WO2017170129A1 - Permanent magnet manufacturing method - Google Patents

Permanent magnet manufacturing method Download PDF

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Publication number
WO2017170129A1
WO2017170129A1 PCT/JP2017/011742 JP2017011742W WO2017170129A1 WO 2017170129 A1 WO2017170129 A1 WO 2017170129A1 JP 2017011742 W JP2017011742 W JP 2017011742W WO 2017170129 A1 WO2017170129 A1 WO 2017170129A1
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Prior art keywords
heating
magnetic
permanent magnet
molded body
powder
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PCT/JP2017/011742
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French (fr)
Japanese (ja)
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泰直 三浦
入江 周一郎
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Tdk株式会社
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/032Magnets 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
    • H01F1/04Magnets 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
    • H01F1/06Magnets 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 in the form of particles, e.g. powder
    • H01F1/08Magnets 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 in the form of particles, e.g. powder pressed, sintered, or bound together
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus 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
    • H01F41/02Apparatus 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C12/00Alloys based on antimony or bismuth
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C19/00Alloys based on nickel or cobalt
    • C22C19/07Alloys based on nickel or cobalt based on cobalt
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys

Definitions

  • the present invention relates to a method for manufacturing a permanent magnet.
  • rare earth magnets neodymium (Nd—Fe—B) magnets are known as the most powerful permanent magnets.
  • Such permanent magnets using rare earth elements are used in various fields such as audio / video equipment, rotating equipment, communication equipment, measuring equipment, automobile parts, etc.
  • rare earth elements are expensive, permanent magnets that do not use rare earth elements are desired.
  • MnBi is known as a magnetic material that does not use rare earth elements. MnBi exhibits a strong magnetic anisotropy and has the property that the magnetic anisotropy increases with increasing temperature. In particular, it is known to have a very high coercive force at a high temperature of 200 ° C. or higher.
  • Patent Document 1 As a conventional method for producing a MnBi magnet, there is known a method for producing a high-purity MnBi magnet by sintering a compact obtained by mixing Mn powder and Bi powder in a magnetic field (Patent Document 1). However, the manufacturing method as described in Patent Document 1 cannot obtain a MnBi magnet having sufficiently high magnetic properties. Another method for producing MnBi magnets is to make Mn-Bi alloy produced by arc melting or high frequency melting amorphous by liquid quenching method, crystallized by heat treatment, and filled with MnBi powder anisotropicized by grinding. In addition, there is a method of manufacturing a MnBi magnet by applying pressure in a magnetic field.
  • An object of the present invention is to provide a manufacturing method capable of solving the above-described problems in the prior art and manufacturing a permanent magnet having excellent magnetic properties.
  • a method for producing a permanent magnet according to the present invention includes a temporary molding step of pressing a magnetic powder containing MnBi in a magnetic field to obtain a temporary molded body, infrared heating and microwave heating of the temporary molded body A heating step of heating to a predetermined temperature by at least one method selected from high-frequency induction heating, and a molding step of pressing the temporary molded body heated to the predetermined temperature to obtain a molded body And
  • the magnetic powder containing MnBi is pressed in a magnetic field in the temporary molding step to produce a temporary molded body, thereby improving the adhesion between the magnetic powders.
  • heat conduction improves, it can be heated up quickly to a desired temperature in a heating process.
  • the area where the magnetic powder comes into contact with the atmosphere can be reduced by preparing the temporary molded body, it is possible to suppress a decrease in magnetic characteristics due to oxidation.
  • the temporary molded body is heated by at least one heating method selected from infrared heating, microwave heating, and high frequency induction heating in the heating step, the temporary molded body can be heated uniformly in a short time, and magnetic characteristics High permanent magnets can be obtained.
  • the magnetic powder containing MnBi preferably contains one or more kinds of magnetic powder selected from Sm—Fe—N, Nd—Fe—B, and Sm—Co.
  • Sm—Fe—N, Nd—Fe—B, and Sm—Co based magnetic materials produce powders with high magnetic properties. By including these magnetic powders, permanent magnets with high magnetic properties are produced. be able to.
  • the temporary molded body contains a metal binder.
  • the metal binder heated to the melting point or higher melts, the filling rate of the magnetic powder is improved, and a permanent magnet having high magnetic properties can be produced.
  • the magnetic powder containing MnBi includes an LTP phase, a QHTP phase, an HTP phase, and the like, and is preferably an LTP phase having a large magnetic anisotropy.
  • the magnetic powder may contain a magnetic material other than MnBi.
  • a permanent magnet having high magnetic properties can be obtained by mixing magnetic materials having high magnetic properties such as rare earth alloys such as Sm—Fe—N, Nd—Fe—B, and Sm—Co. One of these magnetic materials may be used, or two or more of them may be included.
  • the magnetic powder used in the present invention is preferably an anisotropic magnet powder. Anisotropic magnet powder can align the magnetization direction by applying a magnetic field, and can produce a permanent magnet with strong magnetic force.
  • the particle size of the magnetic powder can be applied in a wide range, but the average particle size is preferably 0.5 ⁇ m or more and 200 ⁇ m or less.
  • the average particle size is 0.5 ⁇ m or more, oxidation is suppressed and productivity is improved.
  • the average particle size is 200 ⁇ m or less, the number of contacts between the particles increases, and the heating time can be shortened, so that productivity is improved.
  • the temporary molded body contains a metal binder.
  • a metal binder By adding a low melting point metal binder, a permanent magnet having high density and high magnetic properties can be obtained.
  • the metal binder is not particularly limited, but one or more selected from copper, cobalt, tin, phosphorus, zinc, silver, nickel, iron, aluminum, molybdenum, chromium, titanium, manganese, gallium, bismuth and tungsten. Metals or their alloys can be used.
  • the metal binder is preferably a low melting point metal at 150 ° C to 300 ° C. A diffusion phase is formed at the interface between the magnetic powder of the permanent magnet and the metal binder. It is preferable that the metal binder has a low melting point and is molded at a low temperature because surface diffusion of the metal binder to the magnetic powder can be suppressed and high magnetic properties can be obtained.
  • the mixing ratio of the magnetic powder and the metal binder is preferably 1 to 15 wt% of the metal binder with respect to 85 to 99 wt% of the magnetic powder.
  • the amount of magnetic powder By setting the amount of magnetic powder to 85 wt% or more and the amount of metal binder to 15 wt% or less, high magnetic properties can be obtained.
  • a permanent magnet having high strength can be obtained by setting the amount of magnetic powder to 99 wt% or less and the amount of metal binder to 1% or more.
  • Additives other than metal binders may be used as necessary.
  • the kind of additive is not particularly limited, a surfactant, a coupling agent, a lubricant, a release agent, a flame retardant, a stabilizer, an inorganic filler, a pigment, and the like can be used.
  • This additive provides fluidity to fill the mold, slipperiness to align the magnetization direction by applying a magnetic field, releasability when taking out from the mold, water repellency, density improvement or strength improvement of the molded body.
  • a plurality of types of additives may be used in combination.
  • the magnetic powder or a mixture of magnetic powder and a metal binder is filled in a mold, a magnetic field is applied, a temporary molding pressure is applied, and a temporary molded body is obtained.
  • the temperature can be quickly raised to a desired temperature, and not only the deterioration of magnetic properties due to oxidation can be suppressed, but also a permanent magnet having a high density can be produced.
  • a decrease in magnetic properties due to oxidation in the heating process can be suppressed.
  • the magnetic field orientation direction may be a direction parallel to or perpendicular to the pressing direction.
  • Longitudinal magnetic field shaping with the magnetic field parallel to the pressing direction is effective when a cylindrical shaped body is oriented in the axial direction, and transverse magnetic field shaping with the magnetic field perpendicular to the pressing direction. Is effective when orienting a cube or a rectangular parallelepiped, or when orienting a ring magnet axially (uniaxial direction).
  • the molding pressure in the temporary molding step is preferably 50 MPa or more, more preferably 100 MPa or more, further preferably 300 MPa or more, or the mold temperature is preferably 150 ° C. or less, more preferably 100 ° C. or less, more preferably 60 ° C. or less, Particularly preferably, by setting the temperature to 23 ° C. or less, the relative density of the temporary molded body can be increased, and the temporary molded body can be heated more uniformly and quickly in the heating step. Furthermore, it is possible to suppress damage to the temporary molded body in the heating process and the molding process and to suppress a decrease in orientation during pressurization in the molding process. In consideration of the durability of the mold, the molding pressure in the temporary molding process is preferably 1000 MPa or less.
  • FIG. 1 shows an embodiment of a forming apparatus in a magnetic field in the method for producing a permanent magnet according to the present embodiment.
  • the forming apparatus 1 in a magnetic field has an electromagnet 2 and an upper punch 4a at the upper and lower parts in the drawing. It has a structure having a pressure device 3 having a lower punch 4b and a die 4c having a heating device 4d. It is preferable to reduce the residual magnetic flux density in the temporary molded body by subjecting the temporary molded body to AC demagnetization. During AC demagnetization, it is preferable to raise the temperature of the mold to a predetermined temperature because the residual magnetization becomes smaller.
  • the temporary molded body is heated using at least one heating method selected from infrared heating, microwave heating, and high frequency induction heating. Since the mixture can be heated uniformly in a short time, a permanent magnet with high magnetic properties can be obtained.
  • infrared heating it is preferable to use infrared rays having a wavelength peak of 0.70 to 3.0 ⁇ m.
  • the wavelength peak is shorter than 0.70 ⁇ m, it becomes close to visible light.
  • the heating rate is increased, and by shortening the heating time of the mixture, the oxidation of the magnetic powder is suppressed and the deterioration of the magnetic properties can be reduced.
  • microwave heating is used as the heating method, the microwave is preferably 0.5 to 50 GHz or less. Generation
  • the frequency is preferably 1 to 30 MHz.
  • the magnetic powder and the metal binder are selectively and rapidly self-heated to 150 ° C. to 350 ° C., preferably 250 ° C. to 300 ° C., several tens of seconds to several minutes, preferably 1 to 3 minutes. Raise the temperature.
  • a high-density permanent magnet can be obtained by uniformly raising the temperature of the entire mixture.
  • the temperature can be raised to a predetermined temperature in a short time, the processing time can be shortened and oxidation of the magnetic powder can be suppressed.
  • auxiliary heating means such as atmospheric convection heating in some cases, and by using such a heating method, heating with more uniform heating efficiency can be performed. Can do.
  • FIG. 2 shows an embodiment of a heating device in the method of manufacturing a permanent magnet according to the present embodiment.
  • the heating device 5 includes a metal furnace wall 7a including a heat insulating material or a heat insulating layer.
  • a circulating atmosphere outlet 6a and a circulating atmosphere inlet 6b are provided on the upper side in the figure
  • a heated product inlet 7b is provided on the right side in the figure
  • a heated article discharge port 7c is provided on the left side in the figure.
  • the coil 11a and the coil 11b are arranged on the upper and lower surfaces of the temporary molded body 9 to form a structure. By passing an alternating current having a desired frequency through the coils 11a and 11b, the temporary molded body is induction-heated.
  • the temporary molded body in the mold cavity may be directly irradiated without using the heating device as shown in FIG.
  • the mold and the temporary molded body may be heated at the same time while the temporary molded body is filled in the mold.
  • pressurization may be performed while heating in the mold cavity.
  • the temporary molded body conveyed on the belt conveyor is heated by at least one method selected from infrared heating, microwave heating, and high-frequency induction heating, and evenly by the heated circulating atmosphere ejected from the circulating atmosphere ejection outlet It will be heated. Since the heating time is as short as about 0.5 to 3 minutes, oxidation of the magnetic powder is suppressed and a permanent magnet having excellent magnetic properties can be obtained.
  • the molding process of the present invention is a process in which a temporary molded body heated to a predetermined temperature in the heating process is filled in a mold and pressed to obtain a permanent magnet.
  • a high density permanent magnet can be obtained by pressurizing at a high molding pressure of 10 MPa or more.
  • a high-density permanent magnet can be obtained by pressing at a molding pressure of preferably 50 MPa or more, more preferably 100 MPa or more, and even more preferably 500 MPa or more. In consideration of the durability of the mold, it is preferable to pressurize at a pressure of 1500 MPa or less. In the molding step, heating is preferable because the density of the permanent magnet is increased and a permanent magnet having high magnetic properties can be obtained.
  • the molding temperature is preferably lower than the decomposition temperature 355 ° C. of MnBi, more preferably 250 ° C. to 300 ° C.
  • the molding temperature is preferably equal to or higher than the melting point of the metal binder.
  • the temporary forming step, heating step, and forming step are preferably performed in an inert gas atmosphere to prevent oxidation of the magnetic powder.
  • MnBi anisotropic magnet powder A specified amount of Mn having a purity of 99.9% and Bi having a purity of 99.9% were respectively weighed with an electronic balance, and an ingot was produced by arc melting. The produced ingot was melted using high frequency melting in an Ar atmosphere, and a MnBi ribbon was produced by a liquid quenching method. The obtained ribbon was heated in an Ar atmosphere at 300 ° C. for 12 hours. Then, it grind
  • Nd 2 Fe 14 B anisotropic magnet powder An Nd—Fe—B alloy having an atomic fraction of 13% Nd, 12% Co, 1% Ga, 6% B, and the balance Fe is held in hydrogen gas at 700 to 900 ° C. Decomposed into hydride, Fe 2 B, and Fe. Next, the hydrogen pressure was lowered in this temperature region to dissociate hydrogen from the Nd hydride, thereby obtaining a fine magnetic powder of Nd 2 Fe 14 B crystal. The obtained magnetic powder was further mechanically pulverized to obtain anisotropic magnet powder having an average particle size of 150 ⁇ m.
  • the metal binder used in the examples and comparative examples was obtained as follows.
  • Bi powder and Sn powder Bi powder (purity: 3N, particle size: 30 ⁇ m) and Sn powder (purity: 3N, particle size: 60 ⁇ m) were both made of high-purity chemicals.
  • Bi (Bi-Sn alloy powder)
  • Sn (product made from high purity chemical, purity: 3N, particle size: 2 to 3 mm)
  • the ingot obtained by melting was mechanically pulverized to obtain a 130 ⁇ m alloy powder.
  • MnBi and Sm—Fe—N, Nd—Fe—B, and Sm—Co anisotropic magnet powders and metal binders were weighed using an electronic balance at the weight ratios shown in Table 1, respectively, in an Ar atmosphere. Dispersion mixing was performed for 1 hour using a V-type mixer to prepare a mixture.
  • the temporary molded body obtained by the above method was heated using the heating apparatus shown in FIG. 2 under the heating conditions shown in Table 3, and the temporary molded body was filled in a mold.
  • a 10 mm square cubic permanent magnet sample was prepared by applying the mold temperature, applied magnetic field and molding pressure shown in Table 2. The holding time of the molding pressure was 1 minute.
  • (BH) max and Br of the magnetic powder were measured with a vibrating sample magnetometer (VSM) after orientation of the magnetic powder was performed in a magnetic field of 10 kOe, and the magnetic powder was fixed to paraffin.
  • a value calculated as the sum of products of (BH) max and volume ratio of each magnetic powder is defined as a theoretical maximum (BH) max.
  • (BH) max is 50% or less of the theoretical maximum (BH) max.
  • the (BH) max of the sample manufactured in this example was 55% or more of the theoretical maximum (BH) max, it was judged that good magnetic properties were obtained.
  • the measured density was calculated by measuring the weight and volume of the obtained sample.
  • the calculated density of the mixed powder was calculated from the specific gravity described in Tables 5 and 6 and the weight ratio in Table 1, and the relative density was calculated by dividing the measured density by the calculated density.
  • the heat conduction of the magnetic powder is improved and the heating process is uniformly and quickly heated, so that deterioration of magnetic properties due to oxidation can be suppressed.
  • Permanent magnets with high magnetic properties were produced.
  • the mixture was heated by at least one heating method selected from infrared heating, microwave heating, and high frequency induction heating, so that the temperature of the mixture could be increased uniformly in a short time.
  • the magnetic powder could be heated uniformly in a short time, and a permanent magnet excellent in density and magnetic properties could be obtained.
  • Example 1 As can be seen from Example 1 and Examples 12 to 14, within the range shown in Table 2, the higher the molding pressure in the molding process, the higher the relative density and the higher the magnetic properties.
  • Example 24 to 28 even when the heating method was changed to high frequency induction heating with respect to Example 1, a sample having magnetic characteristics equivalent to those obtained when infrared heating was performed could be obtained. In particular, a sample having relatively high magnetic properties could be obtained in the frequency range of 2 to 10 MHz.
  • Example 29 and 30 even when the heating method is changed to a combination of infrared heating and high frequency induction heating, and microwave heating and high frequency induction heating as compared to Example 1, a sample having high magnetic properties can be obtained. did it.
  • a sample having a higher (BH) max could be obtained by adding Sm 2 Fe 17 N 3 , Nd 2 Fe 14 B, or Sm 2 Co 17 to MnBi.
  • the method for producing a permanent magnet of the present invention is used as a method for producing a permanent magnet for an element of an electric / electronic device.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Hard Magnetic Materials (AREA)
  • Powder Metallurgy (AREA)

Abstract

The present invention provides a method for manufacturing a permanent magnet, said method characterized in comprising a preforming step for obtaining a preform by pressurizing a magnetic powder containing MnBi in a magnetic field; a heating step for heating the preform using at least one method selected from infrared heating, microwave heating, and high frequency induction heating; and a molding step for obtaining a compact by pressurizing the heated preform. According to the present invention, it is possible to increase the adhesion between magnetic powder particles by fabricating the preform made in the preforming step by pressurizing the magnetic powder containing MnBi in a magnetic field. The thermal conduction is thereby improved, and it is therefore possible to quickly raise the temperature to the desired temperature in the heating step. As a result, it is possible to obtain a permanent magnet having high magnetic characteristics.

Description

永久磁石の製造方法Method for manufacturing permanent magnet
 本発明は、永久磁石の製造方法に関する。 The present invention relates to a method for manufacturing a permanent magnet.
 希土類磁石の中ではネオジム(Nd-Fe-B系)磁石が最も強力な永久磁石として知られている。このような希土類元素を使用する永久磁石は、音響・映像機器、回転機器、通信機器、計測機器、自動車部品等の多分野で用いられ、需要が高まるにつれ、磁気特性向上のほか、工業的生産性、機械的強度、耐食性等の向上が要求されているが、希土類元素は高価であるため希土類元素を使用しない永久磁石が望まれている。 Among rare earth magnets, neodymium (Nd—Fe—B) magnets are known as the most powerful permanent magnets. Such permanent magnets using rare earth elements are used in various fields such as audio / video equipment, rotating equipment, communication equipment, measuring equipment, automobile parts, etc. As the demand increases, in addition to improving magnetic properties, industrial production However, since rare earth elements are expensive, permanent magnets that do not use rare earth elements are desired.
 希土類元素を使用しない磁性材料としてはMnBiが知られている。MnBiは強い磁気異方性を示し、温度の上昇とともに磁気異方性が高くなるという性質を有している。特に200℃以上の高温で非常に高い保磁力を有することが知られている。 MnBi is known as a magnetic material that does not use rare earth elements. MnBi exhibits a strong magnetic anisotropy and has the property that the magnetic anisotropy increases with increasing temperature. In particular, it is known to have a very high coercive force at a high temperature of 200 ° C. or higher.
 従来のMnBi磁石を製造する方法としては、Mn粉末とBi粉末を混合した成形体を磁場中で焼結することで高純度のMnBi磁石を製造する方法が知られている(特許文献1)。しかし、特許文献1に記載のような製造方法では、十分高い磁気特性をもつMnBi磁石を得ることができなかった。
 他にMnBi磁石を製造する方法としては、アーク溶解や高周波溶解で作製したMn-Bi合金を液体急冷法でアモルファス化し、熱処理によって結晶化させ、粉砕によって異方化したMnBi粉末を金型に充填し、磁場中で加圧することによってMnBi磁石を製造する方法等がある。
 また、磁場中で加圧を行うことでMnBi磁石を製造する方法ではMnBi粉末を加熱する必要があるが、MnBi粉末を加熱するとMnBi粉末の酸化が起こり、磁気特性の低下を避けることができない。MnBi粉末を金型に充填し、金型を熱媒にしてMnBiを加熱する方法では加熱に時間がかかり、磁性粉末の酸化が進むことで磁気特性の低下を招く。
As a conventional method for producing a MnBi magnet, there is known a method for producing a high-purity MnBi magnet by sintering a compact obtained by mixing Mn powder and Bi powder in a magnetic field (Patent Document 1). However, the manufacturing method as described in Patent Document 1 cannot obtain a MnBi magnet having sufficiently high magnetic properties.
Another method for producing MnBi magnets is to make Mn-Bi alloy produced by arc melting or high frequency melting amorphous by liquid quenching method, crystallized by heat treatment, and filled with MnBi powder anisotropicized by grinding. In addition, there is a method of manufacturing a MnBi magnet by applying pressure in a magnetic field.
In addition, in the method of producing an MnBi magnet by applying pressure in a magnetic field, it is necessary to heat the MnBi powder. However, when the MnBi powder is heated, the MnBi powder is oxidized, and a decrease in magnetic properties cannot be avoided. In a method in which MnBi powder is filled in a mold and MnBi is heated using the mold as a heating medium, heating takes time, and the magnetic powder is oxidized, leading to a decrease in magnetic properties.
特開2015-63725JP2015-63725
 本発明は、上記の従来技術に存在する問題点を解決し、磁気特性の優れた永久磁石を製造することが可能な製造方法を提供することを目的としている。 An object of the present invention is to provide a manufacturing method capable of solving the above-described problems in the prior art and manufacturing a permanent magnet having excellent magnetic properties.
 上記目的を達成するため、本発明の永久磁石の製造方法は、MnBiを含む磁性粉末を磁場中で加圧して仮成形体を得る仮成形工程と、前記仮成形体を赤外線加熱、マイクロ波加熱、高周波誘導加熱から選択される少なくとも1つの方法で所定の温度に加熱する加熱工程と、前記所定の温度に加熱した仮成形体を加圧して成形体を得る成形工程と、を有することを特徴とする。 In order to achieve the above object, a method for producing a permanent magnet according to the present invention includes a temporary molding step of pressing a magnetic powder containing MnBi in a magnetic field to obtain a temporary molded body, infrared heating and microwave heating of the temporary molded body A heating step of heating to a predetermined temperature by at least one method selected from high-frequency induction heating, and a molding step of pressing the temporary molded body heated to the predetermined temperature to obtain a molded body And
 本発明によれば、仮成形工程においてMnBiを含む磁性粉末を磁場中で加圧して仮成形体を作製することで、磁性粉末同士の密着性を上げることができる。これにより熱伝導が向上するため、加熱工程において素早く所望の温度に昇温することができる。その結果、酸化による磁気特性の低下を抑えられるだけでなく、密度むらの小さい永久磁石を作製することができる。また、仮成形体を作製することにより、磁性粉末が雰囲気に触れる面積を小さくすることができるので、酸化による磁気特性の低下を抑えることができる。さらに、加熱工程において仮成形体を赤外線加熱、マイクロ波加熱、高周波誘導加熱から選択される少なくとも1つの加熱方法で加熱するため、仮成形体を短時間で均一に昇温するができ、磁気特性が高い永久磁石を得ることができる。 According to the present invention, the magnetic powder containing MnBi is pressed in a magnetic field in the temporary molding step to produce a temporary molded body, thereby improving the adhesion between the magnetic powders. Thereby, since heat conduction improves, it can be heated up quickly to a desired temperature in a heating process. As a result, it is possible to produce a permanent magnet that not only suppresses deterioration of magnetic properties due to oxidation but also has low density unevenness. Moreover, since the area where the magnetic powder comes into contact with the atmosphere can be reduced by preparing the temporary molded body, it is possible to suppress a decrease in magnetic characteristics due to oxidation. Further, since the temporary molded body is heated by at least one heating method selected from infrared heating, microwave heating, and high frequency induction heating in the heating step, the temporary molded body can be heated uniformly in a short time, and magnetic characteristics High permanent magnets can be obtained.
 前記MnBiを含む磁性粉末には、MnBi以外に、Sm-Fe-N系、Nd-Fe-B系、Sm-Co系から選ばれる1種類以上の磁性粉末が含まれていることが好ましい。Sm-Fe-N系、Nd-Fe-B系、Sm-Co系の磁性材料は磁気特性の高い粉末が得られるため、これらの磁性粉末が含まれることで磁気特性が高い永久磁石を作製することができる。 In addition to MnBi, the magnetic powder containing MnBi preferably contains one or more kinds of magnetic powder selected from Sm—Fe—N, Nd—Fe—B, and Sm—Co. Sm—Fe—N, Nd—Fe—B, and Sm—Co based magnetic materials produce powders with high magnetic properties. By including these magnetic powders, permanent magnets with high magnetic properties are produced. be able to.
 前記仮成形体には、金属バインダーが含まれていることが好ましい。成形工程において、融点以上に加熱された金属バインダーが融けて磁性粉末の充填率が向上し、磁気特性が高い永久磁石を作製することができる。 It is preferable that the temporary molded body contains a metal binder. In the molding process, the metal binder heated to the melting point or higher melts, the filling rate of the magnetic powder is improved, and a permanent magnet having high magnetic properties can be produced.
 本発明によれば、磁気特性が高い永久磁石の製造方法を提供することが可能となる。 According to the present invention, it is possible to provide a method for manufacturing a permanent magnet having high magnetic properties.
本発明の永久磁石の製造方法のおける好適な磁場中成形装置を示す模式図である。It is a schematic diagram which shows the suitable shaping | molding apparatus in a magnetic field in the manufacturing method of the permanent magnet of this invention. 本発明の永久磁石の製造方法における好適な加熱装置を示す模式図である。It is a schematic diagram which shows the suitable heating apparatus in the manufacturing method of the permanent magnet of this invention.
 本発明の永久磁石の製造方法について以下の工程ごとに説明する。 The manufacturing method of the permanent magnet of the present invention will be described for each of the following steps.
(1) 磁性粉末の準備
 本発明ではMnBiを含む磁性粉末を用いる。MnBiにはLTP相、QHTP相、HTP相などがあるが、大きな磁気異方性をもつLTP相であることが好ましい。また、磁性粉末にMnBi以外の磁性材料が含まれてもよい。特に、Sm-Fe-N系、Nd-Fe-B系、Sm-Co系などの希土類合金のような磁気特性の高い磁性材料を混合することで磁気特性の高い永久磁石を得ることができる。これら磁性材料のうち1種類でもよいし、2種類以上を含んでもよい。本発明に使用する磁性粉末は異方性磁石粉末であることが好ましい。異方性磁石粉末は磁場を印加することで磁化方向を揃えることができ、磁力の強い永久磁石を作製することができる。
(1) Preparation of magnetic powder In this invention, the magnetic powder containing MnBi is used. MnBi includes an LTP phase, a QHTP phase, an HTP phase, and the like, and is preferably an LTP phase having a large magnetic anisotropy. The magnetic powder may contain a magnetic material other than MnBi. In particular, a permanent magnet having high magnetic properties can be obtained by mixing magnetic materials having high magnetic properties such as rare earth alloys such as Sm—Fe—N, Nd—Fe—B, and Sm—Co. One of these magnetic materials may be used, or two or more of them may be included. The magnetic powder used in the present invention is preferably an anisotropic magnet powder. Anisotropic magnet powder can align the magnetization direction by applying a magnetic field, and can produce a permanent magnet with strong magnetic force.
 磁性粉末の粒度も広範囲に適用可能であるが、平均粒径は0.5μm以上200μm以下であることが好ましい。平均粒径が0.5μm以上であると、酸化が抑制されるとともに生産性が向上する。平均粒径が200μm以下であると、粒子同士の接点が増え、加熱時間を短縮化できるので生産性が向上する。 The particle size of the magnetic powder can be applied in a wide range, but the average particle size is preferably 0.5 μm or more and 200 μm or less. When the average particle size is 0.5 μm or more, oxidation is suppressed and productivity is improved. When the average particle size is 200 μm or less, the number of contacts between the particles increases, and the heating time can be shortened, so that productivity is improved.
 また、仮成形体には金属バインダーが含まれていることが好ましい。低融点の金属バインダーを添加することで、高い密度をもつ磁気特性の高い永久磁石を得ることができる。金属バインダーは特に限定されないが、銅、コバルト、スズ、リン、亜鉛、銀、ニッケル、鉄、アルミニウム、モリブデン、クロム、チタン、マンガン、ガリウム、ビスマスおよびタングステンから選択される1種または2種以上の金属もしくはそれらの合金を用いることができる。金属バインダーは、150℃~300℃の低融点金属が好ましい。永久磁石の磁性粉末と金属バインダーとの界面は拡散相が形成されている。金属バインダーを低融点とし、低温で成形を行うことで金属バインダーの磁性粉末への表面拡散を抑えることができ、高い磁気特性を得ることができるので好ましい。 Further, it is preferable that the temporary molded body contains a metal binder. By adding a low melting point metal binder, a permanent magnet having high density and high magnetic properties can be obtained. The metal binder is not particularly limited, but one or more selected from copper, cobalt, tin, phosphorus, zinc, silver, nickel, iron, aluminum, molybdenum, chromium, titanium, manganese, gallium, bismuth and tungsten. Metals or their alloys can be used. The metal binder is preferably a low melting point metal at 150 ° C to 300 ° C. A diffusion phase is formed at the interface between the magnetic powder of the permanent magnet and the metal binder. It is preferable that the metal binder has a low melting point and is molded at a low temperature because surface diffusion of the metal binder to the magnetic powder can be suppressed and high magnetic properties can be obtained.
 MnBiとSm-Fe-N系、Nd-Fe-B系、Sm-Co系の磁性粉末を混合する場合や、磁性粉末と金属バインダーを混合する場合、アトライター、ヘンシェルミキサー又はV型混合機等で混合することで混合物を得る。金属バインダーを均一に混合するには有機溶剤などを用いることが好ましい。また、混合物を造粒することも好ましい。 When mixing MnBi with Sm—Fe—N, Nd—Fe—B, or Sm—Co based magnetic powder, or when mixing magnetic powder and metal binder, attritor, Henschel mixer or V-type mixer, etc. To obtain a mixture. In order to uniformly mix the metal binder, it is preferable to use an organic solvent or the like. It is also preferable to granulate the mixture.
 磁性粉末と金属バインダーとの混合比率は、磁性粉末85~99wt%に対して、金属バインダー1~15wt%とすることが好ましい。磁性粉末の量を85wt%以上、金属バインダーの量を15wt%以下とすることで高い磁気特性を得ることができる。一方、磁性粉末の量を99wt%以下、金属バインダーの量を1%以上とすることで強度の高い永久磁石を得ることができる。 The mixing ratio of the magnetic powder and the metal binder is preferably 1 to 15 wt% of the metal binder with respect to 85 to 99 wt% of the magnetic powder. By setting the amount of magnetic powder to 85 wt% or more and the amount of metal binder to 15 wt% or less, high magnetic properties can be obtained. On the other hand, a permanent magnet having high strength can be obtained by setting the amount of magnetic powder to 99 wt% or less and the amount of metal binder to 1% or more.
 金属バインダー以外の添加剤を、必要に応じて使用しても良い。添加剤の種類は特に限定されないが、界面活性剤、カップリング剤、潤滑剤、離型剤、難燃剤、安定剤、無機充填剤や顔料等を用いることができる。この添加剤は、金型へ充填するための流動性、磁場をかけて磁化方向を揃えるための滑り性、金型から取り出す際の離型性、成形体の撥水性、密度向上或いは強度向上を示すものであればよく、複数種類の添加剤を組み合わせて用いてもよい。 Additives other than metal binders may be used as necessary. Although the kind of additive is not particularly limited, a surfactant, a coupling agent, a lubricant, a release agent, a flame retardant, a stabilizer, an inorganic filler, a pigment, and the like can be used. This additive provides fluidity to fill the mold, slipperiness to align the magnetization direction by applying a magnetic field, releasability when taking out from the mold, water repellency, density improvement or strength improvement of the molded body. As long as it is shown, a plurality of types of additives may be used in combination.
(2)仮成形工程
 本実施形態では、磁性粉末もしくは磁性粉末と金属バインダーを混合した混合物を金型に充填して磁場を印加し、仮成形圧を加えて仮成形体を得ることで、加熱工程において素早く所望の温度に昇温することができるようになり、酸化による磁気特性の低下を抑えられるだけでなく、高い密度をもつ永久磁石を作製することができる。また、磁性粉末が雰囲気に触れる面積が小さくなるので、加熱工程における酸化による磁気特性の低下が抑えられる。
(2) Temporary molding step In this embodiment, the magnetic powder or a mixture of magnetic powder and a metal binder is filled in a mold, a magnetic field is applied, a temporary molding pressure is applied, and a temporary molded body is obtained. In the process, the temperature can be quickly raised to a desired temperature, and not only the deterioration of magnetic properties due to oxidation can be suppressed, but also a permanent magnet having a high density can be produced. In addition, since the area where the magnetic powder comes into contact with the atmosphere is reduced, a decrease in magnetic properties due to oxidation in the heating process can be suppressed.
 高い配向度を得るためには強い磁場の印加が必要であり、静磁場の印加の場合でも、非連続的に磁場を印加するパルス方式の場合でも、磁場の強さは10kOe以上であることが好ましい。磁場配向方向は、加圧方向に対して平行な方向でも、垂直な方向でもよい。加圧方向に対して磁場を平行な方向とする縦磁場成形は円柱状の成形体を軸方向に配向する場合に有効であり、加圧方向に対して磁場を垂直な方向とする横磁場成形は立方体や直方体を配向する場合やリング磁石をアキシャル(一軸方向)に配向させる場合に有効である。仮成形工程における成形圧力を好ましくは50MPa以上、より好ましくは100MPa以上、さらに好ましくは300Mpa以上とし、または金型温度を好ましくは150℃以下、より好ましくは100℃以下、さらに好ましくは60℃以下、特に好ましくは23℃以下とすることで、仮成形体の相対密度を上げることができ、加熱工程においてより均一に素早く仮成形体を加熱することができる。さらに、加熱工程や成形工程における仮成形体の破損を抑えられるとともに成形工程における加圧時の配向の低下を抑えられる。また、金型の耐久性を考慮すると仮成形工程における成形圧力は1000MPa以下であることが好ましい。 In order to obtain a high degree of orientation, it is necessary to apply a strong magnetic field, and the strength of the magnetic field must be 10 kOe or more regardless of whether a static magnetic field is applied or a pulse system in which a magnetic field is applied discontinuously. preferable. The magnetic field orientation direction may be a direction parallel to or perpendicular to the pressing direction. Longitudinal magnetic field shaping with the magnetic field parallel to the pressing direction is effective when a cylindrical shaped body is oriented in the axial direction, and transverse magnetic field shaping with the magnetic field perpendicular to the pressing direction. Is effective when orienting a cube or a rectangular parallelepiped, or when orienting a ring magnet axially (uniaxial direction). The molding pressure in the temporary molding step is preferably 50 MPa or more, more preferably 100 MPa or more, further preferably 300 MPa or more, or the mold temperature is preferably 150 ° C. or less, more preferably 100 ° C. or less, more preferably 60 ° C. or less, Particularly preferably, by setting the temperature to 23 ° C. or less, the relative density of the temporary molded body can be increased, and the temporary molded body can be heated more uniformly and quickly in the heating step. Furthermore, it is possible to suppress damage to the temporary molded body in the heating process and the molding process and to suppress a decrease in orientation during pressurization in the molding process. In consideration of the durability of the mold, the molding pressure in the temporary molding process is preferably 1000 MPa or less.
 図1は本実施形態の永久磁石の製造方法における磁場中成形装置の一実施形態を示すものであって、磁場中成形装置1は、電磁石2をそなえ、かつ図示上部と下部に上パンチ4aと下パンチ4bをそなえた加圧装置3を有し、さらに加熱装置4dをそなえたダイス4cをそなえた構造をなすものである。仮成形体に交流脱磁を施すことで仮成形体内の残留磁束密度を小さくすることが好ましい。交流脱磁の際、金型を所定温度に昇温することで、残留磁化がより小さくなるので好ましい。 FIG. 1 shows an embodiment of a forming apparatus in a magnetic field in the method for producing a permanent magnet according to the present embodiment. The forming apparatus 1 in a magnetic field has an electromagnet 2 and an upper punch 4a at the upper and lower parts in the drawing. It has a structure having a pressure device 3 having a lower punch 4b and a die 4c having a heating device 4d. It is preferable to reduce the residual magnetic flux density in the temporary molded body by subjecting the temporary molded body to AC demagnetization. During AC demagnetization, it is preferable to raise the temperature of the mold to a predetermined temperature because the residual magnetization becomes smaller.
(3)加熱工程
 本実施形態では、仮成形体を赤外線加熱、マイクロ波加熱、高周波誘導加熱から選択される少なくとも1つの加熱方法を用いて加熱する。混合物を短時間で均一に加熱することができるので、磁気特性の高い永久磁石を得ることができる。
(3) Heating step In the present embodiment, the temporary molded body is heated using at least one heating method selected from infrared heating, microwave heating, and high frequency induction heating. Since the mixture can be heated uniformly in a short time, a permanent magnet with high magnetic properties can be obtained.
 加熱方法として赤外線加熱を用いる場合、波長のピークが0.70~3.0μmの赤外線を用いることが好ましい。波長のピークを0.70μmよりも短いと可視光線に近くなる。波長のピークを3.0μmよりも短くすることで加熱速度が上がり、混合物の加熱時間が短くなることで磁性粉末の酸化が抑制され、磁気特性の低下を低減することができる。加熱方法としてマイクロ波加熱を用いる場合、マイクロ波は0.5~50GHz以下であることが好ましい。アーク放電の発生を抑制でき、混合物を所望の温度範囲内に昇温することができる。加熱方法として高周波誘導加熱を用いる場合、周波数が1~30MHzであることが好ましい。このように磁性粉末と金属バインダーを選択的かつ急速に自己発熱させることによって、150℃~350℃まで、好ましくは250℃~300℃まで、数十秒~数分で、好ましくは1~3分で昇温する。 When using infrared heating as the heating method, it is preferable to use infrared rays having a wavelength peak of 0.70 to 3.0 μm. When the wavelength peak is shorter than 0.70 μm, it becomes close to visible light. By shortening the wavelength peak to less than 3.0 μm, the heating rate is increased, and by shortening the heating time of the mixture, the oxidation of the magnetic powder is suppressed and the deterioration of the magnetic properties can be reduced. When microwave heating is used as the heating method, the microwave is preferably 0.5 to 50 GHz or less. Generation | occurrence | production of arc discharge can be suppressed and a mixture can be heated up in a desired temperature range. When high frequency induction heating is used as the heating method, the frequency is preferably 1 to 30 MHz. In this way, the magnetic powder and the metal binder are selectively and rapidly self-heated to 150 ° C. to 350 ° C., preferably 250 ° C. to 300 ° C., several tens of seconds to several minutes, preferably 1 to 3 minutes. Raise the temperature.
 このとき、混合物全体を均一に昇温することにより、高い密度の永久磁石を得ることができる。また、短時間で所定の温度まで昇温することができるので、処理時間を短縮するとともに磁性粉末の酸化を抑制することができる。 At this time, a high-density permanent magnet can be obtained by uniformly raising the temperature of the entire mixture. In addition, since the temperature can be raised to a predetermined temperature in a short time, the processing time can be shortened and oxidation of the magnetic powder can be suppressed.
 加熱に際して、雰囲気対流加熱などの補助加熱手段を併用して加熱を行うようにすることも場合によっては好ましく、このような加熱方法を併用することでむらのない一層加熱効率の良い加熱を行うことができる。 When heating, it may be preferable to use auxiliary heating means such as atmospheric convection heating in some cases, and by using such a heating method, heating with more uniform heating efficiency can be performed. Can do.
 図2は本実施形態の永久磁石の製造方法における加熱装置の一実施形態を示すものであって、加熱装置5は、断熱材もしくは断熱層を内包させた金属製の炉体壁7aをそなえ、かつ図示上側に循環雰囲気流出口6aと循環雰囲気流入口6bを有し、さらに図示右側に加熱品搬入口7bを有すると共に図示左側に加熱品排出口7cを有し、内部が仮成形体収容空間7dとなっている炉体7と、仮成形体を載置したトレイ9を搬送するベルトコンベア10と、ベルトコンベア10の上方に設けた複数の赤外線加熱源(赤外線ランプ)もしくはマイクロ波加熱源8、仮成形体9の上面及び下面に配置されたコイル11a、コイル11bをそなえた構造をなすものである。コイル11a、コイル11bに所望の周波数の交流電流を流すことにより、仮成形体が誘導加熱される。 FIG. 2 shows an embodiment of a heating device in the method of manufacturing a permanent magnet according to the present embodiment. The heating device 5 includes a metal furnace wall 7a including a heat insulating material or a heat insulating layer. In addition, a circulating atmosphere outlet 6a and a circulating atmosphere inlet 6b are provided on the upper side in the figure, a heated product inlet 7b is provided on the right side in the figure, and a heated article discharge port 7c is provided on the left side in the figure. A furnace body 7 that is 7d, a belt conveyor 10 that conveys a tray 9 on which a temporary molded body is placed, and a plurality of infrared heating sources (infrared lamps) or microwave heating sources 8 provided above the belt conveyor 10 The coil 11a and the coil 11b are arranged on the upper and lower surfaces of the temporary molded body 9 to form a structure. By passing an alternating current having a desired frequency through the coils 11a and 11b, the temporary molded body is induction-heated.
 赤外線加熱やマイクロ波加熱の場合、図2のような加熱装置を用いずに金型キャビティ内の仮成形体に直接照射しても良い。高周波加熱の場合、金型に仮成形体が充填された状態で金型と仮成形体を同時に加熱しても良い。このように、金型キャビティ内で加熱を行いながら、加圧を行っても良い。 In the case of infrared heating or microwave heating, the temporary molded body in the mold cavity may be directly irradiated without using the heating device as shown in FIG. In the case of high-frequency heating, the mold and the temporary molded body may be heated at the same time while the temporary molded body is filled in the mold. Thus, pressurization may be performed while heating in the mold cavity.
 ベルトコンベア上に搬送される仮成形体は赤外線加熱、マイクロ波加熱、高周波誘導加熱から選択される少なくとも1つの方法で加熱されるとともに、循環雰囲気噴出出口から噴出する加熱された循環雰囲気によってむらなく加熱されることになる。そして、この加熱時間は0.5~3分程度の短時間であるため、磁性粉末の酸化が抑制され、磁気特性が優れた永久磁石を得ることができる。 The temporary molded body conveyed on the belt conveyor is heated by at least one method selected from infrared heating, microwave heating, and high-frequency induction heating, and evenly by the heated circulating atmosphere ejected from the circulating atmosphere ejection outlet It will be heated. Since the heating time is as short as about 0.5 to 3 minutes, oxidation of the magnetic powder is suppressed and a permanent magnet having excellent magnetic properties can be obtained.
(4)成形工程
 本発明の成形工程は、加熱工程で所定の温度に加熱された仮成形体を金型に充填し、加圧して永久磁石を得る工程である。10MPa以上の高い成形圧力で加圧を行うことで高い密度の永久磁石を得ることができる。好ましくは50MPa以上、より好ましくは100MPa以上、さらに好ましくは500MPa以上の成形圧力で加圧を行うことで、密度の高い永久磁石を得ることができる。また、金型の耐久性を考慮すると1500MPa以下の圧力で加圧することが好ましい。成形工程において、加熱を施すことで永久磁石の密度が高くなり、磁気特性の高い永久磁石が得られるので好ましい。成形温度はMnBiの分解温度355℃よりも低い方が好ましく、より好ましくは250℃~300℃である。仮成形体が金属バインダーを含む場合、成形温度は金属バインダーの融点以上であることが好ましい。
(4) Molding process The molding process of the present invention is a process in which a temporary molded body heated to a predetermined temperature in the heating process is filled in a mold and pressed to obtain a permanent magnet. A high density permanent magnet can be obtained by pressurizing at a high molding pressure of 10 MPa or more. A high-density permanent magnet can be obtained by pressing at a molding pressure of preferably 50 MPa or more, more preferably 100 MPa or more, and even more preferably 500 MPa or more. In consideration of the durability of the mold, it is preferable to pressurize at a pressure of 1500 MPa or less. In the molding step, heating is preferable because the density of the permanent magnet is increased and a permanent magnet having high magnetic properties can be obtained. The molding temperature is preferably lower than the decomposition temperature 355 ° C. of MnBi, more preferably 250 ° C. to 300 ° C. When the temporary molded body includes a metal binder, the molding temperature is preferably equal to or higher than the melting point of the metal binder.
 仮成形工程、加熱工程、成形工程は磁性粉末の酸化を防止するため不活性ガス雰囲気中で行われることが好ましい。 The temporary forming step, heating step, and forming step are preferably performed in an inert gas atmosphere to prevent oxidation of the magnetic powder.
  得られた永久磁石には、必要により塗装やめっきなどの表面処理を施す。 ∙ Surface treatment such as painting or plating is applied to the obtained permanent magnets as necessary.
 以下、実施例により本発明の効果を例証する。実施例および比較例で用いた磁性粉末は下記の方法により得た。 Hereinafter, the effect of the present invention is illustrated by examples. The magnetic powder used in Examples and Comparative Examples was obtained by the following method.
(MnBi異方性磁石粉末)
 純度99.9%のMnと純度99.9%のBiをそれぞれ電子天秤で規定量秤量し、アーク溶解でインゴットを作製した。作製したインゴットをAr雰囲気中で高周波溶解を用いて溶解し、液体急冷法でMnBi薄帯を作製した。得られた薄帯をAr雰囲気中で300℃×12時間加熱を行った。その後、ボールミルで20時間粉砕し、平均粒径が5μmの異方性磁石粉末を得た。
(MnBi anisotropic magnet powder)
A specified amount of Mn having a purity of 99.9% and Bi having a purity of 99.9% were respectively weighed with an electronic balance, and an ingot was produced by arc melting. The produced ingot was melted using high frequency melting in an Ar atmosphere, and a MnBi ribbon was produced by a liquid quenching method. The obtained ribbon was heated in an Ar atmosphere at 300 ° C. for 12 hours. Then, it grind | pulverized for 20 hours with the ball mill, and obtained the anisotropic magnet powder whose average particle diameter is 5 micrometers.
(SmFe17異方性磁石粉末)
 住友金属鉱山製のSmFe17粉末を使用した。平均粒径は5μmである。
(Sm 2 Fe 17 N 3 anisotropic magnet powder)
Sm 2 Fe 17 N 3 powder manufactured by Sumitomo Metal Mining was used. The average particle size is 5 μm.
(NdFe14B異方性磁石粉末)
 原子分率で13%のNd、12%のCo、1%のGa、6%のB、残部がFeとなるNd-Fe-B合金を700~900℃の水素ガス中に保持して、Nd水素化物、FeB、Feに分解した。次に、この温度領域で水素圧を下げ、Nd水素化物から水素を解離させ、微細なNdFe14B結晶体の磁性粉末を得た。得られた磁性粉末をさらに機械的に粉砕して、平均粒径150μmの異方性磁石粉末を得た。
(Nd 2 Fe 14 B anisotropic magnet powder)
An Nd—Fe—B alloy having an atomic fraction of 13% Nd, 12% Co, 1% Ga, 6% B, and the balance Fe is held in hydrogen gas at 700 to 900 ° C. Decomposed into hydride, Fe 2 B, and Fe. Next, the hydrogen pressure was lowered in this temperature region to dissociate hydrogen from the Nd hydride, thereby obtaining a fine magnetic powder of Nd 2 Fe 14 B crystal. The obtained magnetic powder was further mechanically pulverized to obtain anisotropic magnet powder having an average particle size of 150 μm.
(SmCo17異方性磁石粉末)
 Sm(Co0.59Cu0.07Fe0.22Zr0.028.3で表されるSmCo17系金属間化合物合金を溶解、鋳造し、これをアルゴンガス雰囲気炉中にて1160℃で4時間加熱した後、200℃まで毎分35℃の速度で急冷して析出硬化処理を行った。常温まで冷却されたインゴットを、アルゴンガス雰囲気炉中にて800℃で2時間、740℃で3時間の2段加熱により時効処理し、常温まで毎分65℃の速度で冷却した。その後、このインゴットを機械的に粉砕して平均粒径50μmの異方性磁石粉末を得た。
(Sm 2 Co 17 anisotropic magnet powder)
Sm 2 Co 17- based intermetallic compound alloy represented by Sm (Co 0.59 Cu 0.07 Fe 0.22 Zr 0.02 ) 8.3 was melted and cast, and this was cast in an argon gas atmosphere furnace After heating at 1160 ° C for 4 hours, precipitation hardening was performed by rapidly cooling to 200 ° C at a rate of 35 ° C per minute. The ingot cooled to room temperature was aged by two-stage heating at 800 ° C. for 2 hours and 740 ° C. for 3 hours in an argon gas atmosphere furnace, and cooled to room temperature at a rate of 65 ° C. per minute. Thereafter, the ingot was mechanically pulverized to obtain anisotropic magnet powder having an average particle size of 50 μm.
 実施例および比較例で用いた金属バインダーは以下のようにして得た。 The metal binder used in the examples and comparative examples was obtained as follows.
(Bi粉末およびSn粉末)
 Bi粉末(純度:3N、粒径:30μm)およびSn粉末(純度:3N、粒径:60μm)はいずれも高純度化学製のものを使用した。
(Bi powder and Sn powder)
Bi powder (purity: 3N, particle size: 30 μm) and Sn powder (purity: 3N, particle size: 60 μm) were both made of high-purity chemicals.
(Bi-Sn合金粉末)
 Bi(高純度化学製、純度:3N、粒径:2~3mm)とSn(高純度化学製、純度:3N、粒径:2~3mm)を58:42wt%に秤量して混合を行い、溶解して得られたインゴットを機械的に粉砕して、130μmの合金粉末を得た。
(Bi-Sn alloy powder)
Bi (product made from high purity chemical, purity: 3N, particle size: 2 to 3 mm) and Sn (product made from high purity chemical, purity: 3N, particle size: 2 to 3 mm) are weighed to 58:42 wt% and mixed. The ingot obtained by melting was mechanically pulverized to obtain a 130 μm alloy powder.
(混合物の作製)
 MnBiとSm-Fe-N系、Nd-Fe-B系、Sm-Co系の異方性磁石粉末および金属バインダーを表1に示す重量比率でそれぞれ電子天秤を用いて量り取り、Ar雰囲気中でV型混合器を用いて1時間分散混合を行い、混合物を作製した。
(Production of mixture)
MnBi and Sm—Fe—N, Nd—Fe—B, and Sm—Co anisotropic magnet powders and metal binders were weighed using an electronic balance at the weight ratios shown in Table 1, respectively, in an Ar atmosphere. Dispersion mixing was performed for 1 hour using a V-type mixer to prepare a mixture.
Figure JPOXMLDOC01-appb-T000001
 
Figure JPOXMLDOC01-appb-T000001
 
(仮成形体の作製)
 上記の方法で得られた混合物を金型に充填し、表2に記載の金型温度、印加磁場、成形圧力を加えることで仮成形体を得た。その後、交流脱磁により仮成形体の脱磁を行った。
(Preparation of temporary molded body)
The mixture obtained by the above method was filled in a mold, and a mold temperature shown in Table 2, an applied magnetic field, and a molding pressure were applied to obtain a temporary molded body. Thereafter, the temporary molded body was demagnetized by AC demagnetization.
Figure JPOXMLDOC01-appb-T000002
Figure JPOXMLDOC01-appb-T000002
(永久磁石の作製)
 上記の方法で得られた仮成形体を図2に示す加熱装置を用いて表3に記載の加熱条件で加熱し、仮成形体を金型に充填した。表2に記載の金型温度、印加磁場、成形圧力を加えることで10mm角立方体の永久磁石の試料を作製した。成形圧力の保持時間は1分とした。
(Preparation of permanent magnet)
The temporary molded body obtained by the above method was heated using the heating apparatus shown in FIG. 2 under the heating conditions shown in Table 3, and the temporary molded body was filled in a mold. A 10 mm square cubic permanent magnet sample was prepared by applying the mold temperature, applied magnetic field and molding pressure shown in Table 2. The holding time of the molding pressure was 1 minute.
Figure JPOXMLDOC01-appb-T000003
Figure JPOXMLDOC01-appb-T000003
 得られた永久磁石の試料について、下記の方法により、(1)磁気特性と(2)相対密度を測定した。測定結果を表4に示す。
(1) 磁気特性
 得られた10mm立方の試料を用いてBHトレーサ(玉川製作所製、最大磁場:30kOe)により残留磁化(Br)、飽和磁化(4πMs)、最大エネルギー積(BH)max測定し、配向度Br/4πMsを算出した。各磁性粉末の体積比率は、表1に記載の磁性粉末と金属バインダーの重量比率および表5、6に記載の磁性粉末と金属バインダーの比重を用いて算出した。磁性粉末と金属バインダーの比重はピクノメーター法を用いて測定した。磁性粉末の(BH)maxとBrは、10kOeの磁場で磁性粉末の配向処理を行い、磁性粉末をパラフィンに固定したのちに振動試料型磁力計(VSM)で測定した。各磁性粉末の(BH)maxと体積比率の積の和として算出した値を理論最大(BH)maxとする。仮成形体を作製せずに粉末状の混合物を加熱する場合や、加熱方法が赤外線加熱、マイクロ波加熱、高周波誘導加熱から選ばれる少なくとも1つの方法で加熱を行わない場合、得られる成形体の(BH)maxは理論最大(BH)maxの50%以下である。本実施例にて作製した試料の(BH)maxが理論最大(BH)maxの55%以上である場合を良好な磁気特性が得られたと判断した。
(2)相対密度
 得られた試料の重量と体積を測定して実測密度を算出した。表5、6に記載の比重と表1の重量比率から混合粉末の計算密度を算出し、実測密度を計算密度で割ることで相対密度を算出した。
With respect to the obtained permanent magnet sample, (1) magnetic properties and (2) relative density were measured by the following methods. Table 4 shows the measurement results.
(1) Magnetic characteristics Using the obtained 10 mm cubic sample, residual magnetization (Br), saturation magnetization (4πMs), and maximum energy product (BH) max were measured with a BH tracer (manufactured by Tamagawa Seisakusho, maximum magnetic field: 30 kOe). The degree of orientation Br / 4πMs was calculated. The volume ratio of each magnetic powder was calculated using the weight ratio of the magnetic powder and the metal binder described in Table 1 and the specific gravity of the magnetic powder and the metal binder described in Tables 5 and 6. The specific gravity of the magnetic powder and the metal binder was measured using a pycnometer method. (BH) max and Br of the magnetic powder were measured with a vibrating sample magnetometer (VSM) after orientation of the magnetic powder was performed in a magnetic field of 10 kOe, and the magnetic powder was fixed to paraffin. A value calculated as the sum of products of (BH) max and volume ratio of each magnetic powder is defined as a theoretical maximum (BH) max. When heating the powder mixture without producing a temporary molded body, or when heating is not performed by at least one method selected from infrared heating, microwave heating, and high frequency induction heating, (BH) max is 50% or less of the theoretical maximum (BH) max. When the (BH) max of the sample manufactured in this example was 55% or more of the theoretical maximum (BH) max, it was judged that good magnetic properties were obtained.
(2) Relative density The measured density was calculated by measuring the weight and volume of the obtained sample. The calculated density of the mixed powder was calculated from the specific gravity described in Tables 5 and 6 and the weight ratio in Table 1, and the relative density was calculated by dividing the measured density by the calculated density.
Figure JPOXMLDOC01-appb-T000004
Figure JPOXMLDOC01-appb-T000004
Figure JPOXMLDOC01-appb-T000005
Figure JPOXMLDOC01-appb-T000005
Figure JPOXMLDOC01-appb-T000006
Figure JPOXMLDOC01-appb-T000006
 本発明によれば仮成形工程で仮成形体を作製することで、磁性粉末の熱伝導が向上し、加熱工程において均一かつ素早く加熱されるようになるため、酸化による磁気特性の劣化を抑えられ、高い磁気特性をもつ永久磁石を作製できた。加熱工程において混合物を赤外線加熱、マイクロ波加熱、高周波誘導加熱から選択される少なくとも1つの加熱方法で加熱するため、混合物を短時間で均一に昇温することができた。その結果、短時間で均一に磁性粉末を加熱することができ、密度と磁気特性に優れた永久磁石を得ることができた。 According to the present invention, by preparing a temporary molded body in the temporary molding process, the heat conduction of the magnetic powder is improved and the heating process is uniformly and quickly heated, so that deterioration of magnetic properties due to oxidation can be suppressed. Permanent magnets with high magnetic properties were produced. In the heating step, the mixture was heated by at least one heating method selected from infrared heating, microwave heating, and high frequency induction heating, so that the temperature of the mixture could be increased uniformly in a short time. As a result, the magnetic powder could be heated uniformly in a short time, and a permanent magnet excellent in density and magnetic properties could be obtained.
 実施例1~4からわかるように、仮成形工程における金型温度を上げることで密度の高い仮成形体が得られ、成形工程における配向の乱れが抑制された結果、より配向度Br/4πMsの高い試料を得ることができた。 As can be seen from Examples 1 to 4, by increasing the mold temperature in the temporary molding step, a high-density temporary molded body is obtained, and as a result of suppressing the disorder of orientation in the molding step, the degree of orientation Br / 4πMs is further increased. A high sample could be obtained.
 実施例1、5、6からわかるように、仮成形工程における成形圧力を上げることで密度の高い仮成形体が得られ、成形工程における配向の乱れが抑制された結果、より配向度Br/4πMsの高い試料を得ることができた。 As can be seen from Examples 1, 5, and 6, by increasing the molding pressure in the temporary molding step, a high-density temporary molded body is obtained, and as a result of suppressing the disorder of orientation in the molding step, the degree of orientation Br / 4πMs is further increased. A high sample was obtained.
 実施例1、7、8からわかるように、加熱時間1分で十分に仮成形体が加熱されるため、相対密度が高く、磁気特性の高い試料を得ることができた。 As can be seen from Examples 1, 7, and 8, since the temporary molded body was sufficiently heated in 1 minute, a sample having a high relative density and high magnetic properties could be obtained.
 実施例1、9、10からわかるように、表2に記載の範囲内では、成形工程における金型温度が高いほど相対密度が高く、磁気特性の高い試料を得ることができた。 As can be seen from Examples 1, 9, and 10, within the range shown in Table 2, a sample having a higher relative density and a higher magnetic property could be obtained as the mold temperature in the molding process was higher.
 実施例1、11からわかるように、成形工程における磁場の有無にかかわらず十分に高い磁気特性をもつ試料を得ることができた。 As can be seen from Examples 1 and 11, a sample having sufficiently high magnetic properties could be obtained regardless of the presence or absence of a magnetic field in the molding process.
 実施例1、実施例12~14からわかるように、表2に記載の範囲内では、成形工程における成形圧力が高いほど相対密度が高く、磁気特性の高い試料を得ることができた。 As can be seen from Example 1 and Examples 12 to 14, within the range shown in Table 2, the higher the molding pressure in the molding process, the higher the relative density and the higher the magnetic properties.
 実施例1、15~18からわかるように、表3の範囲内で赤外線加熱の波長を変更した場合、十分な磁気特性をもつ試料を得ることができた。特に、波長のピークが0.75~2.0μmの範囲では高い磁気特性をもつ試料を得ることができた。 As can be seen from Examples 1 and 15 to 18, when the wavelength of infrared heating was changed within the range of Table 3, a sample having sufficient magnetic properties could be obtained. In particular, a sample having high magnetic properties could be obtained in the wavelength peak range of 0.75 to 2.0 μm.
 実施例19~23のように、実施例1に対して加熱方法をマイクロ波加熱に変更した場合も赤外線加熱を行った場合と同等の磁気特性をもつ試料を得ることができた。特に周波数が1~30MHzの範囲で比較的磁気特性の高い試料を得ることができた。 As in Examples 19 to 23, when the heating method was changed to microwave heating with respect to Example 1, a sample having magnetic characteristics equivalent to those obtained when infrared heating was performed could be obtained. In particular, a sample having relatively high magnetic properties could be obtained in the frequency range of 1 to 30 MHz.
 実施例24~28のように、実施例1に対して加熱方法を高周波誘導加熱に変更した場合も赤外線加熱を行った場合と同等の磁気特性をもつ試料を得ることができた。特に周波数が2~10MHzの範囲で比較的磁気特性の高い試料を得ることができた。 As in Examples 24 to 28, even when the heating method was changed to high frequency induction heating with respect to Example 1, a sample having magnetic characteristics equivalent to those obtained when infrared heating was performed could be obtained. In particular, a sample having relatively high magnetic properties could be obtained in the frequency range of 2 to 10 MHz.
 また、実施例29、30のように、実施例1に対して加熱方法を赤外線加熱と高周波誘導加熱、マイクロ波加熱と高周波誘導加熱の組み合わせに変更した場合も磁気特性の高い試料を得ることができた。 Further, as in Examples 29 and 30, even when the heating method is changed to a combination of infrared heating and high frequency induction heating, and microwave heating and high frequency induction heating as compared to Example 1, a sample having high magnetic properties can be obtained. did it.
 比較例1のように仮成形を行わないと、加熱工程において赤外線加熱を行った場合でもMnBiが酸化し、Brが減少するため、十分な(BH)maxが得られなかった。 If the temporary molding was not performed as in Comparative Example 1, even when infrared heating was performed in the heating step, MnBi was oxidized and Br decreased, so that sufficient (BH) max could not be obtained.
 比較例2のように雰囲気対流加熱のみで加熱を行った場合、加熱に時間がかかり、酸化による磁気特性の低下が生じたため、十分な磁気特性をもつ試料が得られなかった。 When heating was performed only by atmospheric convection heating as in Comparative Example 2, it took a long time to heat and a decrease in magnetic properties due to oxidation occurred, so a sample having sufficient magnetic properties could not be obtained.
 比較例3のように成形工程前に混合物を加熱せずに成形を行うと、混合物が加熱されていないために十分な密度をとることができず、磁気特性の高い試料を得ることができなかった。 If the mixture is not heated before the forming step as in Comparative Example 3, the mixture is not heated, so that sufficient density cannot be obtained and a sample with high magnetic properties cannot be obtained. It was.
 実施例31~33のように、MnBiにSmFe17、NdFe14B、またはSmCo17を加えることでより(BH)maxの高い試料を得ることができた。 As in Examples 31 to 33, a sample having a higher (BH) max could be obtained by adding Sm 2 Fe 17 N 3 , Nd 2 Fe 14 B, or Sm 2 Co 17 to MnBi.
 実施例34~38のように、金属バインダーを添加することでより相対密度の高い試料を得ることができた。 As in Examples 34 to 38, a sample having a higher relative density could be obtained by adding a metal binder.
 本発明の永久磁石の製造方法は電気・電子機器の素子用の永久磁石の製造方法として用いられる。 The method for producing a permanent magnet of the present invention is used as a method for producing a permanent magnet for an element of an electric / electronic device.
1.磁場中成形装置
2.電磁石
3.加圧装置
4a.上パンチ
4b.下パンチ
4c.ダイス
4d.加熱装置
5.熱処理装置
6.循環雰囲気機構
6a.循環雰囲気流出口
6b.循環雰囲気流入口
7.炉体
7a.断熱材もしくは断熱層を内包させた金属製の炉体壁
7b.熱処理品搬入口
7c.熱処理品搬出口
7d.仮成形体収容空間
8.近赤外線加熱源
9.仮成形体(もしくはこれを載置したトレイ)
10.ベルトコンベア
11a,11b.コイル
1. 1. Magnetic field forming apparatus 2. electromagnet Pressurizing device 4a. Upper punch 4b. Lower punch 4c. Dice 4d. 4. Heating device 5. Heat treatment apparatus Circulating atmosphere mechanism 6a. Circulating atmosphere outlet 6b. 6. Circulating atmosphere inlet Furnace 7a. Metal furnace wall 7b containing a heat insulating material or heat insulating layer. Heat treatment product inlet 7c. Heat treatment product outlet 7d. Temporary molded body accommodation space8. Near infrared heating source 9. Temporary molded body (or tray on which this is placed)
10. Belt conveyors 11a, 11b. coil

Claims (3)

  1.  MnBiを含む磁性粉末を磁場中で加圧をして仮成形体を得る仮成形工程と、
    前記仮成形体を赤外線加熱、マイクロ波加熱、高周波誘導加熱から選択される少なくとも1つの方法で加熱する加熱工程と、
    加熱した前記仮成形体を加圧して成形体を得る成形工程と、
    を有することを特徴とする永久磁石の製造方法。
    A temporary molding step of obtaining a temporary molded body by pressing magnetic powder containing MnBi in a magnetic field;
    A heating step of heating the temporary molded body by at least one method selected from infrared heating, microwave heating, and high-frequency induction heating;
    A molding step of pressing the heated temporary molded body to obtain a molded body;
    The manufacturing method of the permanent magnet characterized by having.
  2.  前記磁性粉末は、MnBi以外にSm-Fe-N系、Nd-Fe-B系、Sm-Co系から選ばれる1種類以上の磁性材料を含むことを特徴とする請求項1に記載の永久磁石の製造方法。 2. The permanent magnet according to claim 1, wherein the magnetic powder includes one or more magnetic materials selected from Sm—Fe—N, Nd—Fe—B, and Sm—Co in addition to MnBi. Manufacturing method.
  3.  前記仮成形体が金属バインダーを含むことを特徴とする請求項1又は2に記載の永久磁石の製造方法。 The method for producing a permanent magnet according to claim 1, wherein the temporary molded body contains a metal binder.
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