WO2018092665A1 - 金属粉末の製造方法 - Google Patents
金属粉末の製造方法 Download PDFInfo
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- WO2018092665A1 WO2018092665A1 PCT/JP2017/040352 JP2017040352W WO2018092665A1 WO 2018092665 A1 WO2018092665 A1 WO 2018092665A1 JP 2017040352 W JP2017040352 W JP 2017040352W WO 2018092665 A1 WO2018092665 A1 WO 2018092665A1
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
- C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
- C22C33/0285—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/16—Metallic particles coated with a non-metal
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- B22—CASTING; POWDER METALLURGY
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- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/026—Spray drying of solutions or suspensions
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- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/16—Making metallic powder or suspensions thereof using chemical processes
- B22F9/18—Making metallic powder or suspensions thereof using chemical processes with reduction of metal compounds
- B22F9/24—Making metallic powder or suspensions thereof using chemical processes with reduction of metal compounds starting from liquid metal compounds, e.g. solutions
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- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/16—Making metallic powder or suspensions thereof using chemical processes
- B22F9/30—Making metallic powder or suspensions thereof using chemical processes with decomposition of metal compounds, e.g. by pyrolysis
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0433—Nickel- or cobalt-based alloys
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23D—ENAMELLING OF, OR APPLYING A VITREOUS LAYER TO, METALS
- C23D5/00—Coating with enamels or vitreous layers
- C23D5/02—Coating with enamels or vitreous layers by wet methods
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/06—Metallic powder characterised by the shape of the particles
- B22F1/065—Spherical particles
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- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2201/00—Treatment under specific atmosphere
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- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/15—Nickel or cobalt
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- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/35—Iron
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- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
- B22F2302/25—Oxide
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
- B22F2302/25—Oxide
- B22F2302/256—Silicium oxide (SiO2)
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- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
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- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
Definitions
- the present invention relates to a method for producing a metal powder coated with a glassy thin film.
- the surface of the soft magnetic powder was covered with an insulating material, and an insulating material coating layer was interposed between the particles, and the eddy current generated in the magnetic core was divided between the particles, so that it was used at a high frequency. In some cases, eddy current loss has been reduced.
- Patent Document 1 soft magnetic powder prepared in advance using a powder coating method such as mechanofusion, a wet method such as electroless plating or sol-gel, or a dry method such as sputtering is used.
- An inorganic insulating layer made of low-melting glass is formed on the surface of the powder, and then the soft magnetic powder on which the inorganic insulating layer is formed and the resin powder are mixed, thereby softly covering the surface with the inorganic insulating layer and the resin particle layer.
- Magnetic powder is disclosed.
- Patent Document 2 discloses a method for producing a composite coated soft magnetic powder in which a coating layer mainly composed of boron nitride is formed on the surface of an iron-based soft magnetic powder using an inexpensive material. Specifically, iron oxide powder, silicon carbide powder, carbon powder, and borosilicate glass powder prepared in advance were mixed using a mixer or the like, and the obtained mixed powder was mixed in a non-oxidizing atmosphere containing nitrogen. By performing heat treatment at ⁇ 1600 ° C., a boron nitride layer and a metal oxide layer formed by decomposition of borosilicate glass are formed on the surface of the Fe—Si alloy powder.
- the particle diameter and particle size distribution of the soft magnetic powder prepared in advance may be in an appropriate range depending on the case. Need to adjust.
- the coating process for forming the insulating layer on the surface it is essential to control the composition of the insulator to be coated and the coating amount. For this reason, it has been extremely difficult to form a uniform and homogeneous insulating layer on the surface of the soft magnetic powder.
- the soft magnetic powder itself is generally produced by a conventionally known gas atomization method, mechanical pulverization method, and gas phase reduction method.
- a spray pyrolysis method is known as a method for producing a metal powder mainly used for a conductor paste.
- Patent Literature 5 Patent Literature 6 and Patent Literature 7, a solution containing one or more kinds of thermally decomposable metal compounds is sprayed into fine droplets, and the droplets are separated from the decomposition temperature of the metal compound.
- a technique is disclosed in which metal particles are produced by heating at a high temperature, desirably near the melting point of the metal or higher, to thermally decompose the metal compound. According to these spray pyrolysis methods, metal powder having good crystallinity, high density and high dispersibility can be obtained, and the particle size can be easily controlled.
- a precursor such as a metal, a semi-metal, or an oxide thereof, which is difficult to dissolve in the metal powder is added to the metal compound solution that is a raw material of the target metal powder.
- a coating layer can be formed on the surface of the metal powder at the same time as the generation of the metal powder. This is because the crystallinity of the metal powder obtained by the spray pyrolysis method is good, and since there are few defects inside the particles and almost no grain boundaries, a coating produced by pyrolysis is formed inside the metal powder. This is considered to be caused by being ejected on the surface of the particle and being generated at a high concentration near the surface.
- the composition of the product basically matches the composition of the metal compound in the solution, it is easy to control the composition of the coating layer as well as the metal powder.
- metal particles having a coating layer on the surface can be obtained by the spray pyrolysis method without requiring a new coating step.
- An invention is described in which a metal powder coated with a vitreous thin film on at least a part of its surface is produced by a pyrolysis method without providing a new coating step.
- the metal powder described in Patent Document 8 is mainly used for a conductor paste for forming a conductor layer of a multilayer ceramic electronic component, and in particular, the oxidation resistance of the metal powder during firing of the conductor paste. Since the surface of the powder is coated with a vitreous thin film for the purpose of improving the glass, the vitreous thin film must cover the entire surface of the metal powder if an effective amount is adhered for that purpose. It is said that at least a part of the surface of the metal powder may be covered.
- metal powders coated with various glassy thin films can be produced by a manufacturing method described in Patent Document 8 in many combinations of glass compositions and metal species.
- the formation of metal particles There was a tendency that the glassy thin film could not be uniformly coated, and the vitreous thin film tended to be coated only on a part of the surface of the metal powder. In that case, it can be improved to some extent by strictly controlling various control factors such as furnace heating temperature, atmosphere, and cooling conditions.
- the more factors to be controlled the more precisely the control factors can be controlled. It becomes difficult.
- the above-described tendency is strongly observed when the metal powder is a soft magnetic powder containing iron (Fe).
- An object of the present invention is to provide a production method for easily obtaining a metal powder having a homogeneous glassy thin film.
- the present invention provides a solution comprising a thermally decomposable metal compound and a glass precursor that generates a glassy material that is not thermally dissolved with the metal that is thermally decomposed to form fine droplets.
- heating is performed at a temperature higher than the decomposition temperature of the metal compound and the decomposition temperature of the glass precursor and higher than the melting point of the metal generated from the metal compound.
- This is a method for producing a metal powder comprising the metal, producing a vitreous material near the surface of the metal powder, and producing a metal powder having a vitreous thin film on the surface,
- the metal is mainly composed of a base metal,
- a metal powder having a glassy thin film having a uniform film thickness and a uniform glass composition can be obtained relatively easily without strictly controlling many complicated control factors.
- FIG. 4 shows the result of element mapping of nickel in FIG.
- FIG. 4 shows the result of element mapping of FIG. 4 with iron.
- FIG. 4 shows the result of element mapping of barium with barium.
- FIG. 4 shows the result of element mapping of silicon in FIG.
- FIG. 4 shows the result of element mapping of FIG. 4 with oxygen.
- 18 is a TEM image showing a particle surface according to Experimental Example 17;
- FIG. 3 is a phase equilibrium diagram (in terms of mass%) of BaO—CaO—SiO 2 glass as an example of a phase equilibrium diagram.
- the metal powder is not particularly limited, and includes powders of single metals and alloys, but the effects of the present invention are more enjoyable when producing metal powders having a relatively high melting point. can do. Therefore, the melting point (Tm M ) of the metal is preferably 900 ° C. or higher and particularly preferably 1100 ° C. or higher.
- the metal preferably contains iron, and is particularly preferably a nickel-iron alloy containing nickel and iron.
- a numerical range indicated using the symbol “ ⁇ ” indicates a range including numerical values described before and after “ ⁇ ” unless otherwise specified.
- the “main component” means a component whose content exceeds 50% by mass.
- the nickel-iron alloy may further contain a metal such as molybdenum, copper, or chromium.
- the particle size of the metal powder is not limited, but the average particle size is preferably about 0.2 to 20 ⁇ m.
- (Tm M -Tm G ) is in the range of ⁇ 80 to 400 ° C., particularly preferably in the range of ⁇ 50 to 300 ° C. That is, it is particularly preferable that the present invention satisfies the following formula (2). ⁇ 50 [° C.] ⁇ (Tm M ⁇ Tm G ) ⁇ 300 [° C.] (2)
- the liquidus temperature Tm G is affected by the glassy composition. Therefore, in the present invention, the glass composition is determined so that the above-described conditions are satisfied with respect to the melting point Tm M of the target metal, and the glass raw material (glass precursor) is prepared.
- Tm M and Tm G can easily satisfy the above conditions by using silicate glass.
- a material in which the SiO 2 content in the vitreous thin film is 40% by mass or more based on the oxide is particularly preferable to use a material in which the SiO 2 content in the vitreous thin film is 40% by mass or more based on the oxide. Varies depending on the melting temperature Tm M metal is preferably Tm G is 900 ° C. or higher, particularly preferably 1100 ° C. or higher.
- the silicate glass preferably contains an alkaline earth metal.
- the silicate glass preferably contains at least one selected from the group consisting of MgO, CaO, SrO, and BaO on an oxide basis.
- the alkaline earth metal is preferably contained in an amount of 20% by mass or more based on the oxide.
- the presence of an iron component can also be confirmed in the vitreous thin film on the surface of the metal powder. Since no iron-based compound is used for the glass raw material (precursor), the iron component in the glass is derived from the iron compound contained in the metal compound used as the raw material for the metal powder, and is heated during heating. It is thought that it diffused inside. And by including an iron component in glass, the wettability between the iron component in the metal powder and the glass is improved, and as a result, a strong glass film is formed even on the metal powder containing iron. The present inventors speculate that it has become possible.
- the metal powder of the present invention is produced by a spray pyrolysis method. Specifically, a solution containing a thermally decomposable metal compound and a glass precursor that generates a glassy material that is not thermally dissolved with the metal generated from the metal compound by thermal decomposition is made into fine droplets. Is heated at a temperature higher than the decomposition temperature of the metal compound and the glass precursor, and higher than the melting point of the metal produced from the metal compound. While producing
- the glass precursor is not limited as long as the oxide (glass) generated after pyrolysis does not dissolve in the metal particles under the metal particle production conditions according to the present method and vitrifies.
- glass precursors include boric acid, silicic acid, phosphoric acid, various borates, silicates, phosphates, and various metal nitrates, sulfates, chlorides, ammonium salts, phosphates, carboxylates, alcoholates, and resin acids.
- a heat-decomposable salt such as a salt, a double salt or a complex salt is appropriately selected and used.
- the mixed solution of the metal compound and the glass precursor is made into fine droplets by an ultrasonic type or two-fluid nozzle type sprayer, and then heated at a temperature higher than the decomposition temperature of the metal compound and the decomposition temperature of the glass precursor.
- thermal decomposition When two or more compounds are mixed as the metal compound, heating is performed at a temperature higher than the decomposition temperature of the metal compound having the highest decomposition temperature.
- the heat treatment is performed at a high temperature equal to or higher than the melting point of the main component metal. It is possible to obtain the effect of ejecting the glass component even at a heating temperature lower than the melting point, but in that case, a metal powder with good crystallinity cannot be obtained, and the shape becomes non-uniform. Is insufficient.
- the atmosphere during heating is appropriately selected from oxidizing, reducing, and inert atmospheres depending on the type of metal compound and glass precursor, the heating temperature, etc., but the metal produces a metal powder containing a base metal as a main component.
- a reducing atmosphere is particularly preferred.
- a reducing agent that is soluble in the solution and does not exhibit reducing properties when not heated (for example, during preparation of a spray solution) and exhibits reducing properties only during heating is added to the solution.
- the reducing agent at least one selected from the group consisting of methanol, ethanol, propanol, ethylene glycol, propylene glycol, diethylene glycol, and tetraethylene glycol can be used.
- the base metal is not particularly limited, but iron, cobalt, nickel, copper, and the like are preferable.
- the present invention is preferably iron, nickel, and an alloy containing these.
- the reducing agent added to the solution is preferably added so that the content in the whole solution is 5% by mass to 5 to 30% by mass.
- a larger amount of the reducing agent is advantageous for reduction of the metal compound, but in the case of the spray pyrolysis method, the concentration of the solution is increased and spraying becomes difficult. If the amount of the reducing agent added to the solution is within the above range, even if a metal compound that is difficult to reduce is used, most of it can be reduced, and spraying of the solution is hindered. Absent.
- a reducing gas in addition to the use of the reducing agent, it is preferable to further contain a reducing gas in a range of 1 to 20% by volume in a carrier gas for carrying fine droplets.
- the reducing gas at least one selected from the group consisting of hydrogen, carbon monoxide, methane, and ammonia gas can be used.
- Spray pyrolysis can be carried out while easily controlling the reduction without causing any problems.
- the present invention Since the present invention generates metal powder from a raw material mixed solution by spray pyrolysis, the composition of each component of the thermally decomposable metal compound and the glass precursor and the addition amount of the glass precursor to the metal compound are selected. As a result, a metal powder having a vitreous thin film on the target surface can be obtained.
- the total content in the mixed solution of the thermally decomposable metal compound and the glass precursor is based on the amount of metal component generated from the metal compound by pyrolysis and the oxide generated from the glass precursor by pyrolysis.
- the total concentration of both components in the mixed solution in terms of the amount of the glass component is less than 500 g / L, and is preferably 20 to 100 g / L from the viewpoint of ease of control.
- the amount of the metal component is determined by pyrolysis.
- the total amount of metal components generated from The mixing ratio of the metal compound and the glass precursor in the mixed solution is determined by the mass ratio of the glass component amount on the oxide basis to the metal component to be obtained by spray pyrolysis. If the amount of the glass component based on the oxide generated from the glass precursor is less than 0.1% by mass with respect to the amount of the metal component generated from the metal compound, there is no effect.
- the glass precursor is added so that the amount of the glass component on the basis of the oxide is 0.1 to 20% by mass with respect to the amount of the metal component. Is practical, and it is particularly desirable to add so as to be 0.5 to 15% by mass.
- the production method of the present invention makes it possible to easily obtain metal powder particles whose entire surface is uniformly coated with a homogeneous glassy thin film, but this is not a problem in practical use. Metal powder particles with a somewhat non-uniform glassy film may be produced.
- the metal powder obtained by the production method of the present invention does not exclude such powder that does not cause a problem in practice.
- Example 1 The nickel nitrate hexahydrate and iron nitrate weighed to obtain the metals shown in Table 1 were dissolved in water so that the metal component concentrations in the solutions shown in the same table were obtained.
- Component The numerical value of the glass composition in the table indicates the content ratio in terms of mass% with respect to the total mass number when converted into an oxide.
- surface is the glass component amount (mass%) on the oxide reference
- TEOS tetraethylorthosilicate
- the metal component concentration (g / L) in the solutions shown in Table 1 and Tables 2 and 3 is the metal compound content per liter of the solution converted into a metal component generated from the metal compound by thermal decomposition. is there. Further, the amount of reducing agent in the solutions shown in Table 1 and Tables 2 and 3 is the content (% by mass) of the reducing agent with respect to the whole solution.
- This raw material solution was made into fine droplets using an ultrasonic sprayer, and nitrogen gas having a flow rate shown in Table 1 was used as a carrier and supplied into a ceramic tube heated to 1550 ° C. in an electric furnace. The droplets were pyrolyzed through the heating zone and collected in a powder state.
- the collected powder was a nickel-iron alloy powder, and no other diffraction lines were detected. Further, when the powder was washed with 5% dilute hydrochloric acid, the amount of additive in the powder after washing was greatly reduced although nickel and iron were hardly dissolved.
- FIG. 1 is a TEM image showing an entire particle image of the powder immediately after collection, and shows the result of line analysis of the powder in the direction of the arrow in FIG. 2 by energy dispersive X-ray analysis (EDX). 3 shows.
- EDX energy dispersive X-ray analysis
- FIGS. 5 to 9 show the results of mapping from the TEM image of the powder shown in FIG. 4 for each element of nickel, iron, barium, silicon, and oxygen. From the above analysis, the powder is formed on the surface of the nickel-iron alloy powder in a high concentration of silicon and barium, is amorphous in X-ray, and exists in a homogeneous BaO—SiO 2 glass state. It was shown that. Further, as shown in FIG. 6, the presence of iron was confirmed in the vitreous thin film on the surface of the nickel-iron alloy powder.
- Table 1 shows the melting point (Tm M ) of the alloy and the liquid phase temperature (Tm G ) determined from the phase equilibrium diagram for the mixed oxide of the glass component, and the glass coverage [%] on the particle surface determined from the area by element mapping. And the vitreous thin film thickness [nm] obtained from the TEM image.
- Example 2 A nickel-iron alloy powder coated with a BaO—SiO 2 vitreous thin film was obtained in the same manner as in Experimental Example 1 except that the glass components were as shown in Table 1. The results of analysis conducted in the same manner as in Experimental Example 1 are also shown in Table 1.
- Example 17 as shown in FIG. 10, large and small irregularities were formed to give a rough surface as a whole, and the vitreous thin film was not uniformly formed on the surface of the metal powder. This is because the metal was insufficiently reduced, and the aforementioned irregularities were formed on the surface of the metal powder, and a part of the surface remained a metal oxide, and a vitreous thin film was formed thereon. Presumed to be non-uniform.
- Example 18 to 21 In each experimental example, iron nitrate is used as the metal component, the metal component concentration in the solution and the glass component are set as shown in Table 2, and the reducing agent shown in Table 2 is added to the carrier gas. In the same manner as in Example 1, an iron powder coated with a glassy thin film was obtained. The amount of the reducing agent in the solution is the content (% by mass) of the reducing agent with respect to the entire solution as described above. In these experimental examples, hydrogen gas and carbon monoxide in an amount (volume%) shown in Table 2 were added to nitrogen gas as a carrier gas. The results of analysis conducted in the same manner as in Experimental Example 1 are also shown in Table 2.
- Example 26 In Experimental Example 1, a raw material solution was prepared in the same manner as in Experimental Example 1 except that the amount of the reducing agent was 35% by mass. However, the ultrasonic sprayer could not generate fine droplets, and the experiment was stopped. .
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Abstract
Description
特許文献5、特許文献6及び特許文献7には、1種又は2種以上の熱分解性金属化合物を含む溶液を噴霧して微細な液滴にし、その液滴を該金属化合物の分解温度より高い温度、望ましくは該金属の融点近傍又はそれ以上の高温で加熱し、金属化合物を熱分解して金属粒子を生成する技術が開示されている。これらの噴霧熱分解法によれば、結晶性が良く、高密度かつ高分散性の金属粉末を得ることができ、粒径のコントロールも容易である。しかも噴霧熱分解法においては、目的とする金属粉末の原料である金属化合物溶液中に、当該金属粉末に固溶しにくい金属や半金属、或いはそれらの酸化物等の前駆体を添加しておくことにより、金属粉末の生成と同時に、その表面に被覆層を形成できるという優れた利点がある。これは噴霧熱分解法によって得られる金属粉末の結晶性が良好であり、しかも粒子内部に欠陥が少なく粒界をほとんど含まないことから、熱分解により生成した被覆物が金属粉末の内部に生成しにくく、粒子表面に弾き出され、表面近傍に高濃度に生成されることによるものと考えられている。その上、生成物の組成は基本的に溶液中の金属化合物の組成と一致するため、金属粉末のみならず被覆層の組成制御も容易である。
本発明者等の検討によれば、金属粉末が特に鉄(Fe)を含む軟磁性粉末である場合に、上述した傾向が強く見られた。
前記金属が卑金属を主成分とするものであり、
前記溶液中に、当該溶液に可溶であって上記加熱時に還元性を示す還元剤を、当該溶液全体に対する質量%で5~30質量%含む金属粉末の製造方法である。
本発明において金属粉末としては特に限定はなく、単一金属の粉末の他、合金の粉末を含むが、本発明の作用効果は、比較的高い融点を持つ金属粉末を製造する場合に、より享受することができる。それ故、前記金属の融点(TmM)としては900℃以上が好ましく、1100℃以上であることが特に好ましい。
ガラス質薄膜を構成するガラス質(単にガラスという場合もある)としては、非晶質のものでも、非晶質膜中に結晶を含んでいるものであってもよいが、金属の融点(TmM)と、当該ガラスの成分を酸化物の混合物(ここでは「混合酸化物」という)として捉えた場合の液相温度(TmG)との差(=TmM-TmG)が-100℃以上、500℃以下の範囲内にあることが好ましい。すなわち、本発明は下式(1)を満たしていることが好ましい。
-100〔℃〕≦(TmM-TmG)≦500〔℃〕 ・・・(1)
金属の融点TmMと液相温度TmGとが前出の条件を満たしている場合には、金属粉末表面全体をガラス質薄膜で被覆することが容易になる。
(TmM-TmG)の値は、-100℃を下回るとガラス原料(ガラス前駆体)からのガラス化が起きにくくなり、また500℃を上回ると生成したガラスの流動性が高すぎるために、ガラスの金属粉末表面上での偏析や当該表面の一部露出等が生じやすくなり、どちらの場合でも金属粉末表面全体をガラス質薄膜で被覆することが難しくなる。
より好ましくは、(TmM-TmG)は-80~400℃の範囲内であり、特に好ましくは-50~300℃の範囲内である。すなわち、本発明は下式(2)を満たしていることが特に好ましい。
-50〔℃〕≦(TmM-TmG)≦300〔℃〕 ・・・(2)
液相温度TmGは、ガラス質の組成に影響される。従って本発明においては、目的とする金属の融点TmMに対して上述した条件が満たされるようにガラス組成を決め、ガラス原料(ガラス前駆体)の調製を行う。
本発明の金属粉末は、噴霧熱分解法によって製造される。具体的には、熱分解性の金属化合物と、熱分解して当該金属化合物から生成する金属と固溶しないガラス質を生成するガラス前駆体とを含む溶液を微細な液滴にし、当該液滴をキャリアガス中に分散させた状態で、前記金属化合物の分解温度及び前記ガラス前駆体の分解温度より高く、且つ、前記金属化合物から生成する金属の融点よりも高い温度で加熱することにより、当該金属からなる金属粉末を生成させると共に、当該金属粉末の表面近傍にガラス質を生成させて、表面にガラス質薄膜を備えた金属粉末を製造する。
本発明において、加熱処理は主成分金属の融点又はそれ以上の高温で行う。なお、融点より低い加熱温度でもガラス成分の弾き出しの効果を得ることはできるが、その場合、結晶性の良い金属粉末が得られず、その形状も不均一になるため、高密度化や分散性が不十分なものとなる。
使用する金属化合物の種類にも因るが、溶液中に添加する還元剤は、溶液全体での含有量が質量%で、5~30質量%となるように添加することが好ましい。
また本発明においては、必要に応じて、上記還元剤の使用に加えて更に、微細な液滴を搬送するキャリアガスに還元性ガスを1~20体積%の範囲で含有することが好ましい。還元性ガスの例としては、水素、一酸化炭素、メタン、アンモニアガスから成る群から選ばれる少なくとも1種を用いることができる。溶液中に還元剤を含有させると共に、キャリアガスに還元性ガスを含ませることで、特に還元しにくい金属化合物を用いた場合でも、溶液中の還元剤量を増やすことなく、溶液の噴霧に支障をきたさずに容易に還元をコントロールしながら噴霧熱分解を行うことができる。
表1に示す金属が得られるよう秤量した硝酸ニッケル六水和物、硝酸鉄を、同表に示した溶液中の金属成分濃度になるように水に溶解し、これに、表1に示すガラス成分[表中のガラス組成の数値は、酸化物に換算したときの合計質量数に対する含有割合を質量%で示したものである。また表中のガラス成分添加量は、金属成分量に対しての酸化物基準でのガラス成分量(質量%)であり、表2、3においても同様である。]が得られるよう秤量したテトラエチルオルソシリケート(TEOS)及び硝酸バリウムと、還元剤としてエチレングリコール(MEG)とを添加・混合して原料溶液を作製した。なお、表1並びに表2、3に示した溶液中の金属成分濃度(g/L)は、熱分解により金属化合物から生成する金属成分に換算しての、溶液1Lあたりの金属化合物含有量である。また、表1並びに表2、3に示した溶液中の還元剤量は溶液全体に対する還元剤の含有量(質量%)である。
この原料溶液を、超音波噴霧器を用いて微細な液滴とし、表1に示す流量の窒素ガスをキャリアとして、電気炉で1550℃に加熱されたセラミック管中に供給した。液滴は加熱ゾーンを通って加熱分解され、粉末の状態で捕集した。
ガラス成分を表1記載の通りとなるようにした以外は実験例1と同様にして、BaO-SiO2ガラス質薄膜で被覆されたニッケル-鉄合金粉末を得た。実験例1と同様に行った分析結果を表1に併記する。
各実験例において、金属組成、ガラス成分、ガラス成分の添加量及び溶液に添加する還元剤量[溶液全体に対する還元剤の含有量(質量%)]を表1記載の通りとなるようにした以外は実験例1、2と同様に、ガラス質薄膜で被覆されたニッケル-鉄合金粉末を得た。なお、ガラス成分のカルシウム源としては硝酸カルシウムを、また、マンガン源としては硝酸マンガンを、更にビスマス源としてはクエン酸ビスマスを使用した。実験例1と同様に行った分析結果を表1に併記する。
各実験例において、金属成分として硝酸鉄を用い、溶液中の金属成分濃度、ガラス成分を表2記載の通りになるようにし、キャリアガスに表2に示した還元剤を添加した以外は実験例1と同様にして、ガラス質薄膜で被覆された鉄粉末を得た。溶液中の還元剤量は前記と同様に溶液全体に対する還元剤の含有量(質量%)である。また、これらの実験例ではキャリアガスとしての窒素ガスに対し、表2に記載した量(体積%)の水素ガスと一酸化炭素を添加した。実験例1と同様に行った分析結果を表2に併記する。
実験例1において、金属組成、溶液中の金属成分濃度、ガラス成分、及び溶液に添加する還元剤[溶液中の還元剤量は溶液全体に対する含有量(質量%)]を表3記載となるように変更した以外は実験例1と同様にしてガラス質薄膜で被覆された金属粉末を得た。なお、実験例22には還元剤としてテトラエチレングリコール(TEG)を用い、実験例23~25では実験例1と同様のMEGを用いた。実験例1と同様に行った分析結果を表3に併記する。
実験例1において、還元剤量を35質量%にした以外は実験例1と同様にして原料溶液を調製したところ、超音波噴霧器では微細な液滴を発生させることができず、実験を中止した。
Claims (12)
- 熱分解性の金属化合物と、熱分解して当該金属化合物から生成する金属と固溶しないガラス質を生成するガラス前駆体とを含む溶液を微細な液滴にし、当該液滴をキャリアガス中に分散させた状態で、前記金属化合物の分解温度及び前記ガラス前駆体の分解温度より高く、且つ、前記金属化合物から生成する金属の融点よりも高い温度で加熱することにより、当該金属からなる金属粉末を生成させると共に、当該金属粉末の表面近傍にガラス質を生成させて、表面にガラス質薄膜を備えた金属粉末を製造する方法であって、
前記金属が卑金属を主成分とするものであり、
前記溶液中に、当該溶液に可溶であって上記加熱時に還元性を示す還元剤を、当該溶液全体に対する質量%で5~30質量%含む金属粉末の製造方法。 - 前記還元剤がメタノール、エタノール、プロパノール、エチレングリコール、プロピレングリコール、ジエチレングリコール、テトラエチレングリコールからなる群から選ばれる少なくとも1種を含む請求項1に記載の金属粉末の製造方法。
- 前記キャリアガス中に還元性ガスを1~20体積%含む請求項1又は2に記載の金属粉末の製造方法。
- 前記還元性ガスが水素、一酸化炭素、メタン、アンモニアガスから成る群から選ばれる少なくとも1種である請求項1乃至3の何れか一項に記載の金属粉末の製造方法。
- 前記熱分解性金属化合物とガラス前駆体の前記溶液中での合計含有量が、熱分解により前記金属化合物から生成される金属成分量と、熱分解により前記ガラス前駆体から生成される酸化物基準でのガラス成分量とに換算しての両成分の合計濃度で20~100g/Lである請求項1乃至4の何れか一項に記載の金属粉末の製造方法。
- 前記金属の融点TmMと、前記ガラス質の混合酸化物の液相温度TmGとが、下式(1)を満たすよう、前記ガラス前駆体を調製する請求項1乃至5の何れか一項に記載の金属粉末の製造方法。
-100〔℃〕≦(TmM-TmG)≦500〔℃〕・・・(1) - 前記金属が鉄を含む請求項1乃至6の何れか一項に記載の金属粉末の製造方法。
- 前記金属がニッケル及び鉄を含む請求項1乃至7の何れか一項に記載の金属粉末の製造方法。
- 前記ニッケルと鉄の質量比が、ニッケル:鉄=40:60~85:15である請求項8に記載の金属粉末の製造方法。
- 前記熱分解性の金属化合物が鉄化合物を含み、前記ガラス質薄膜に前記鉄化合物由来の鉄成分が含まれる請求項7乃至9の何れか一項に記載の金属粉末の製造方法。
- 前記ガラス質が酸化物基準でSiO2を40質量%以上含む請求項1乃至10の何れか一項に記載の金属粉末の製造方法。
- 前記ガラス質が酸化物基準でMgO、CaO、SrO、BaOからなる群から選ばれる少なくとも1種を含む請求項11に記載の金属粉末の製造方法。
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KR102305736B1 (ko) | 2021-09-28 |
US20200061715A1 (en) | 2020-02-27 |
WO2018092664A1 (ja) | 2018-05-24 |
KR102305733B1 (ko) | 2021-09-28 |
JPWO2018092665A1 (ja) | 2019-10-17 |
TWI761392B (zh) | 2022-04-21 |
TW201825210A (zh) | 2018-07-16 |
JP7133150B2 (ja) | 2022-09-08 |
CN109952168B (zh) | 2022-05-10 |
TWI761391B (zh) | 2022-04-21 |
JPWO2018092664A1 (ja) | 2019-10-17 |
MY192419A (en) | 2022-08-19 |
TW201832847A (zh) | 2018-09-16 |
EP3542931A4 (en) | 2020-06-24 |
CA3043296A1 (en) | 2018-05-24 |
CA3043293A1 (en) | 2018-05-24 |
KR20190085940A (ko) | 2019-07-19 |
EP3542932A1 (en) | 2019-09-25 |
US11426791B2 (en) | 2022-08-30 |
CN109982798B (zh) | 2022-09-06 |
KR20190086469A (ko) | 2019-07-22 |
US20190314893A1 (en) | 2019-10-17 |
CN109982798A (zh) | 2019-07-05 |
MY193167A (en) | 2022-09-26 |
CN109952168A (zh) | 2019-06-28 |
EP3542931A1 (en) | 2019-09-25 |
US11458536B2 (en) | 2022-10-04 |
EP3542932A4 (en) | 2020-06-24 |
JP7068663B2 (ja) | 2022-05-17 |
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