WO2018025931A1 - 軟磁性材料の製造方法 - Google Patents
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- WO2018025931A1 WO2018025931A1 PCT/JP2017/028128 JP2017028128W WO2018025931A1 WO 2018025931 A1 WO2018025931 A1 WO 2018025931A1 JP 2017028128 W JP2017028128 W JP 2017028128W WO 2018025931 A1 WO2018025931 A1 WO 2018025931A1
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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
- C22C33/00—Making ferrous alloys
- C22C33/003—Making ferrous alloys making amorphous alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/08—Ferrous alloys, e.g. steel alloys containing nickel
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/10—Ferrous alloys, e.g. steel alloys containing cobalt
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/12—Ferrous alloys, e.g. steel alloys containing tungsten, tantalum, molybdenum, vanadium, or niobium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/16—Ferrous alloys, e.g. steel alloys containing copper
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- 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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- 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
- H01F1/15341—Preparation processes therefor
- H01F1/1535—Preparation processes therefor by powder metallurgy, e.g. spark erosion
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C2200/00—Crystalline structure
- C22C2200/02—Amorphous
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C2202/00—Physical properties
- C22C2202/02—Magnetic
Definitions
- the present invention relates to a method for producing a soft magnetic material.
- the present invention particularly relates to a method for producing a soft magnetic material that achieves both high saturation magnetization and low coercivity.
- the soft magnetic material used for the core part of the parts has both high saturation magnetization and low coercivity.
- the soft magnetic material having high saturation magnetization is an Fe-based nanocrystalline soft magnetic material.
- the Fe-based nanocrystalline soft magnetic material is a soft magnetic material whose main component is Fe and in which nanocrystals are dispersed by 30% by volume or more.
- Patent Document 1 discloses that Fe 100-pqr-S Cu p B q Si r Sn s (where p, q, r, and s are atomic%, and 0.6 ⁇ p ⁇ 1 .6, 6 ⁇ q ⁇ 20, 0 ⁇ r ⁇ 17, and 0.005 ⁇ s ⁇ 24).) Fe-based nanocrystalline soft magnetic materials are disclosed.
- Patent Document 1 discloses that an Fe group is obtained by heat-treating an alloy having a composition represented by Fe 100-pq-rs Cu p B q Si r Sn S and having an amorphous phase. Obtaining nanocrystalline soft magnetic materials is disclosed.
- the Fe-based nanocrystalline soft magnetic material has high saturation magnetization because its main component is Fe.
- the Fe-based nanocrystalline soft magnetic material can be obtained by heat-treating an alloy having an amorphous phase (also referred to as annealing. The same shall apply hereinafter). If the Fe content in the amorphous alloy is large, a crystalline phase ( ⁇ -Fe) is likely to be generated from the amorphous phase, and the crystalline phase is likely to grow and coarsen. Therefore, an element for suppressing grain growth is added to the material, but the Fe content in the material is reduced by the amount of the added element, so that the saturation magnetization is lowered.
- the present invention has been made to solve the above problems, and an object of the present invention is to provide a method for producing a soft magnetic material that achieves both high saturation magnetization and low coercivity.
- composition formula 1 is Fe 100-xy B x M y , where M is at least one element selected from Nb, Mo, Ta, W, Ni, Co, and Sn, and x and y is atomic% and satisfies 10 ⁇ x ⁇ 16 and 0 ⁇ y ⁇ 8,
- composition formula 2 is Fe 100- abc B a Cu b M ′ c , and M ′ is at least one element selected from Nb, Mo, Ta, W, Ni, and Co.
- a method for producing a soft magnetic material ⁇ 2> The method according to ⁇ 1>, wherein the molten metal is quenched to obtain the alloy. ⁇ 3> The method according to ⁇ 1> or ⁇ 2>, wherein the rate of temperature increase is 125 ° C./second or more. ⁇ 4> The method according to ⁇ 1> or ⁇ 2>, wherein the rate of temperature increase is 325 ° C./second or more.
- ⁇ 5> The method according to any one of ⁇ 1> to ⁇ 4>, wherein the alloy is held for not less than the crystallization start temperature and less than the FeB compound formation start temperature for 0 to 17 seconds.
- ⁇ 6> The alloy is sandwiched between heated blocks to heat the alloy, The method according to any one of ⁇ 1> to ⁇ 5>, comprising:
- the alloy in order to obtain a high saturation magnetization, even if the main component of the alloy having an amorphous phase is Fe, the alloy is not less than the crystallization start temperature and less than the Fe—B compound formation start temperature.
- the crystal phase can be refined and a low coercive force can be obtained. That is, according to the present invention, it is possible to provide a method for producing a soft magnetic material that achieves both high saturation magnetization and low coercivity.
- FIG. 1 is a perspective view showing an outline of an apparatus for sandwiching an amorphous alloy between heated blocks and heating the amorphous alloy.
- FIG. 2 is a graph showing the relationship between the heating time when the amorphous alloy is heated and the temperature of the amorphous alloy.
- FIG. 3 is a graph showing the relationship between the holding temperature and the coercive force when an amorphous alloy having the composition of Fe 86 B 13 Cu 1 is heat-treated.
- FIG. 4 shows the relationship between the holding temperature and the coercive force when an amorphous alloy having the composition of Fe 85 B 13 Nb 1 Cu 1 is heat-treated (heating rate: 415 ° C./second, holding time: 0 second). It is a graph to show.
- FIG. 1 is a perspective view showing an outline of an apparatus for sandwiching an amorphous alloy between heated blocks and heating the amorphous alloy.
- FIG. 2 is a graph showing the relationship between the heating time when the amorphous alloy is heated and the temperature
- FIG. 5 shows the relationship between retention time and coercive force when an amorphous alloy having a composition of Fe 85 B 13 Nb 1 Cu 1 is heat-treated (temperature increase rate: 415 ° C./second, retention temperature: 500 ° C.). It is a graph to show.
- FIG. 6 shows the relationship between the rate of temperature rise and the coercivity when an amorphous alloy having the composition of Fe 85 B 13 Nb 1 Cu 1 is heat-treated (holding temperature: 500 ° C., holding time: 0 to 80 seconds). It is a graph to show.
- FIG. 7 is a graph showing the relationship between the holding temperature and the coercive force when an amorphous alloy having a composition of Fe 87 B 13 is heat-treated.
- FIG. 8 is a graph showing the relationship between the holding temperature and the coercive force when an amorphous alloy having the composition of Fe 87 B 13 is heat-treated (heating rate: 415 ° C./second, holding time: 0 second).
- FIG. 9 is a graph showing the relationship between the rate of temperature rise and the coercive force when an amorphous alloy having the composition of Fe 87 B 13 is heat-treated (holding temperature: 485 ° C., holding time: 0 to 30 seconds).
- FIG. 10 shows the X of the soft magnetic material after the amorphous alloy is rapidly heated and held for a short time (heating rate: 415 ° C./second, holding temperature: 485 to 570 ° C., holding time: 0 to 30 seconds). It is a figure which shows a line diffraction result.
- an alloy whose main component is Fe and having an amorphous phase is rapidly heated to a temperature range above the crystallization start temperature and below the Fe—B compound formation start temperature. And hold for a short time.
- the main component is Fe means that the content of Fe in the material is 50 atomic% or more.
- the “alloy having an amorphous phase” refers to containing 50% by volume or more of an amorphous phase in the alloy, and this may be simply referred to as “amorphous alloy”.
- An “alloy” has forms such as ribbons, flakes, granules, and bulk.
- an element that becomes a heterogeneous nucleation site is an element that does not easily dissolve in Fe.
- An example of an element that becomes a heterogeneous nucleation site and does not easily dissolve in Fe is Cu.
- the amorphous alloy contains Cu
- Cu becomes a nucleation site
- heterogeneous nucleation occurs from these Cu clusters, and the crystal phase becomes finer.
- the amorphous alloy contains Cu, even when the amorphous alloy is heated at a low speed (about 1.7 ° C./second), sufficient nucleation occurs and a fine crystalline phase is obtained. Conceivable.
- the amorphous alloy is rapidly heated (10 ° C./second or more) and immediately cooled. By holding for a short time (0 to 80 seconds), it is considered that the coarsening of the microstructure is avoided and a fine crystal phase is obtained.
- the details are as follows. Note that the holding time of 0 seconds means immediately cooling after the rapid temperature rise or terminating the holding.
- the heterogeneous nucleation rate is governed by atomic transport and critical nucleus size. If the atomic transport is high and the critical nucleus size is small, the heterogeneous nucleation rate increases and the microstructure becomes finer. In order to realize these two conditions, it is effective to introduce a supercooled liquid region in the amorphous material. This is because the viscous flow in the supercooled liquid is very large, and the strain energy due to nucleation in the supercooled liquid is much smaller than that in the amorphous body. Therefore, when there is a supercooled liquid region, many embryos are core. However, in the conventional heat treatment (annealing), the amorphous body is crystallized at a relatively low temperature where the transition from the solid to the supercooled liquid is limited.
- the amorphous alloy is rapidly heated to a temperature higher than the crystallization start temperature (10 ° C. / Seconds or more).
- the amorphous alloy is rapidly heated, the grain growth rate increases, so the holding time is shortened (0 to 80 seconds), and the grain growing time is shortened. From the viewpoint of atom transport, it is better to raise the temperature as high as possible rather than the crystallization start temperature.
- the temperature of the amorphous alloy reaches the Fe—B compound production start temperature, the Fe—B compound is produced. Since the Fe—B compound has a large magnetocrystalline anisotropy, it increases the coercive force.
- the temperature of the amorphous alloy it is preferable to rapidly raise the temperature of the amorphous alloy to a temperature range higher than the crystallization start temperature and lower than the Fe—B compound formation start temperature.
- addition of Cu is not essential due to the effect of increasing the nucleation frequency by rapid heating. For this reason, a non-magnetic Cu-free nanostructure with a higher Fe concentration can be realized, and higher saturation magnetization than before can be obtained.
- Rapid heating is necessary in the temperature range above the crystallization start temperature and below the Fe—B compound formation start temperature.
- the amorphous alloy is heated slowly at a temperature lower than the crystallization start temperature, when the temperature of the amorphous alloy reaches the crystallization start temperature, it is difficult to immediately shift to rapid temperature increase. is there.
- the temperature may be rapidly increased from the time when the temperature of the amorphous alloy is lower than the crystallization start temperature, and the rapid temperature increase may be continued even after the amorphous alloy reaches the crystallization start temperature.
- the rapid temperature increase described above is effective when an element that becomes a heterogeneous nucleation site does not exist in the amorphous alloy. And when the element which becomes a heterogeneous nucleation site like Cu exists in an amorphous alloy, the effect that Cu becomes a nucleation site and a crystal grain refines, and rapid temperature rise The effect of remarkably increasing the nucleation frequency and making the crystal grains fine can be obtained in a superimposed manner.
- the amorphous alloy is rapidly heated to a temperature higher than the crystallization start temperature and lower than the Fe—B compound formation start temperature, and immediately cooled or reached.
- the present inventors have found that it is preferable to perform a heat treatment for a short time at the above temperature. It has been found that such heat treatment is effective regardless of whether or not an element that becomes a heterogeneous nucleation site such as Cu exists in the amorphous alloy.
- amorphous alloy An alloy having an amorphous phase (amorphous alloy) is prepared.
- the amorphous alloy has an amorphous phase of 50% by volume or more.
- the content of the amorphous phase in the amorphous alloy is 60% by volume or more, 70% by volume or more. Or 90 volume% or more is preferable.
- the amorphous alloy has a composition represented by Composition Formula 1 or Composition Formula 2.
- the amorphous alloy having the composition represented by the composition formula 1 does not contain an element that becomes a heterogeneous nucleation site.
- the amorphous alloy having the composition represented by the composition formula 2 (hereinafter sometimes referred to as “amorphous alloy of the composition formula 2”) contains an element that becomes a heterogeneous nucleation site.
- Composition formula 1 is Fe 100-xy B x M y .
- M is at least one element selected from Nb, Mo, Ta, W, Ni, Co, and Sn, and x and y are 10 ⁇ x ⁇ 16 and 0 ⁇ y ⁇ . Satisfy 8 x and y are atomic%, x represents the content of B, and y represents the content of M.
- the main component is Fe, that is, the content of Fe is 50 atomic% or more.
- the Fe content is represented by the balance of B and M. From the viewpoint that the soft magnetic material obtained by rapidly heating and holding the amorphous alloy has high saturation magnetization, the Fe content is 80 atomic% or more, 84 atomic% or more, or 88 atomic% or more. Is preferred.
- An amorphous alloy is obtained by rapidly cooling a molten metal whose main component is Fe.
- B boron
- the main phase of the amorphous alloy is an amorphous phase.
- that the main phase of the alloy is an amorphous phase means that the content of the amorphous phase in the alloy is 50% by volume or more.
- the content of B in the amorphous alloy is preferably 11 atomic% or more, and more preferably 12 atomic% or more.
- the content of B in the amorphous alloy is 16 atomic% or less, the formation of the Fe—B compound can be avoided when the amorphous phase is crystallized.
- the content of B in the amorphous alloy is preferably 15 atomic% or less, and more preferably 14 atomic% or less.
- the amorphous alloy of composition formula 1 may contain M in addition to Fe and B, if necessary.
- M is at least one element selected from Nb, Mo, Ta, W, Ni, Co, and Sn.
- the amorphous alloy when at least one of Mb, Nb, Mo, Ta, W, and Sn is selected and the amorphous alloy contains these elements, when the amorphous alloy is rapidly heated and held, the crystalline phase Suppresses the growth of coercive force by suppressing grain growth. At the same time, the amorphous phase remaining in the alloy is stabilized after the amorphous alloy is rapidly heated and held.
- the amorphous alloy is rapidly heated and held, atomic transport occurs in a region where the amorphous alloy transitions to a supercooled state, thereby increasing the nucleation frequency.
- the amorphous alloy contains these elements, the Fe content in the amorphous alloy is reduced, and the saturation magnetization is lowered. Therefore, the content of these elements in the amorphous alloy is preferably minimized.
- the magnitude of the induced magnetic anisotropy can be controlled. Further, when the amorphous alloy contains Co, saturation magnetization can be increased.
- the amorphous alloy contains M
- the above-described effect is exhibited by the amount of M. That is, for Nb, Mo, Ta, W, and Sn, suppression of crystal phase grain growth and stabilization of the amorphous phase, and for Ni and Co, control of the magnitude of induced magnetic anisotropy and Demonstrates the effect of increasing saturation magnetization.
- the M content is preferably 0.2 atomic% or more, and more preferably 0.5 atomic% or more.
- M is 8 atomic% or less, Fe and B, which are essential elements of the amorphous alloy, will not be excessively reduced. As a result, the amorphous alloy was obtained by rapidly heating and holding the amorphous alloy. Soft magnetic materials can achieve both high saturation magnetization and low coercivity.
- content of M is the sum total of content of those elements.
- the amorphous alloy of composition formula 1 may contain inevitable impurities such as S, O, and N in addition to Fe, B, and M.
- Inevitable impurities refer to impurities such as impurities contained in the raw material that cannot be avoided, or incurring a significant increase in manufacturing cost.
- the purity of the alloy of composition formula 1 containing such inevitable impurities is preferably 97% by mass or more, more preferably 98% by mass or more, and more preferably 99% by mass or more. Even more preferred.
- composition formula 2 items different from the composition formula 1 will be described.
- the composition formula 2 is Fe 100- abc B a Cu b M ′ c .
- M ′ is at least one element selected from Nb, Mo, Ta, W, Ni, and Co, and a, b, and c are 10 ⁇ a ⁇ 16, 0 ⁇ b ⁇ 2 and 0 ⁇ c ⁇ 8 are satisfied.
- a, b, and c are atomic%, a shows the content of B, b shows the content of Cu, and c shows the content of M ′.
- the amorphous alloy of composition formula 2 requires Cu.
- the amorphous alloy of composition formula 2 may contain M ′ in addition to Fe, B, and Cu, if necessary.
- M ′ is at least one element selected from Nb, Mo, Ta, W, Ni, and Co.
- the Cu content in the amorphous alloy is preferably 0.2 atomic% or more, and more preferably 0.5 atomic% or more.
- the amorphous alloy can be produced by liquid quenching without generating a crystal phase.
- the Cu content in the amorphous alloy is preferably 1 atomic% or less, and more preferably 0.7 atomic% or less.
- the amorphous alloy of composition formula 2 may contain inevitable impurities such as S, O, and N in addition to Fe, B, Cu, and M ′.
- Inevitable impurities refer to impurities such as impurities contained in the raw material that cannot be avoided, or incurring a significant increase in manufacturing cost.
- the purity of the amorphous alloy of composition formula 2 containing such inevitable impurities is preferably 97% by mass or more, more preferably 98% by mass or more, and 99% by mass or more. It is even more preferable.
- the amorphous alloy is heated at a temperature increase rate of 10 ° C./second or more, and is maintained for 0 to 80 seconds at a temperature higher than the crystallization start temperature and lower than the formation start temperature of the Fe—B compound.
- the rate of temperature increase is faster. It may be the above.
- the rate of temperature rise is preferably 415 ° C./second or less.
- the temperature raising rate may be an average rate from the start of heating to the start of holding. When the holding time is 0 second, the average speed from the start of heating to the start of cooling may be used. Alternatively, it may be an average speed over a certain temperature range. For example, it may be an average speed between 100 and 400 ° C.
- the holding time is 0 second or more, a fine crystal phase can be obtained from the amorphous phase.
- the holding time of 0 seconds means immediately cooling after the rapid temperature rise or terminating the holding.
- the holding time is preferably 3 seconds or more.
- the holding time is 80 seconds or less, coarsening of the crystal phase can be avoided. From the viewpoint of avoiding coarsening of the crystal phase, the holding time may be 60 seconds or less, 40 seconds or less, 20 seconds or less, or 17 seconds or less.
- the holding temperature is equal to or higher than the crystallization start temperature, the amorphous phase can be converted into a crystalline phase. Since the holding time is short, the holding temperature can be increased.
- the holding temperature may be determined as appropriate in consideration of the holding time.
- the holding temperature exceeds the Fe—B compound production start temperature, strong crystal magnetic anisotropy occurs due to the formation of the Fe—B compound, and as a result, the coercive force increases. Therefore, by maintaining the highest temperature that does not reach the Fe—B compound production start temperature, the crystal phase can be refined without producing the Fe—B compound. In order to refine the crystal phase in this way, the amorphous alloy may be held just below the formation start temperature of the Fe—B compound.
- the formation start temperature of the Fe—B compound is a temperature that is 5 ° C. or less lower than the formation start temperature of the retained Fe—B compound, a temperature that is 10 ° C. or less lower than the formation start temperature of the Fe—B compound, It may be a temperature lower by 20 ° C. or lower than the production start temperature.
- the heating method is not particularly limited as long as the amorphous alloy can be heated at the temperature increase rate described so far.
- An infrared furnace is a furnace that rapidly heats an object to be heated by reflecting light emitted from an infrared lamp on a concave surface.
- FIG. 1 is a perspective view showing an outline of an apparatus for sandwiching an amorphous alloy between blocks that have already been heated to a desired holding temperature, and rapidly heating and holding the amorphous alloy.
- the block 2 is provided with a heating element (not shown).
- a temperature controller 3 is connected to the heating element.
- the amorphous alloy 1 is heated by sandwiching the amorphous alloy 1 in the previously heated block 2 so that heat transfer between the solids occurs between the amorphous alloy 1 and the block 2. can do.
- the material of the block 2 is not particularly limited. Examples of the material of the block 2 include metals, alloys, and ceramics.
- the amorphous alloy When the amorphous alloy is heated at a rate of 100 ° C./second or more, the amorphous alloy itself generates heat due to the heat released when the amorphous phase is crystallized.
- the temperature of an amorphous alloy is rapidly increased using an atmosphere furnace or an infrared furnace, it is difficult to control the temperature in consideration of heat generation of the amorphous alloy itself. For this reason, when an atmosphere furnace or an infrared furnace is used, the temperature of the amorphous alloy is higher than the target, and the crystal phase is often coarsened.
- the amorphous alloy 1 is heated by sandwiching the amorphous alloy 1 between the heated blocks 2 as shown in FIG.
- the temperature takes into account the self-heating of the amorphous alloy. Easy to control. Therefore, when the amorphous alloy is rapidly heated as shown in FIG. 1, the temperature of the amorphous alloy does not become higher than the target, and the coarsening of the crystal phase can be avoided.
- the temperature of the amorphous alloy when the temperature of the amorphous alloy is rapidly increased, the temperature of the amorphous alloy can be precisely controlled, so that the amorphous alloy is held immediately below the formation start temperature of the Fe—B compound.
- the crystal phase can be refined without forming an Fe—B compound.
- Method for producing amorphous alloy Next, a method for producing an amorphous alloy will be described. If the amorphous alloy which has a composition represented by the composition formula 1 and the composition formula 2 mentioned above is obtained, there will be no restriction
- an ingot prepared such that the amorphous alloy has a composition represented by composition formula 1 or composition formula 2 is prepared in advance, and the ingot is melted. And quenching the molten metal to obtain an amorphous alloy. If there is an element that is depleted when the ingot is melted, an ingot having a composition that allows for the depleted amount is prepared. Moreover, when crushing and melt
- the method for rapidly cooling the molten metal may be a conventional method, such as a single roll method using a cooling roll made of copper or a copper alloy.
- the peripheral speed of the cooling roll in the single roll method may be a standard peripheral speed when an amorphous alloy whose main component is Fe is manufactured.
- the peripheral speed of the cooling roll may be, for example, 15 m / second or more, 30 m / second or more, or 40 m / second or more, and may be 55 m / second or less, 70 m / second or less, or 80 m / second or less.
- the temperature of the molten metal when discharging the molten metal to a single roll is preferably 50 to 300 ° C. higher than the melting point of the ingot.
- atmospheres such as an inert gas, are preferable.
- Raw materials were weighed so as to have a predetermined composition, arc-melted, and then cast into a mold to produce an ingot.
- As the raw material pure Fe, Fe—B alloy, pure Cu or the like was used.
- the finely cut ingot was charged into the nozzle of a liquid quenching device (single roll method) and melted by high-frequency heating to obtain a molten metal. Then, the molten metal was discharged onto a copper roll having a peripheral speed of 40 to 70 m / s to obtain an amorphous alloy having a width of 1 mm.
- the amorphous alloy was analyzed by X-ray diffraction (XRD) before the heat treatment described below.
- XRD X-ray diffraction
- the crystallization start temperature, the Fe—B compound formation start temperature, and the Curie temperature of the amorphous phase were measured. For these measurements, differential thermal analysis (DTA: Differential Thermal Analysis) and thermo-magnetic gravimetric analysis (TMGA: Thermo-Magneto-Gravimetric Analysis) were used.
- the amorphous alloy was sandwiched between heated blocks, and the amorphous alloy was heated for a certain time. By this heating, the amorphous phase in the amorphous alloy was crystallized to obtain a sample of a soft magnetic material.
- the temperature increase rate is based on a temperature range of 100 to 400 ° C. as shown in FIG.
- sample evaluation The following evaluation was performed about the sample after heat processing. Using a vibrating sample magnetometer (VSM), saturation magnetization was measured (maximum applied magnetic field 10 kOe). The coercive force was measured using a direct current BH analyzer. The crystal phase was identified by XRD analysis.
- VSM vibrating sample magnetometer
- Table 1-1 to Table 1-5 Evaluation results are shown in Table 1-1 to Table 1-5.
- Table 1-1 to Table 1-5 the composition of the amorphous alloy, the heating conditions, the crystallization start temperature, the Fe—B compound formation start temperature, and the Curie temperature of the amorphous phase are also shown.
- FIG. 3 is a graph showing the relationship between the holding temperature and the coercive force when an amorphous alloy having the composition of Fe 86 B 13 Cu 1 is heat-treated.
- FIG. 4 shows the relationship between the holding temperature and the coercive force when an amorphous alloy having the composition of Fe 85 B 13 Nb 1 Cu 1 is heat-treated (heating rate: 415 ° C./second, holding time: 0 second). It is a graph to show.
- FIG. 5 shows the relationship between retention time and coercive force when an amorphous alloy having a composition of Fe 85 B 13 Nb 1 Cu 1 is heat-treated (temperature increase rate: 415 ° C./second, retention temperature: 500 ° C.). It is a graph to show.
- FIG. 4 shows the relationship between the holding temperature and the coercive force when an amorphous alloy having the composition of Fe 85 B 13 Nb 1 Cu 1 is heat-treated (temperature increase rate: 415 ° C./second, retention temperature: 500 °
- FIG. 7 is a graph showing the relationship between the holding temperature and the coercive force when an amorphous alloy having a composition of Fe 87 B 13 is heat-treated.
- FIG. 8 is a graph showing the relationship between the holding temperature and the coercive force when an amorphous alloy having the composition of Fe 87 B 13 is heat-treated (heating rate: 415 ° C./second, holding time: 0 second).
- FIG. 9 is a graph showing the relationship between the rate of temperature rise and the coercive force when an amorphous alloy having the composition of Fe 87 B 13 is heat-treated (holding temperature: 485 ° C., holding time: 0 to 30 seconds). .
- FIG. 10 shows a soft magnetic material after the amorphous alloy is rapidly heated and held for a short time (temperature rising rate: 415 ° C./second, holding temperature: 485 to 570 ° C., holding time: 0 to 30 seconds). It is a figure which shows the X-ray-diffraction result of.
- the reason why there is an example in which the coercive force does not increase even though the holding temperature is higher than the Fe—B compound formation start temperature is considered as follows.
- the Fe—B compound formation start temperatures shown in Table 1-1 to Table 1-5 are measured by differential thermal analysis.
- the sample heating rate in differential thermal analysis is very slow.
- the production start temperature of a compound is affected by the rate of temperature increase. Therefore, it is considered that the Fe—B compound production start temperature measured by differential thermal analysis is lower than the Fe—B compound production start temperature when the amorphous alloy is rapidly heated. This is also supported by the fact that no peak of the Fe—B compound is observed in the X-ray diffraction analysis of the samples of all Examples as shown in FIG.
- the average crystal grain size was calculated from the half width based on the X-ray diffraction chart of FIG. 10, it was confirmed that the average crystal grain size was 30 nm or less.
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Abstract
Description
〈1〉下記組成式1又は組成式2で表される組成を有し、かつ非晶質相を有する合金を準備すること、及び、
前記合金を昇温速度10℃/秒以上で加熱し、かつ、結晶化開始温度以上、Fe-B化合物生成開始温度未満で、0~80秒にわたり保持すること、
を含み、
前記組成式1がFe100-x-yBxMyであり、Mは、Nb、Mo、Ta、W、Ni、Co、及びSnから選ばれる少なくとも1種の元素であり、かつ、x及びyが、原子%で、10≦x≦16及び0≦y≦8を満たし、
前記組成式2がFe100-a-b-cBaCubM´cであり、M´は、Nb、Mo、Ta、W、Ni、及びCoから選ばれる少なくとも1種の元素であり、かつ、a、b、及びcが、原子%で、10≦a≦16、0<b≦2、及び0≦c≦8を満たす、
軟磁性材料の製造方法。
〈2〉溶湯を急冷し、前記合金を得る、〈1〉項に記載の方法。
〈3〉前記昇温速度が125℃/秒以上である、〈1〉又は〈2〉項に記載の方法。
〈4〉前記昇温速度が325℃/秒以上である、〈1〉又は〈2〉項に記載の方法。
〈5〉前記合金を、前記結晶化開始温度以上、FeB化合物生成開始温度未満で、0~17秒にわたり保持する、〈1〉~〈4〉項のいずれか一項に記載の方法。
〈6〉前記合金を、加熱したブロックの間に挟み込んで、前記合金を加熱すること、
を含む、〈1〉~〈5〉項のいずれか一項に記載の方法。
非晶質相を有する合金(非晶質合金)を準備する。上述したように、非晶質合金は、50体積%以上の非晶質相を有する。非晶質合金を急速昇温及び保持して、より多くの微細な結晶相を得る観点から、非晶質合金中の非晶質相の含有量については、60体積%以上、70体積%以上、又は90体積%以上が好ましい。
非晶質合金を、昇温速度10℃/秒以上で加熱し、かつ、結晶化開始温度以上Fe-B化合物の生成開始温度未満で、0~80秒にわたり保持する。
次に、非晶質合金の製造方法について説明する。上述した組成式1及び組成式2で表される組成を有する非晶質合金が得られれば、非晶質合金の製造方法に制限はない。上述したように、合金は、薄帯、薄片、粒状物、及びバルク等の形態を有する。所望の形態を得るために、非晶質合金の製造方法を適宜選択することができる。
所定の組成になるように、原材料を秤量し、これをアーク溶解した後、鋳型に鋳造し、鋳塊を作製した。原材料としては、純Fe、Fe-B合金、純Cu等を用いた。
図1に示したように、非晶質合金を加熱したブロックの間に挟み込み、非晶質合金を一定時間加熱した。この加熱により、非晶質合金中の非晶質相を結晶化し、軟磁性材料の試料とした。なお、昇温速度は、図2に示すように、100~400℃の温度域に基づく。
熱処理後の試料について、次の評価を行った。振動試料型磁力計(VSM:Vibrating Sample Magnetometer)を用いて、飽和磁化を測定した(最大印加磁場10kOe)。直流BHアナライザーを用いて、保磁力を測定した。XRD分析によって、結晶相の同定を行った。
2 ブロック
3 温度調節器
Claims (6)
- 下記組成式1又は組成式2で表される組成を有し、かつ非晶質相を有する合金を準備すること、及び、
前記合金を昇温速度10℃/秒以上で加熱し、かつ、結晶化開始温度以上、Fe-B化合物の生成開始温度未満で、0~80秒にわたり保持すること、
を含み、
前記組成式1がFe100-x-yBxMyであり、Mは、Nb、Mo、Ta、W、Ni、Co、及びSnから選ばれる少なくとも1種の元素であり、かつ、x及びyが、原子%で、10≦x≦16及び0≦y≦8を満たし、
前記組成式2がFe100-a-b-cBaCubM´cであり、M´は、Nb、Mo、Ta、W、Ni、及びCoから選ばれる少なくとも1種の元素であり、かつ、a、b、及びcが、原子%で、10≦a≦16、0<b≦2、及び0≦c≦8を満たす、
軟磁性材料の製造方法。 - 溶湯を急冷し、前記合金を得る、請求項1に記載の方法。
- 前記昇温速度が125℃/秒以上である、請求項1又は2に記載の方法。
- 前記昇温速度が325℃/秒以上である、請求項1又は2に記載の方法。
- 前記合金を、前記結晶化開始温度以上、Fe-B化合物の生成開始温度未満で、0~17秒にわたり保持する、請求項1~4のいずれか一項に記載の方法。
- 前記合金を、加熱したブロックの間に挟み込んで、前記合金を加熱すること、
を含む、請求項1~5のいずれか一項に記載の方法。
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US16/323,228 US11352677B2 (en) | 2016-08-04 | 2017-08-02 | Method of producing soft magnetic material |
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EP3680353A1 (en) * | 2019-01-10 | 2020-07-15 | Toyota Jidosha Kabushiki Kaisha | Method for producing alloy ribbon |
WO2020142810A1 (en) * | 2019-01-11 | 2020-07-16 | Monash University | Iron based alloy |
US10825592B2 (en) | 2017-12-06 | 2020-11-03 | Toyota Jidosha Kabushiki Kaisha | Method for producing soft magnetic material |
EP3842555A1 (en) | 2019-12-26 | 2021-06-30 | Hitachi Metals, Ltd. | Soft magnetic alloy, soft magnetic alloy ribbon, method of manufacturing soft magnetic alloy ribbon, and magnetic core |
EP4040453A1 (en) | 2021-01-22 | 2022-08-10 | Hitachi Metals, Ltd. | Soft magnetic alloy, soft magnetic alloy ribbon, method of manufacturing soft magnetic alloy ribbon, magnetic core, and component |
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JP7234809B2 (ja) * | 2019-06-06 | 2023-03-08 | トヨタ自動車株式会社 | 合金薄帯片の製造方法 |
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US10825592B2 (en) | 2017-12-06 | 2020-11-03 | Toyota Jidosha Kabushiki Kaisha | Method for producing soft magnetic material |
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