization starts, and the temperature at which nanocrystallization starts is 50 ° C. From the low temperature to the highest temperature, the temperature may be increased at a moderate temperature increase rate of 0.2 to 1 ° C./min on average. By doing in this way, nanocrystallization can be performed efficiently and stably. In the cooling process after nanocrystallization, it is preferable to cool at a cooling rate of 2 to 5 ° C./min in a temperature range from the highest temperature to 200 ° C. Usually, after cooling to below 100 ° C., the alloy can be taken out into the atmosphere.
- a heat treatment step of heating and cooling to a crystallization temperature region may be performed after a nano-crystallizable Fe-based amorphous alloy ribbon is wound or laminated.
- the magnetic field is applied as described above. By making the direction of the applied magnetic field the height direction of the magnetic core, a desired induced magnetic anisotropy can be imparted.
- DSC differential scanning calorimeter
- the produced magnetic core was subjected to heat treatment and magnetic field application with the temperature and magnetic field application profiles shown in FIG.
- the magnetic field was continuously applied over a temperature range of 440 to 480 ° C. (temperature range from a low crystallization start temperature of 60 ° C. to a crystallization start temperature of 20 ° C.) during the temperature rising period.
- the magnetic field application direction was the width direction of the alloy ribbon, that is, the height direction of the magnetic core.
- the magnetic field strength was 120 kA / m.
- the maximum temperature reached in the heat treatment is 580 ° C.
- the relative magnetic permeability ⁇ at 100 kHz of the 10 magnetic cores (alloys) after the heat treatment was in the range of 27,000 to 30,000.
- Measurement was performed under conditions of an oscillation level of 0.5 V and an average of 16 using HP4194A manufactured by Agilent Technologies.
- the insulation coated conductor was passed through the center of the toroidal magnetic core and connected to an input / output terminal for measurement.
- Example 1 Ten toroidal magnetic cores were similarly produced using an Fe-based amorphous alloy ribbon having the same composition and size as in Example 1. As shown in FIG. 5, the manufactured magnetic core was heat-treated according to the same profile as the temperature profile of Example 1 shown in FIG. 1 without applying a magnetic field (without a magnetic field).
- the relative magnetic permeability ⁇ at 100 kHz of the 10 magnetic cores (alloys) after the heat treatment was in the range of 20,000 to 24,000.
- Example 2 Using the same Fe-based amorphous alloy ribbon as in Example 1, ten toroidal magnetic cores were similarly produced.
- the produced magnetic core was subjected to heat treatment and magnetic field application with the temperature and magnetic field application profiles shown in FIG. Only the temperature range of the magnetic field application is different from that of the first embodiment (FIG. 1), and other conditions are the same as those of the first embodiment.
- the application of the magnetic field is in a temperature range of 480 to 520 ° C. (temperature range from a low crystallization start temperature of 20 ° C. to a high crystallization start temperature of 20 ° C.).
- the relative permeability ⁇ at 100 kHz of the 10 magnetic cores (alloys) after the heat treatment was in the range of 31,000-32,000.
- Example 2 a higher relative magnetic permeability ⁇ can be obtained at 100 kHz than in Example 1. This indicates that if a magnetic field is applied in a temperature range including the crystallization start temperature by DSC, the relative permeability ⁇ at 100 kHz can be further improved even when the magnetic field is applied at the same magnetic field strength. ing.
- Example 3 Using the same Fe-based amorphous alloy ribbon as in Example 1, ten toroidal magnetic cores were similarly produced.
- the manufactured magnetic core was subjected to heat treatment and magnetic field application with the temperature and magnetic field application profiles shown in FIG. Only the magnetic field strength of the applied magnetic field is different from that of the second embodiment (FIG. 2), and other conditions are the same as those of the second embodiment.
- a magnetic field strength of 60 kA / m was applied as the magnetic field was raised.
- the relative permeability ⁇ at 100 kHz of the 10 magnetic cores (alloys) after the heat treatment was in the range of 28,000 to 30,000.
- Example 4 Using the same Fe-based amorphous alloy as in Example 1, ten toroidal magnetic cores were similarly produced. The produced magnetic core was subjected to heat treatment and magnetic field application with the temperature and magnetic field application profiles shown in FIG. Only the magnetic field strength of the applied magnetic field is different from that of the second embodiment (FIG. 2), and other conditions are the same as those of the second embodiment. A magnetic field was applied at a magnetic field strength of 240 kA / m when the temperature was raised.
- the relative permeability ⁇ at 100 kHz of the 10 magnetic cores (alloys) after the heat treatment was in the range of 27,000 to 29,000.
- Comparative Example 2 Using the same Fe-based amorphous alloy ribbon as in Example 1, ten toroidal magnetic cores were similarly produced. The produced magnetic core was subjected to heat treatment and magnetic field application with the temperature and magnetic field application profiles shown in FIG. In Comparative Example 2, the magnetic field strength and the application time in the magnetic field application are the same as in Examples 1 and 2 (FIGS. 1 and 2), but the temperature range of the magnetic field application is from 560 ° C. to the highest equivalent temperature 580 ° C. This leads to cooling. In this temperature range, the magnetic field application start temperature is 60 ° C. higher than the crystallization start temperature.
- the relative permeability ⁇ at 100 kHz of the 10 magnetic cores (alloys) after the heat treatment was in the range of 24,000 to 25,000.
- Comparative Example 2 the relative permeability ⁇ at 100 kHz is only 4000 higher than in Comparative Example 1 where no magnetic field is applied.
- the relative permeability ⁇ at a frequency of 10 kHz was evaluated in Comparative Example 1 and Comparative Example 2, it was about 80,000 in Comparative Example 1 and about 35,000 in Comparative Example 2.
- a high relative permeability ⁇ This is because, when a magnetic field is applied in a high temperature region that is higher by 50 ° C. than the crystallization start temperature, the magnetic anisotropy imparted to the magnetic core becomes too large, and the relative permeability ⁇ at 100 kHz decreases. It is estimated that this occurred.
- Example 3 Using the same Fe-based amorphous alloy ribbon as in Example 1, ten toroidal magnetic cores were similarly produced. A magnetic field was applied to the manufactured magnetic core for the entire period of the heat treatment step with the temperature and magnetic field application profiles shown in FIG. The applied magnetic field strength was 290 kA / m.
- the relative permeability ⁇ at 100 kHz of the 10 magnetic cores (alloys) after the heat treatment was in the range of 14,000 to 15,000.
- Example 5 At 1%, Cu: 1%, Nb: 2.5%, Si: 13.5%, B: 7.2%, the molten alloy consisting of the balance Fe and inevitable impurities is rapidly cooled by a single roll method. A Fe-based amorphous alloy ribbon having a thickness of 60 mm and a thickness of 18 ⁇ m was obtained. After slitting this Fe-based amorphous alloy ribbon to a width of 3 mm, it was wound to an outer diameter of 20 mm and an inner diameter of 10 mm to produce 10 toroidal magnetic cores. The crystallization start temperature of this alloy was measured and found to be 480 ° C.
- the produced magnetic core was heat-treated with the heat treatment profile shown in FIG.
- the holding temperature was 580 ° C.
- the magnetic field was applied in the temperature range of 480 to 520 ° C. (temperature range from the crystallization start temperature to the crystallization start temperature 40 ° C.) during the temperature increase.
- the magnetic field application direction was the width direction of the alloy ribbon, that is, the height direction of the magnetic core.
- the magnetic field strength was 120 kA / m.
- the relative permeability ⁇ at 100 kHz was in the range of 19,000 to 22,000.
- Example 4 Using the same Fe-based amorphous alloy ribbon as in Example 5, ten toroidal magnetic cores were similarly produced.
- the manufactured magnetic core was heat-treated without applying a magnetic field (with no magnetic field) using the temperature and magnetic field application profiles shown in FIG.
- the relative magnetic permeability ⁇ at 100 kHz of the 10 magnetic cores (alloys) after the heat treatment was in the range of 17,000 to 18,000.
- Example 5 When Example 5 is compared with Comparative Example 4 in which no magnetic field is applied, it is confirmed that the relative permeability ⁇ at 100 kHz is clearly improved by applying the magnetic field in the temperature range near the crystallization start temperature. it can.
- the produced magnetic core was heat-treated with the heat treatment profile shown in FIG.
- the holding temperature was 580 ° C.
- the magnetic field was applied in the temperature range of 480 to 520 ° C. (temperature range from the crystallization start temperature to the crystallization start temperature 40 ° C.) during the temperature increase.
- the magnetic field application direction was the width direction of the alloy ribbon, that is, the height direction of the magnetic core.
- the magnetic field strength was 120 kA / m.
- the relative permeability ⁇ at 100 kHz was in the range of 15,000 to 17,000.
- Example 5 Using the same Fe-based amorphous alloy as in Example 6, ten toroidal magnetic cores were similarly produced. The manufactured magnetic core was heat-treated without applying a magnetic field (with no magnetic field) using the temperature and magnetic field application profiles shown in FIG.
- the relative permeability ⁇ at 100 kHz of the 10 magnetic cores (alloys) after the heat treatment was in the range of 9,000 to 12,000.
- Example 6 When Example 6 is compared with Comparative Example 5 in which no magnetic field is applied, the relative permeability ⁇ at 100 kHz can be clearly increased by applying a magnetic field in the temperature range near the crystallization start temperature. I can confirm.
- Example 7 A molten alloy having the same alloy composition as that of Example 1 (crystallization start temperature: 500 ° C.) was rapidly cooled by a single roll method to obtain a Fe-based amorphous alloy ribbon having a width of 50 mm and a thickness of 18 ⁇ m. After slitting this Fe-based amorphous alloy ribbon to a width of 15 mm, it was wound to an outer diameter of 31 mm and an inner diameter of 21 mm to produce four toroidal magnetic cores.
- the manufactured magnetic core was heat-treated with the heat treatment profile shown in FIG.
- the magnetic field was applied in the temperature range of 480 to 520 ° C. when the temperature was raised.
- the magnetic field application direction was the width direction of the alloy ribbon, that is, the height direction of the magnetic core.
- the magnetic field strength was 120 kA / m.
- the relative permeability ⁇ at 100 kHz was in the range of 28,000 to 29,000.
- Example 2 in which the thickness of the Fe-based amorphous alloy ribbon is 15 ⁇ m or less is more than Example 7 in which the thickness exceeds 15 ⁇ m. Also, it was confirmed that the relative permeability ⁇ at 100 kHz was slightly increased.
- the method for producing an Fe-based nanocrystalline alloy according to an embodiment of the present invention can be applied to the production of a magnetic core such as a common mode choke coil or a high-frequency transformer.
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Abstract
Description
本発明の実施形態によるFe基ナノ結晶合金の製造方法は、ナノ結晶化可能なFe基非晶質合金リボンを、結晶化温度領域に加熱し、冷却する熱処理工程を含み、前記熱処理工程において、示差走査熱量計での結晶化開始温度の50℃低温から結晶化開始温度の20℃高温までの温度範囲の少なくとも一部を含み、且つ前記結晶化開始温度の50℃高温を超えない昇温期間中の温度範囲で、すなわち、前記の昇温期間中の温度範囲において選択的に、前記合金リボンの幅方向に磁場を印加する。
本発明の実施形態による磁心の製造方法は、ナノ結晶化可能なFe基非晶質合金リボンを巻回または積層した後、結晶化温度領域に加熱し、冷却する熱処理工程を含み、これによって巻回または積層されたFe基ナノ結晶合金リボンを備える磁心を製造する方法であって、前記熱処理工程において、示差走査熱量計での結晶化開始温度の50℃低温から結晶化開始温度の20℃高温までの温度範囲を少なくとも一部を含み、且つ前記結晶化開始温度の50℃高温を超えない昇温期間中の温度範囲で、すなわち、前記の昇温期間中の温度範囲において選択的に、前記磁心の高さ方向に磁場を印加する。
原子%で、Cu:1%、Nb:3%、Si:15.5%、B:6.5%、残部Fe及び不可避不純物からなる合金溶湯を単ロ-ル法により急冷し、幅50mm、厚さ13μmのFe基非晶質合金リボンを得た。このFe基非晶質合金リボンを、幅3mmにスリットした後、外径20mm、内径10mmに巻回し、トロイダル磁心を10ヶ作製した。示差走査熱量計(DSC)で測定したところ、この合金の結晶化開始温度は500℃であった。
実施例1と同様の組成およびサイズを有するFe基非晶質合金リボンを用いて、同様にトロイダル磁心を10ヶ作製した。作製した磁心に対して、図5に示すように、磁場印加をすることなく(無磁場で)、図1に示した実施例1の温度プロファイルと同じプロファイルに従って熱処理を行った。
実施例1と同様のFe基非晶質合金リボンを用いて、同様にトロイダル磁心を10ヶ作製した。作製した磁心に対して、図2に示す温度及び磁場印加のプロファイルで熱処理及び磁場印加を行った。磁場印加の温度範囲のみが実施例1(図1)と異なっており、他の条件は実施例1と同様である。磁場の印加は、480~520℃の温度範囲(結晶化開始温度の20℃低温から結晶化開始温度の20℃高温の温度範囲)である。
実施例1と同様のFe基非晶質合金リボンを用いて、同様にトロイダル磁心を10ヶ作製した。作製した磁心に対して、図3に示す温度及び磁場印加のプロファイルでの熱処理及び磁場印加を行った。磁場印加の磁場強度のみが実施例2(図2)と異なっており、他の条件は実施例2と同様である。磁場は昇温時、磁場強度60kA/mを印加した。
実施例1と同様のFe基非晶質合金を用いて、同様にトロイダル磁心を10ヶ作製した。作製した磁心に対して、図4に示す温度及び磁場印加のプロファイルでの熱処理及び磁場印加を行った。磁場印加の磁場強度のみが実施例2(図2)と異なっており、他の条件は実施例2と同様である。磁場は昇温時、磁場強度240kA/mで印加した。
実施例1と同様のFe基非晶質合金リボンを用いて、同様にトロイダル磁心を10ヶ作製した。作製した磁心に対して、図6に示す温度及び磁場印加のプロファイルで熱処理及び磁場印加を行った。比較例2では、磁場印加における磁場強度及び印加時間は、実施例1及び2(図1及び図2)と同様であるが、磁場印加の温度範囲が、560℃から、最高等到達温度580℃を経て冷却に至るものである。この温度範囲は、磁場印加開始温度が、結晶化開始温度の60℃高温である。
実施例1と同様のFe基非晶質合金リボンを用いて、同様にトロイダル磁心を10ヶ作製した。作製した磁心に対して、図7に示す温度及び磁場印加のプロファイルで、熱処理工程の全期間に対して磁場を印加をした。印加した磁場強度は290kA/mとした。
原子%で、Cu:1%、Nb:2.5%、Si:13.5%、B:7.2%、残部Fe及び不可避不純物からなる合金溶湯を単ロ-ル法により急冷し、幅60mm、厚さ18μmのFe基非晶質合金リボンを得た。このFe基非晶質合金リボンを、幅3mmにスリットした後、外径20mm、内径10mmに巻回し、トロイダル磁心を10ヶ作製した。この合金の結晶化開始温度を測定したところ480℃であった。
実施例5と同様のFe基非晶質合金リボンを用いて、同様にトロイダル磁心を10ヶ作製した。作製した磁心に対して、図6に示す温度及び磁場印加のプロファイルで、磁場印加をすることなく(無磁場で)熱処理を行った。
原子%でNi:5%、Cu:0.8%、Nb:2.8%、Si:11%、B:9.8%、残部Fe及び不可避不純物からなる合金溶湯を単ロ-ル法により急冷し、幅50mm、厚さ13μmのFe基非晶質合金リボンを得た。このFe基非晶質合金リボンを、幅3mmにスリットした後、外径20mm、内径10mmに巻回し、トロイダル磁心を10ヶ作製した。この合金の結晶化開始温度を測定したところ480℃であった。
実施例6と同様のFe基非晶質合金を用いて、同様にトロイダル磁心を10ヶ作製した。作製した磁心に対して、図6に示す温度及び磁場印加のプロファイルで、磁場印加をすることなく(無磁場で)熱処理を行った。
実施例1と同様の合金組成(結晶化開始温度:500℃)の合金溶湯を単ロ-ル法により急冷し、幅50mm、厚さ18μmのFe基非晶質合金リボンを得た。このFe基非晶質合金リボンを、幅15mmにスリットした後、外径31mm、内径21mmに巻回し、トロイダル磁心を4ヶ作製した。
Claims (7)
- ナノ結晶化可能なFe基非晶質合金リボンを、結晶化温度領域に加熱し、冷却する熱処理工程を含むFe基ナノ結晶合金の製造方法であって、
前記熱処理工程において、
示差走査熱量計での結晶化開始温度の50℃低温から結晶化開始温度の20℃高温までの温度範囲の少なくとも一部を含み、且つ前記結晶化開始温度の50℃高温を超えない昇温期間中の温度範囲で、前記合金リボンの幅方向に磁場を印加する、Fe基ナノ結晶合金の製造方法。 - 前記合金リボンの幅方向に、磁場強度50kA/m以上300kA/m以下の磁場を印加する、請求項1に記載の製造方法。
- 前記熱処理工程における最高温度到達時に前記磁場を印加しない、請求項1または2に記載の製造方法。
- ナノ結晶化可能なFe基非晶質合金リボンを巻回または積層した後、結晶化温度領域に加熱し、冷却する熱処理工程を含む、Fe基ナノ結晶合金リボンを巻回または積層した磁心の製造方法であって、
前記熱処理工程において、
示差走査熱量計での結晶化開始温度の50℃低温から結晶化開始温度の20℃高温までの温度範囲を少なくとも一部を含み、且つ前記結晶化開始温度の50℃高温を超えない昇温期間中の温度範囲で、前記磁心の高さ方向に磁場を印加する、Fe基ナノ結晶合金磁心の製造方法。 - 前記磁心の高さ方向に、磁場強度50kA/m以上300kA/m以下の磁場を印加する、請求項4に記載の製造方法。
- 前記Fe基ナノ結晶合金リボンは、
厚さが15μm以下であり、幅が250mm以下である、請求項4または5に記載の製造方法。 - 前記熱処理工程における最高温度到達時に前記磁場を印加しない、請求項4から6のいずれかに記載の製造方法。
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