WO2020024870A1 - 合金组成物、Fe基纳米晶合金及其制造方法和磁性部件 - Google Patents

合金组成物、Fe基纳米晶合金及其制造方法和磁性部件 Download PDF

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WO2020024870A1
WO2020024870A1 PCT/CN2019/097735 CN2019097735W WO2020024870A1 WO 2020024870 A1 WO2020024870 A1 WO 2020024870A1 CN 2019097735 W CN2019097735 W CN 2019097735W WO 2020024870 A1 WO2020024870 A1 WO 2020024870A1
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alloy
alloy composition
temperature
based nanocrystalline
examples
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牧野彰宏
门贺
郭海
霍利山
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宁波中科毕普拉斯新材料科技有限公司
牧野彰宏
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Priority to KR1020217000965A priority Critical patent/KR102474993B1/ko
Publication of WO2020024870A1 publication Critical patent/WO2020024870A1/zh
Priority to US17/165,380 priority patent/US20210230723A1/en

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    • C22C2200/06—Quasicrystalline

Definitions

  • the invention relates to an alloy composition, a Fe-based nanocrystalline alloy, and a manufacturing method thereof, which have high saturation magnetic induction strength and excellent soft magnetic characteristics, and are particularly suitable for various magnetic components. Magnetic parts.
  • the magnetostrictive coefficient reaches 14 ⁇ 10 -6 , the magnetic permeability is low, and the soft magnetic properties are poor.
  • the Fe-based nanocrystalline alloy of Patent Document 1 precipitates a large amount of crystals in a quenched state, resulting in a lack of toughness, and there are many problems as application materials.
  • the molecular formula of the alloy composition is Fe a B b Si c P x C y Cu z (where 79 ⁇ a ⁇ 86at%, 5 ⁇ b ⁇ l3at%, 0 ⁇ c ⁇ 8at%, l ⁇ x ⁇ 8at%, 0 ⁇ y ⁇ 5at%, 0.4 ⁇ z ⁇ 1.4at% and 0.08 ⁇ z / x ⁇ 0.8), the main phase of the alloy is amorphous, and has good toughness. Under the optimal heat treatment conditions, ⁇ -Fe nanocrystals can be formed, and the magnetostrictive coefficient is greatly reduced.
  • alloy materials Due to the decrease of the magnetostrictive coefficient and the formation of uniform nanocrystals, alloy materials with high magnetic permeability, low coercivity and high saturation magnetic induction strength were obtained.
  • This particular alloy composition is useful as an initial component to obtain an Fe-based nanocrystalline alloy that has both high saturation magnetic induction and high magnetic permeability.
  • the specific alloy compositions described in Patent Documents 4 to 6 must be heated at a high temperature heating rate (Heating rate (R h )) of 300 ° C./min or more in order to refine the crystals to the nanometer scale.
  • Heating rate (R h ) 300 ° C./min or more in order to refine the crystals to the nanometer scale.
  • the temperature after the temperature rise is maintained in a narrow temperature range of 30 to 40 ° C.
  • heat treatment conditions are easy to meet, but actual magnetic materials or components have dimensions ranging from a few grams to tens of kilograms, and a variety of shapes. Rapid heating is extremely difficult for the industrial sector.
  • a large amount of heat is generated instantaneously due to crystallization, which causes the temperature of large components to rise sharply or even to melt.
  • Patent Document 1 Publication No. 2007-270271
  • Patent Document 2 International Publication No. 2008/068899
  • Patent Document 3 International Publication No. 2008/129803
  • Patent Document 4 Patent No. 4514828
  • Patent Document 5 Patent No. 4548450
  • Patent Document 6 Patent No. 4629807
  • Non-Patent Document 1 Kana Takenaka et al., "Industrialization of nanocrystalline Fe-Si-BP-Cualloys for high magnetic flux density cores". Journal of Magnetism and Magnetic Materials, 1 March 2016, Vol. 401, Pages 479-483 ).
  • an object of the present invention is to provide a Fe-based nanocrystalline alloy having a high saturation magnetic induction strength and excellent soft magnetic characteristics and a manufacturing method in a case where the temperature rising speed is slow and the arrival temperature varies, and at the same time, A magnetic component having excellent soft magnetic characteristics is proposed.
  • the inventors of the present invention have conducted intensive studies and found that a specific alloy composition having an amorphous phase of Fe-VB- (Si) -P- (C) -Cu as the main phase required as V can be used as the Fe required for obtaining the present invention.
  • the basic components of the base nanocrystalline alloy are used to achieve the object of the present invention.
  • the alloy composition related to the present invention is Fe a V ⁇ B b Si c P x C y Cu z , where 79 ⁇ a ⁇ 91at%, 5 ⁇ b ⁇ 13at%, 0 ⁇ c ⁇ 8at%, 1 ⁇ x ⁇ 8at%, 0 ⁇ y ⁇ 5at%, 0.4 ⁇ z ⁇ 1.4at%, 0 ⁇ ⁇ 5at%, and 0.08 ⁇ z / x ⁇ 0.8.
  • the manufacturing method of the Fe-based nanocrystalline alloy according to the present invention is characterized by having both the alloy composition and the heat treatment steps related to the present invention.
  • an alloy component related to the present invention is preferred. Since the alloy component of the present invention includes V as an essential element, during crystallization, the nanocrystalline structure can be stabilized, the nanocrystalline grains can be uniformized, and the soft magnetic characteristics can be improved.
  • the manufacturing method of the Fe-based nanocrystalline alloy of the present invention is that by using the alloy component of the present invention, a high saturation magnetic induction intensity can be obtained even when the temperature rise rate during the crystallization heat treatment is slow and the reaching temperature varies. And Fe-based nanocrystalline alloys with excellent soft magnetic properties.
  • the main phases of the alloy components related to the present invention are all amorphous phases, and its Fe content is preferably at least 81 at%, so that Fe-based nanocrystalline alloys with particularly high saturation magnetic induction strength are obtained; the B content is less than 10 at%, so , The melting point will be reduced, which is conducive to industrial production; Si content above 0.8at%, which will improve the ability to form amorphous, which is conducive to the stable continuous production of thin strips, and can obtain uniform nano-grains. Finally, the P content is between 2-5at%, which can improve the ability of amorphous formation.
  • the alloy composition of the present invention is optimized to 0 ⁇ y ⁇ 3at%, 0.4 ⁇ z ⁇ 1.1at%, and 0.08 ⁇ z / x ⁇ 0.55. In this way, since the C content is less than 3 at%, it is possible to control the non-uniformity of the components caused by the volatilization of C during melting. Since the Cu content is less than 1.1 at% and z / x is in the range of 0.08 to 0.55, the brittleness of the strip can be controlled.
  • the component of the present invention has an amorphous structure and a nano-heterostructure with an initial microcrystallization existing in the amorphous, and an average particle diameter of the initial microcrystallization structure is 0.3-10 nm.
  • the components of the present invention can be prepared in various alloy forms, such as continuous thin strips and powders.
  • the strip In the case of continuous thin strips, the strip can be bent at 180 ° without breaking.
  • ⁇ -Fe is precipitated at a first crystallization temperature (T x1 ), and as the temperature increases, compounds of Fe and B, P, and Si are precipitated at a second crystallization temperature (T x2 ).
  • the alloy of the composition of the present invention can be made into magnetic cores including winding, lamination, and magnetic powder cores, and these magnetic cores can be used in the fields of transformers, inductors, motors and the like.
  • the Fe-based nanocrystalline alloy of the present invention has a coercive force of 20 A / m or less and a saturation magnetic induction intensity of 1.65 T or more.
  • the Fe-based nanocrystalline alloy of the present invention has a wide heat treatment temperature range, and has high saturation magnetic induction strength and excellent soft magnetic characteristics, and can be used for magnetic components, such as a toroidal magnetic core.
  • the Fe-based nanocrystalline alloy of the present invention has an average crystal grain size of 5 to 25 nm.
  • the saturation magnetostriction coefficient is 10 ⁇ 10 -6 or less, or even 5 ⁇ 10 -6 or less.
  • the magnetic component of the present invention is characterized in that it is composed of the Fe-based nanocrystalline alloy; the magnetic component related to the present invention includes a transformer, an inductor, a motor, and the like made of the Fe-based nanocrystalline alloy of the present invention.
  • an alloy composition having a high saturation magnetic induction strength an Fe-based nanocrystalline alloy thereof, a method for manufacturing the same, and an Fe-based nanocrystalline magnetic component regardless of a slow heating rate or a deviation in the arrival temperature.
  • FIG. 1 is a DSC graph of Examples 1 to 8 of the present invention and Comparative Examples 1 to 3 without V.
  • FIG. 1 is a DSC graph of Examples 1 to 8 of the present invention and Comparative Examples 1 to 3 without V.
  • FIG. 2 shows the Fe-based nanocrystals of Examples 1 to 3 and Comparative Example 1 when the set reaching temperature is 420 ° C (a) and Examples 2 to 3 and Comparative Example 1 when the reaching temperature is 430 ° C (b ) The relationship between heat treatment heating rate and coercive force.
  • FIG. 3 is a graph showing the relationship between the heat treatment heating rate and the ⁇ -Fe crystal grain size of the Fe-based nanocrystals of Examples 1 to 3 and Comparative Example 1 when the set reaching temperature is 430 ° C.
  • Fig. 4 shows the heat treatment heating rate and coercive force of Fe-based nanocrystals of Examples 4 and 5 and Comparative Examples 1 and 2 when the set reaching temperature is 420 ° C (a) and the reaching temperature is 430 ° C (b). Diagram.
  • FIG. 5 is a graph showing the relationship between the heat treatment heating rate and the coercive force of the Fe-based nanocrystals of Examples 4 and 6 and Comparative Examples 1 and 2 when the set reaching temperature is 420 ° C.
  • FIG. 6 is a graph showing the relationship between the heat treatment temperature increase rate and the coercive force of Fe-based nanocrystals of Examples 7 and 8 and Comparative Examples 1 and 3 when the set reaching temperature is 410 ° C.
  • FIG. 7 shows examples 1 to 3 and comparative example 1 of the Fe-based nanocrystals of the present invention when the heating rate is 300 ° C / min (a) and the heating rate is 150 ° C / min (b). Diagram of courage.
  • FIG. 8 is a graph showing the relationship between the heat treatment reaching temperature and the coercive force of the Fe-based nanocrystals of Examples 4 and 5 and Comparative Examples 1 and 2 when the heating rate is 150 ° C./min.
  • FIG. 9 shows the Fe core nanocrystals of Example 1 and Comparative Example 1 when the set arrival temperature is 420 ° C, and the heating rates are 100 ° C / min, 150 ° C / min, and 300 ° C / min, respectively. Diagram of coercivity.
  • the at% of the present invention is an atomic percent content.
  • composition formula of the alloy according to the embodiment of the present invention is Fe a V ⁇ B b Si c P x C y Cu z where 79 ⁇ a ⁇ 91at%, 5 ⁇ b ⁇ 13at%, 0 ⁇ c ⁇ 8at%, 1 ⁇ x ⁇ 8at% , 0 ⁇ y ⁇ 5at%, 0.4 ⁇ z ⁇ 1.4at%, 0 ⁇ ⁇ 5at%, and 0.08 ⁇ z / x ⁇ 0.8.
  • the preparation of the Fe-based nanocrystalline alloy according to the embodiment of the present invention includes the alloy composition preparation and crystallization heat treatment steps of the embodiment.
  • the alloy according to the embodiment of the present invention is heat-treated under the protection of an Ar gas atmosphere and has more than two crystallization behaviors, in which the ⁇ -Fe phase is precipitated at the first crystallization temperature (T x1 ).
  • T x1 first crystallization temperature
  • Fe and B Compounds of P and Si are precipitated at a second crystallization temperature (T x2 ).
  • the “crystallization start temperature” refers to a first crystallization start temperature, and the first crystallization start temperature and the second crystallization start temperature can be evaluated using a differential scanning calorimetry (DSC) device.
  • DSC differential scanning calorimetry
  • the alloy composition of the present invention is suitable for preparing the Fe-based nanocrystalline alloy of the present invention.
  • V as an essential element in the alloy composition of the present invention can stabilize the nanocrystalline structure during crystallization, make the nanocrystalline grains uniform, and thereby improve the soft magnetic characteristics. However, if the V content is more than 5 at%, the amorphous forming ability and the saturation magnetic induction intensity are reduced. In addition, the amorphous phase of the alloy composition of the present invention is the main phase.
  • Fe as an essential element can increase the saturation magnetic induction strength and reduce the material cost. If the Fe content is less than 79 at%, a desired saturation magnetic induction cannot be obtained. If the Fe content is higher than 91 at%, it is difficult to form an amorphous phase by the quenching method, and coarse ⁇ -Fe crystal grains may be formed. In this way, a uniform nanocrystalline structure cannot be obtained, resulting in a decrease in soft magnetic properties.
  • the Fe content is preferably 81at% or more.
  • the component of the present invention contains Si, the precipitation of Fe and B compounds in the nanocrystalline structure after crystallization can be suppressed, thereby stabilizing the nanocrystalline structure.
  • the Si content is greater than 8 at%, the saturation magnetic induction strength and the ability to form amorphous will decrease, resulting in deterioration of soft magnetic properties. It is particularly pointed out that when the Si content is above 0.8 at%, the amorphous forming ability is improved, and the continuous production of thin strips can be stabilized. In addition, due to the increase in ⁇ T, a uniform nanocrystalline structure can be obtained.
  • P as an essential element can improve the amorphous forming ability. If the P content is less than 1 at%, it is difficult to form an amorphous phase by the quenching method. If the P content is higher than 8 at%, the saturation magnetic induction strength decreases, and the soft magnetic performance deteriorates. In particular, if the P content is 2 to 5 at%, the ability to form amorphous can be improved.
  • the component of the present invention contains C, the amorphous forming ability can be increased.
  • C because C is cheap, the addition of C can reduce the content of metalloids and reduce the cost of materials.
  • embrittlement occurs, resulting in a decrease in soft magnetic properties.
  • the C content is less than 3 at%, component segregation due to C volatilization can be suppressed.
  • Cu is an essential element, which is beneficial to nanocrystallization.
  • Cu is expensive, and embrittlement and oxidation are easily caused when the Fe content is higher than 81 at%.
  • the Cu content is less than 0.4 at%, it is not conducive to nanocrystallization.
  • the Cu content is higher than 1.4 at%, the non-uniformity of the amorphous phase is caused, which is not conducive to the formation of a uniform nanocrystalline structure, and the soft magnetic performance is reduced.
  • the embrittlement of nanocrystalline alloys is considered, the Cu content should be controlled below 1.1 at%.
  • the amorphous forming ability and the stability of the nanocrystalline structure can be improved.
  • further compounding with Si, B, P, Cu, and V, or compounding with Si, B, P, C, Cu, and V is more conducive to the stability of the nanocrystalline structure.
  • the average grain size of the Fe-based nanocrystalline alloy is 5 to 25 nm.
  • the ratio (z / x) of the P content (x) and the Cu content (z) is lower than 0.08 and higher than 0.8, a uniform nanocrystalline structure cannot be obtained, resulting in a decrease in soft magnetic properties.
  • the ratio (z / x) is preferably between 0.08 and 0.55.
  • the Fe-based nanocrystalline alloy when the Fe-based nanocrystalline alloy is prepared by the composition of the present invention, no matter whether the heat-treating speed is slow or the reaching temperature is different, the Fe-based nanocrystalline alloy having high saturation magnetic induction strength and excellent soft magnetic properties can be obtained.
  • composition of the present invention Ti, Zr, Hf, Nb, Ta, Mo, W, Cr, Co, Ni, Al, Mn, Ag, Zn, Sn, As, Sb, Bi, Y, N, O, Ca , Mg, and one or more of rare earth elements to replace Fe of 3 at% or less.
  • the alloy of the composition of the present invention can be made into various forms, such as a continuous thin strip or a powder form.
  • the shape of the continuous thin strip can be prepared by using a single roll or double roll equipment of Fe-based amorphous thin strip.
  • the amorphous forming ability can be improved, and continuous and stable thin strip preparation can be achieved.
  • the prepared continuous ribbon can be bent at 180 ° without breaking.
  • the powder can be prepared by water atomization and gas atomization methods, and can also be prepared by a strip crushing method.
  • the alloy of the composition of the present invention can be made into a wound magnetic core, a laminated magnetic core, a magnetic powder core, or the like.
  • these magnetic cores can be used in transformers, inductors, motors and other fields.
  • the composition of the present invention heats up at a rate of 100 to 300 ° C / min, and can be heat-treated even above the crystallization start temperature (that is, the first crystallization start temperature).
  • the Fe-based nanocrystalline alloy of the present invention is obtained. It is only because the precipitation of Fe compounds will deteriorate the soft magnetic properties, so the heat treatment temperature should be in the range of T x1 to T x2 .
  • the composition of the present invention can prepare a Fe-based nanocrystalline alloy with high saturation magnetic induction strength and excellent soft magnetic properties in a wide temperature range. Therefore, a magnetic component such as a magnetic ring can be made.
  • the Fe-based nanocrystalline alloy of the present invention has a coercive force of 20 A / m or less and a saturation magnetic induction strength of 1.65 T or more.
  • the saturation magnetostriction coefficient of the Fe-based nanocrystalline alloy of the composition of the present invention is 10 ⁇ 10 -6 or less, or even 5 ⁇ 10 -6 or less, which can avoid deterioration of soft magnetic properties.
  • the magnetic device of the present invention is made of the Fe-based nanocrystalline alloy of the present invention.
  • the so-called magnetic component of the present invention is a magnetic core of a device such as a transformer, an inductor, a motor, and the like prepared by using the Fe-based nanocrystalline alloy of the present invention.
  • the first is the preparation of the alloy. As shown in Examples 1 to 8 in Tables 1 to 4, the weight of the raw materials was first weighed according to the ratio, and the materials were melted in an induction furnace. The melted master alloy was prepared by a single-roller quenching method in the atmosphere to prepare a strip having a thickness of 20 ⁇ m and a width of 10 mm. In addition, strips of the components of Comparative Examples 1 to 3 in Tables 1 to 4 were prepared in the same manner. In addition, Comparative Example 1 is a (Fe 85.7 Si 0.5 B 9.5 P 3.5 Cu 0.8 ) 99 C 1 alloy described in Non-Patent Document 1.
  • Example 1 to 3 in Table 1 0.1 to 1 at% of Fe in the components of Comparative Example 1 was replaced with a V element.
  • Examples 4 and 5 in Table 2 0.1 to 1 at% of the overall composition in Comparative Example 2 was replaced with a V element.
  • Examples 4 and 6 of Table 3 0.01 to 0.1 at% of B and P in Comparative Example 2 were replaced with V elements.
  • Table 4 shows the composition containing no Si.
  • Examples 7 and 8 0.1 to 1 at% of Fe in the composition of Comparative Example 3 was replaced with V element.
  • the thin strip alloys of Examples 1 to 8 and Comparative Examples 1 to 3 prepared were identified by XRD.
  • the first crystallization initiation temperature (T x1 ) and the second crystallization initiation temperature (T x2 ) of each alloy component were measured using a differential scanning calorimeter (DSC), and the heating rate was 40 ° C./min.
  • the measured phases of each alloy component are shown in Tables 1 to 4.
  • the DSC curve of each alloy composition is shown in FIG. 1.
  • the alloy composition of Examples 1 to 4, 6 to 8 is an amorphous single phase (Amo), or most of the amorphous phase (Almost Amo); the alloy composition of Example 5 is an amorphous phase.
  • the main phase adds a portion of the crystalline phase (Cry).
  • the 1-3 alloy composition in the comparative example is an amorphous single phase (Amo).
  • the element V contained in the alloy compositions of Examples 1 to 8 had the effects of increasing the crystallization temperature difference ⁇ T and increasing T x2 .
  • the improvement of T x2 contributes to the improvement of the thermal stability of the nanocrystalline structure. Even during the heat treatment process, it is not easy to precipitate Fe compounds with the self-crystallization heating, and it will not reduce the soft magnetic properties of the alloy. In addition, as ⁇ T increases, the alloy will exhibit good soft magnetic properties over a larger range of heat treatment temperatures.
  • Examples 2 to 8 are compared with the comparative examples in each table, and T x2 is indeed improved; Examples 2, 3, 5, 7, and 8 are compared with each table. For example, ⁇ T did increase.
  • Example 1 to 8 and Comparative Examples 1 to 3 were measured for saturation magnetic induction (Bs) using a vibration sample magnetometer (VSM) under a magnetic field of 800 kA / m.
  • VSM vibration sample magnetometer
  • Tables 1-4 It can be known from Tables 1 to 4 that the saturation magnetic induction of Examples 1 to 8 is between 1.55T and 1.57T, that is, even if the V element is added, Examples 1-8 and Comparative Examples 1-3 have almost the same saturation. Magnetic induction.
  • an Fe-based nanocrystalline alloy of the patented alloy was prepared.
  • the thin strip alloys prepared in Examples 1 to 8 and Comparative Examples 1 to 3 were selected, a length of 50 mm was cut out, and 10 groups of each were selected and covered with aluminum foil.
  • the coated samples were placed in an infrared heat treatment furnace, and the alloy ribbons were heat-treated in an Ar gas protective atmosphere to prepare nanocrystalline alloys of Examples 1 to 8 and Comparative Examples 1 to 3.
  • Heat treatment conditions Different heating rates ( Rh ) and heat treatment arrival temperatures (Annealing temperature (Ta)) are set according to different alloy components. After reaching the set temperature, they are kept for 10 minutes.
  • the coercivity (Hc) of the prepared Fe-based nanocrystalline alloy strip was tested by a DC B-H instrument under a magnetic field of 2 kA / m.
  • the ⁇ -Fe grain size of each Fe-based nanocrystalline alloy can be obtained by calculating the full width at half maximum of the XRD pattern using the Scherrer formula.
  • the test results are shown in Tables 1 to 4 and Figures 2 to 9 respectively.
  • the saturation magnetic induction strength of each nanocrystalline alloy strip was measured.
  • the saturation magnetic induction strengths of all nanocrystalline alloys in Examples 1 to 8 were above 1.7T, and had high saturation magnetic induction strength.
  • the dependence of the coercive force of the Fe-based nanocrystalline alloys of Examples 1 to 3 and Comparative Example 1 shown in Table 1 on the heat treatment heating rate is shown in Figs. 2 (a) and (b).
  • the reaching temperatures (Ta) set in Figures 2 (a) and (b) are 420 ° C and 430 ° C, respectively, which are the optimal heat treatment temperatures.
  • FIG. 3 is a graph showing the dependence of the ⁇ -Fe crystal grain size on the temperature increase rate of the heat treatment of the Fe-based nanocrystalline alloys of Examples 1 to 3 and Comparative Example 1 when the set reaching temperature is 430 ° C.
  • the ⁇ -Fe crystal grains become small due to the addition of V in the entire temperature increase rate range. Therefore, as shown in FIG. 2, the addition of V effectively reduced the coercive force and played a role in grain refinement.
  • the reaching temperatures (Ta) set in Figures 4 (a) and (b) are 420 ° C and 430 ° C, respectively, which are the optimal heat treatment temperatures.
  • the lower limit of the heating rate of Comparative Examples 1 and 2 not including V is 150 to At 180 ° C / min, and for Examples 4 and 5 containing 0.1 at% or more of V element, the lower limit of the heating rate is only about 125-130 ° C / min.
  • FIG. 5 shows the dependency relationship between the coercive force of the Fe-based nanocrystalline alloys of Example 4, 6 and Comparative Example 2, and Comparative Example 1 in Table 3, and the temperature increase rate of heat treatment.
  • the reaching temperature Ta is 420 ° C, which is the optimal heat treatment temperature.
  • the coercivity of Examples 4 and 6 was lower in the alloys of Examples 4 and 6 containing V than in Comparative Example 2 not containing V under the conditions of a temperature increase rate of 50 to 300 ° C./min.
  • the lower limit of the heating rate of Comparative Examples 1 and 2 not containing V was about 170 ° C / min, and Examples 4 and 0.01 containing V element of at least 0.01 at%
  • the lower limit of the heating rate of 6 alloy is reduced to about 130 ° C / min.
  • FIG. 6 shows the dependency relationship between the coercive force of the Fe-based nanocrystalline alloys of Examples 7, 8 and Comparative Example 3, and Comparative Example 1 in Table 4 and the temperature increase rate of the heat treatment.
  • the reaching temperature Ta is 410 ° C, which is the optimal heat treatment temperature.
  • the coercivity of Examples 7 and 8 was lower in the alloys of Examples 7 and 8 containing V than in Comparative Example 3 not containing V under the condition that the heating rate was 50 to 300 ° C./min.
  • Comparative Example 3 without V did not achieve excellent soft magnetic properties with a coercive force of 10 A / m or less at any rate of temperature increase, while the alloys of Examples 7 and 8 containing 0.5 at% or more of V at about 135 ° C / min A coercive force of 10 A / m or less was obtained at the above temperature increasing rate.
  • the alloy of the present invention can obtain excellent soft magnetic properties even if the temperature rise rate of the heat treatment is reduced.
  • Examples 7 (a) and 7 (b) show the dependence between the coercive force of the Fe-based nanocrystalline alloys of Examples 1 to 3 and Comparative Example 1 in Table 1 and the heat treatment reaching temperature.
  • Examples 1 to 3 with V are in the range of 380 to 440 compared with Comparative Example 1 without V. It has lower coercive force in the temperature range of °C.
  • the alloy of Comparative Example 1 not containing V had a coercive force of more than 10 A / m at a temperature of more than 440 ° C, and the soft magnetic performance deteriorated sharply.
  • the alloys of Examples 1 to 3 containing 0.1 at% or more of V had a coercive force of 10 A / m or less even at 440 ° C, and had excellent soft magnetic properties. Due to the addition of V, the deterioration of soft magnetic properties is effectively prevented, and high saturation magnetic induction strength is also obtained in high temperature regions.
  • the alloy of Comparative Example 1 not containing V had a coercive force lower than 10A / m only at 440 ° C.
  • the temperature range of the coercive force below 10 A / m was expanded to 415 to 440 ° C. That is, due to the addition of V, it is possible to obtain a coercive force of 10 A / m or less over a wider temperature range even at a slow temperature increase rate of 150 ° C / min. This can reduce the heat treatment process requirements in actual industrial production and is of great significance.
  • FIG. 8 shows the dependence between the coercive force and the heat treatment reaching temperature of the Fe-based nanocrystalline alloys of Examples 4, 5 and Comparative Example 2 and Comparative Example 1 in Table 2.
  • the heating rate Rh was 150 ° C./min
  • Examples 4 and 5 containing 0.1 at% or more of V were compared with Comparative Examples 1 and 2 not containing V and Comparative Example 1 not containing V.
  • the coercivity of the alloy of 2 and 2 was less than 10 A / m only at a temperature of 440 ° C, and the temperature range of the coercivity of Examples 4 and 5 was less than 10 A / m was expanded to 405 to 440 ° C. That is, as in FIG. 7 (b), the coercive force of 10 A / m or less can be obtained in a wider temperature range due to the addition of V, even at a slow temperature increase rate of 150 ° C / min.
  • Comparative Example 1 only had a short strip (0.1g) and a coercive force of 10A / m or less was obtained at a temperature rise rate of 300 ° C / min.
  • the maximum temperature is lower than that of Comparative Example 1 under all heat treatment conditions, and the crystal grain size is smaller than that of Comparative Example 1 under almost any conditions.
  • Example 1 has lower coercive force than Comparative Example 1 under all heat treatment conditions, and its winding core of 10 g also has a coercivity of 10 A / m or less under the condition of a heating rate of 150 ° C / min. Tenacious.
  • V reduces the dependence of the coercive force on the temperature increase rate of the heat treatment on the one hand (refer to Figures 2, 4, 5, and 6), and on the other hand increases the range of the heat treatment temperature range to obtain a low coercivity (see ( Figures 7 and 8).

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Abstract

本发明公开一种合金组成物、Fe基纳米晶合金及其制造方法和磁性部件。该合金组成物的表达式为Fe aV αB bSi cP xC yCu z，其中79≤a≤91at％、5≤b≤13at％、0≤c≤8at％、1≤x≤8at％、0≤y≤5at％、0.4≤z≤1.4at％、0＜α＜5at％，以及0.08≤z/x≤0.8(at％为原子百分比)。通过对该合金组成物进行结晶化热处理，制造Fe基纳米晶合金。本发明的合金成分，即使在结晶化热处理时的升温速度慢、或到达温度有偏差的情况下，也能容易地获得具有高饱和磁感应强度和优异软磁特性的Fe基纳米晶合金。并且，本发明提供利用该Fe基纳米晶合金制造而成的磁性部件。

Description

合金组成物、Fe基纳米晶合金及其制造方法和磁性部件 技术领域
本发明涉及适用于各种磁性部件的具有高饱和磁感应强度及优良软磁特性的、尤其是具有优良磁特性的合金组成物、Fe基纳米晶合金及其制造方法，以及由纳米晶磁性合金构成的磁性部件。
背景技术
一直以来，人们在利用Fe基软磁非晶获得纳米晶化时，通过添加Nb、Zr等过渡金属，来抑制结晶粒成长，使纳米晶化变得容易，从而得到软磁性能优异的纳米晶合金。但是，添加了Nb和Zr等过渡金属的同时，会带来熔点上升、易氧化、成本高以及饱和磁感应强度大幅下降等问题。通过增加Fe含量，减少Nb等非磁性金属元素的含量，可以增加饱和磁感应强度，但会使得纳米结晶化困难，结晶粒度变大，导致软磁特性恶化。因此，为解决以上问题开发了一系列Fe基纳米晶合金。(参照专利文献1～3)
但是，如专利文献1的Fe基纳米晶合金，磁致伸缩系数达到14×10 -6，且磁导率低，软磁性能差。另外，专利文献1的Fe基纳米晶合金在急冷状态时会大量地析出晶体，导致缺乏韧性，作为应用材料存在很多问题。
因此，为了解决这样的问题，本发明者开发了由Fe、B、Si、P、C、Cu构成，同时具有高饱和磁感应强度和优异软磁特性的Fe基纳米晶合金。(参照专利文献4～6)
本发明者为了得到目标的Fe基纳米晶合金，发现作为初始成分，可以使用专利文献4～6所示的特定的合金组成物。合金组成物的分子式是Fe aB bSi cP xC yCu z(其中79≤a≤86at％，5≤b≤l3at％，0<c≤8at％，l≤x≤8at％，0≤y≤5at％，0.4≤z≤l.4at％以及0.08≤z/x≤0.8)，合金主相是非晶相，并具有很好的韧性。在最佳热处理条件下，可以形成α-Fe纳米晶，且磁致伸缩系数大幅降低。由于磁致伸缩系数的降低和均匀的纳米晶形成，得到了高导磁率、低矫顽力及高饱和磁感应强度的合金材料。这个特定的合金组成作为初始成分有利于获得兼备高饱和磁感应强度和高导磁率的Fe基纳米晶合金。
另外，在这个Fe基纳米晶合金中，本发明者们开发了适用于工业原料的(Fe 85.7Si 0.5B 9.5P 3.5Cu 0.8) 99C 1合金(参照非专利文献1)。
专利文献4～6记载的特定的合金组合物，为了使结晶细化到纳米尺度，必须以升温速度(Heating rate，R h)为300℃/min以上的高速升温速度进行加热，另外，必须把升温后的到达温度保持在30～40℃的狭窄的温度范围。在实验室水平的微量样品中，这种热处理条件是很容 易满足，但实际的磁性材料或部件具有数克变化到数十公斤的尺度，且形状多种多样，要将这些材料全部均匀的、快速的加热，对于工业领域来说是极其困难的。另外，在设定温度附近，由于结晶化产生瞬间的大量发热，导致大构件的温度急升甚至发生熔化。在实际的磁性构件和零件中，由于局部温升的不一致，很难将到达温度保持在较窄的温度范围内。由于热处理的难度，实际的部件得不到和实验室材料一样的优异磁性能，这成了亟需解决的新问题。
专利文献1：公开2007-270271号
专利文献2：国际公开第2008/068899号
专利文献3：国际公开第2008/129803号
专利文献4：专利第4514828号
专利文献5：专利第4584350号
专利文献6：专利第4629807号
非专利文献1：Kana Takenaka et al.,“Industrialization of nanocrystalline Fe-Si-B-P-Cu alloys for high magnetic flux density cores”.Journal of Magnetism and Magnetic Materials,1 March 2016,Vol.401,Pages 479-483)。
发明内容
因此，本发明的目的在于，提供一种在升温速度慢、到达温度有偏差的情况下，也能很容易得到具有高饱和磁感应强度和优异软磁特性的Fe基纳米晶合金以及制造方法，同时提出一种具有优异软磁特性的磁性部件。
本发明的发明人进行了潜心研究，发现以V为必需的Fe-V-B-(Si)-P-(C)-Cu的非晶相为主相的特定合金组成可作为获得本发明所需Fe基纳米晶合金的基础成分使用，实现本发明的目的。
即，本发明相关的合金组成为Fe aV αB bSi cP xC yCu z，其中79≤a≤91at％、5≤b≤13at％、0≤c≤8at％、1≤x≤8at％、0≤y≤5at％、0.4≤z≤1.4at％、0＜α＜5at％，以及0.08≤z/x≤0.8。
本发明涉及的Fe基纳米晶合金的制造方法以同时具有本发明相关的合金组成和热处理步骤为特征。
为了制备本发明的Fe基纳米晶合金，优选和本发明相关的合金成分。本发明的合金成分由于包括V作为必要元素，因此在结晶时，可以稳定纳米晶结构，使纳米晶粒均匀化，从而可以提高软磁特性。另外，本发明的Fe基纳米晶合金的制造方法是，通过使用本发明的合金成分，即使在结晶化热处理时的升温速度慢、到达温度有偏差的情况下，也能获得具有高饱和磁感应强度和优异的软磁特性的Fe基纳米晶合金。
本发明相关的合金成分其主相都是非晶相，其Fe含量在81at％以上为好，这样会获得具有特别高的饱和磁感应强度的Fe基纳米晶合金；B含量要低于10at％，这样，熔点会降低，有利于产业化生产；Si含量在0.8at％以上，这样会改善非晶形成能力，有利于薄带的稳定连续生产，并且可以得到均匀的纳米晶粒。最后，P含量在2-5at％之间，可以提高非晶形成能力。
本发明的合金成分优化为0≤y≤3at％、0.4≤z≤1.1at％、以及0.08≤z/x≤0.55。这样，由于C含量小于3at％，可以控制在熔化时由C的挥发引发的成分不均匀。由于Cu含量小于1.1at％，并且z/x在0.08至0.55范围，可以控制带材脆性。
在本发明的成分中，可以用Ti、Zr、Hf、Nb、Ta、Mo、W、Cr、Co、Ni、Al、Mn、Ag、Zn、Sn、As、Sb、Bi、Y、N、O、Ca、Mg或者稀土类元素中的至少一种元素来替代不高于3at％的Fe。另外，在本发明成分中，具有非晶和存在于非晶中初期微晶化的纳米异质结构，该初期微晶化结构的平均粒径在0.3-10nm。
本发明的成分可以制备各种合金形态，例如连续薄带状、粉末状。在连续薄带的场合，带材可以180°弯曲而不断裂。
本发明成分的合金热处理后，有第一晶化温度(T x1)和第二晶化温度(T x2)，温度差(ΔT＝T x2-T x1)为100～200℃。α-Fe在第一晶化温度(T x1)析出，随着温度升高，Fe和B、P以及Si的化合物在第二晶化温度(T x2)析出。
本发明成分的合金可以制成包括卷绕、叠层、磁粉芯等磁芯，并且这些磁芯可以用于变压器、电感、马达等领域。
本发明的Fe基纳米晶合金具有20A/m以下的矫顽力和1.65T以上的饱和磁感应强度。
本发明的Fe基纳米晶合金的热处理温度范围很宽，并且具有高饱和磁感应强度和优异的软磁特性，可以用于磁性元器件，例如圆环磁芯。
本发明的Fe基纳米晶合金的平均晶化粒径在5～25nm，为了不使磁性恶化，饱和磁致伸缩系数在10×10 -6以下，甚至在5×10 -6以下。
本发明的磁性部件，其特征在于，由所述的Fe基纳米晶合金组成；所述的本发明相关的磁性部件包括用本发明的Fe基纳米晶合金制得的变压器、电感、马达等。
根据本发明，无论升温速度慢还是到达温度有偏差，都可以容易地得到具有高饱和磁感应强度的合金组成物和其Fe基纳米晶合金及其制造方法，以及Fe基纳米晶磁性部件。
附图说明
图1为本发明实施例1～8及不含V的比较例1～3的DSC曲线图。
图2为本发明Fe基纳米晶实施例1～3及比较例1在设定的到达温度为420℃时(a)与 实施例2～3及比较例1在到达温度为430℃时(b)的热处理升温速度和矫顽力的关系图。
图3为本发明Fe基纳米晶实施例1～3及比较例1在设定的到达温度为430℃时的热处理升温速度和α-Fe晶粒尺寸之间的关系图。
图4为本发明Fe基纳米晶实施例4、5及比较例1、2在设定的到达温度为420℃(a)与到达温度为430℃(b)时的热处理升温速度和矫顽力的关系图。
图5为本发明Fe基纳米晶实施例4、6及比较例1、2在设定的到达温度为420℃时的热处理升温速度和矫顽力关系图。
图6为本发明Fe基纳米晶实施例7、8及比较例1、3在设定的到达温度为410℃时的热处理升温速度和矫顽力关系图。
图7为本发明Fe基纳米晶实施例1～3及比较例1在升温速度为300℃/min(a)与升温速度为150℃/min(b)时，设定的热处理到达温度和矫顽力的关系图。
图8为本发明Fe基纳米晶实施例4、5及比较例1、2在升温速度为150℃/min时设定的热处理到达温度和矫顽力的关系图。
图9为本发明Fe基纳米晶实施例1及比较例1在设定的到达温度为420℃，升温速度分别为100℃/min、150℃/min、300℃/min时，磁芯重量和矫顽力的关系图。
具体实施方式
以下，根据实施例和图表对本发明实施情况进行说明。本发明的at％为原子百分含量。
本发明实施例合金组成式是Fe aV αB bSi cP xC yCu z其中79≤a≤91at％、5≤b≤13at％、0≤c≤8at％、1≤x≤8at％、0≤y≤5at％、0.4≤z≤1.4at％、0＜α＜5at％，并且0.08≤z/x≤0.8。
本发明实施例Fe基纳米晶合金的制备包括实施例的合金组成准备和晶化热处理步骤。
本发明实施例的合金是在Ar气氛围保护下进行的热处理，有2次以上晶化行为，其中α-Fe相在第一晶化温度(T x1)析出，在高温时，Fe和B、P以及Si的化合物在第二晶化温度(T x2)析出。“结晶化开始温度”是指第一晶化开始温度，第一结晶化开始温度和第二结晶化开始温度可以使用差示扫描量热分析(DSC)装置进行评价。
本发明的合金组成适合制备本发明的Fe基纳米晶合金。
本发明的合金组成中V作为必备元素，在晶化时可以稳定纳米晶结构，使纳米晶粒均匀化，从而提高软磁特性。但是，如果V含量大于5at％时，非晶形成能力和饱和磁感应强度会下降。另外，本发明合金组成非晶相是主相。
本发明的合金组成中，Fe作为必备元素可以提高饱和磁感应强度和降低材料成本。若Fe含量低于79at％，则不能获得期望的饱和磁感应强度。若Fe含量高于91at％时，急冷法制备很难形成非晶相，会形成粗大α-Fe晶粒。这样便不能获得均匀的纳米晶结构，导致软磁性能 下降。特别是需要具备1.7T以上饱和磁感应强度时，优选Fe含量要在81at％以上。
本发明的合金组成中，B作为必备元素可以提高非晶形成能力。若B含量低于5at％时，急冷法制备很难形成非晶相。若B含量高于13at％时，T x2和T x1的温度差(ΔT＝T x2-T x1)会减小，不利于获得均匀的纳米晶结构，导致软磁性能下降。特别是，产业化所需的低熔点场合，更需要B含量要在10at％以下。
本发明成分中由于含有Si，可以抑制晶化后纳米晶结构中Fe和B的化合物析出，从而稳定纳米晶结构。Si含量大于8at％时，饱和磁感应强度和非晶形成能力会下降，导致软磁性能恶化。特别指出，Si含量在0.8at％以上时，会改善非晶形成能力，可以稳定连续生产薄带。另外，由于ΔT的增加，可以获得均匀的纳米晶结构。
本发明成分中，P作为必备元素可以提高非晶形成能力。若P含量低于1at％，急冷法制备很难形成非晶相。若P含量高于8at％，饱和磁感应强度下降，软磁性能恶化。特别指出，若P含量在2～5at％时，可以提高非晶形成能力。
本发明成分中，由于含有C，可以增加非晶形成能力。另外，由于C的价格便宜，C的添加可以减少类金属的含量，降低材料成本。但是，C含量超过5at％时会引起脆化，导致软磁性能下降。特别指出，C含量在3at％以下时，可以抑制由于C挥发所引起的成分偏析。
本发明成分中，Cu作为必备元素，有利于纳米晶化。Cu价格高，并且在Fe含量高于81at％时，容易引起脆化和氧化。Cu含量低于0.4at％时，不利于纳米晶化。Cu含量高于1.4at％时，会造成非晶相的不均匀，不利于形成均匀的纳米晶结构，导致软磁性能下降。特别指出，如果考虑纳米晶合金的脆化，Cu含量要控制在1.1at％以下为好。
本发明成分中，根据B、Si、P以及C的复合作用，和只用其中一种元素相比，都可以增加非晶形成能力和提高纳米晶结构的稳定性。另外，进一步以Si、B、P、Cu和V进行复合，或者，Si、B、P、C、Cu和V进行复合后，更有利于纳米晶结构的稳定。
由于P和Cu原子间具有强引力，并且以特定比例添加P和Cu，所以在急冷法制备后可以形成10nm以下的团簇。这个纳米尺寸团簇在Fe基纳米晶合金形成的时候诱导bcc Fe微细结构形成，同时由于含有V的缘故，可以稳定纳米晶结构。因此，该Fe基纳米晶合金的晶粒平均粒径在5～25nm。P含量(x)和Cu含量(z)的比值(z/x)在低于0.08和高于0.8的时候，不能获得均匀的纳米晶结构，导致软磁性能下降。若考虑脆化时，优选比值(z/x)在0.08-0.55之间。
根据以上，本发明成分在制备Fe基纳米晶合金时，无论热处理升温速度缓慢，还是到达温度有偏差，都可以获得具有高饱和磁感应强度和优异软磁性能的Fe基纳米晶合金。
本发明成分中，可以以Ti、Zr、Hf、Nb、Ta、Mo、W、Cr、Co、Ni、Al、Mn、Ag、Zn、 Sn、As、Sb、Bi、Y、N、O、Ca、Mg以及稀土元素中的一种以上的元素来替代3at％以下的Fe。
本发明成分的合金可以做成各种形态，例如连续薄带又或者粉末形态。连续薄带的形状，可以利用Fe基非晶薄带的单辊或者双辊设备来制备。另外，这时Si含量在0.8at％以上又或者P含量在2-5at％时，可以提高非晶形成能力，实现连续稳定的薄带制备。而且，所制备的连续薄带可以进行180°弯曲而不断裂。另外，粉末可以通过水雾化和气雾化法来制备，也可以通过带材破碎法来制备。
本发明成分的合金可以制作成卷绕磁芯、层叠磁芯、磁粉芯等。另外，这些磁芯可以应用在变压器、电感、马达等领域。
本发明成分合金的T x2和T x1的温差(ΔT＝T x2-T x1)在100～200℃之间，从工业生产来看，热处理温度范围广。考虑到热处理过程中的发热，T x2越高越好。本发明成分中V会对ΔT的增加有利，特别是对提高T x2有利。由于结晶化时剧烈的发热，被热处理实物的温度会高于设定温度，V的添加会提高恶化软磁性能的化合物的析出温度T x2。因此，本发明成分在宽的热处理温度范围内可以制备具有优异软磁性能的Fe基纳米晶合金。
另外，本发明成分在制备Fe基纳米晶合金时，以100～300℃/min的速度升温，并且，即使在高于结晶化开始温度(即，第一晶化开始温度)热处理时，也可获得本发明的Fe基纳米晶合金。只是由于Fe的化合物析出会导致软磁性能恶化，所以热处理温度要在T x1～T x2范围内。
本发明成分可以在很宽的温度范围制备具有高饱和磁感应强度和优异软磁性能的Fe基纳米晶合金。因此，可以做成磁性元器件，例如，磁性环。本发明成分的Fe基纳米晶合金具有20A/m以下的矫顽力和1.65T以上的饱和磁感应强度。另外，本发明成分的Fe基纳米晶合金的饱和磁致伸缩系数在10×10 -6以下，甚至在5×10 -6以下，可以避免软磁性能恶化。
本发明的磁性器件是用本发明的Fe基纳米晶合金制成。所谓本发明的磁性部件是利用本发明的Fe基纳米晶合金所制备的变压器、电感、马达等器件的磁芯。
【本发明的合金实施例】
首先是合金的制备。如表1～4中实施例1～8所示，先按照比例称量原料重量，采用感应炉融化。熔化好的母合金，在大气中用单辊急冷法制备厚度在20μm、宽度10mm的条带。另外，用同样的方法制备表1～4中比较例1～3成分的条带。另外，比较例1为非专利文献1所记载的(Fe 85.7Si 0.5B 9.5P 3.5Cu 0.8) 99C 1合金。
表1
Figure PCTCN2019097735-appb-000001
表2
Figure PCTCN2019097735-appb-000002
表3
Figure PCTCN2019097735-appb-000003
表4
Figure PCTCN2019097735-appb-000004
表1中实施例1～3，是将比较例1的成分中0.1～1at％的Fe替换为V元素。表2的实施例4和5，是将比较例2中整体组成的0.1～1at％替换为V元素。表3的实施例4与6是把比较例2中0.01～0.1at％的B和P替换为V元素。表4中是不含有Si的组成，实施例7和8，是将比较例3的组成中0.1～1at％的Fe替换为V元素。
对于制备的实施例1～8以及比较例1～3的薄带合金，使用XRD进行相的鉴定。各合金成分的第一晶化开始温度(T x1)以及第二晶化开始温度(T x2)，采用差示扫描量热仪(DSC)进行测定，升温速度是40℃/min。
各合金成分被测定出的相如表1～4所示。另外，各合金组成的DSC曲线如图1所示。检测的T x1、T x2及ΔT(＝T x2-T x1)温度，在图1以及表1～4表示。如表1～4所示，实施例1～4，6～8的合金组成是非晶单相(Amo)、或者大部分是非晶相(Almost Amo)；实施例5的合金组成，是非晶相为主相加一部分结晶相(Cry)。另外，比较例中的1-3合金组成是非晶单相(Amo)。
实施例1～8合金组成所包含的元素V，可以确认具有扩大结晶化温度差ΔT和提升T x2的效果。T x2的提升有助于纳米晶结构的热稳定性提升，即使在热处理过程中，伴随自身晶化发热，也不容易有Fe的化合物析出，不会降低合金的软磁性能。此外，ΔT增大后，合金将在更大的热处理温度范围内展现出良好的软磁性能。如图1以及表1～4所示的实施例2～8与各表中的比较例相对比，T x2确实得到了提高；实施例2、3、5、7和8与各表中的比较例相比，ΔT也确实增大了。
所制备的实施例1～8以及比较例1～3的合金组成条带，采用振动样品磁强计(VSM)在800kA/m的磁场下，测定了其饱和磁感应强度(Bs)，测试结果显示在表1～4中。由表1～4可知，实施例1～8的饱和磁感应强度在1.55T-1.57T之间，也就是说即使添加了V元素，实施例1-8与比较例1-3几乎具有相同的饱和磁感应强度。
【本发明的Fe基纳米晶合金实施例】
接下来，制备了本专利合金的Fe基纳米晶合金。选取实施例1～8以及比较例1～3制备的薄带合金，切取50mm的长度，各自选取10根一组并用铝箔包覆。包覆好的样品放置在红外线热处理炉中，在Ar气保护气氛中对合金薄带进行热处理，制备实施例1～8以及比较例1～3的纳米晶合金。热处理条件：根据合金成分的不同设置不同的升温速度(Heating rate；R h)以及热处理的各到达温度(Annealing temperature；Ta)，达到设定温度后都保温10分钟。
采用直流B-H仪在2kA/m的磁场下测试制备好的Fe基纳米晶合金条带的矫顽力(Hc)。各Fe基纳米晶合金的α-Fe晶粒尺寸可通过XRD图谱的半高宽用Scherrer公式计算获得。测试结果分别通过表1～4以及图2～9表示。另外，测定了各纳米晶合金条带的饱和磁感应强度， 实施例1～8中所有纳米晶合金的饱和磁感应强度都在1.7T以上，具有高饱和磁感应强度。
【矫顽力对热处理升温速度依赖性改善的实施例】
表1所示的实施例1～3以及比较例1的Fe基纳米晶合金的矫顽力与热处理升温速度的依赖性，显示在图2(a)和(b)中。图2(a)和(b)中设定的到达温度(Ta)分别为420℃和430℃，这是最佳热处理温度。
如图2(a)及(b)所示升温速度在50～300℃/min条件下，含V的实施例1-3与不含V的比较例1相比较，实施例1-3具有更低的矫顽力。另外，如图2(a)所示，在设定的到达温度为420℃时，得到10A/m以下矫顽力的优异软磁性能时，不含V的比较例1的升温速度下限为170℃/min，而含有0.1at％以上V元素的实施例1～3合金的升温速度下限为130～140℃/min。如图2(b)所示，设定的到达温度为430℃时，得到10A/m以下矫顽力的优异软磁性能，不含V的比较例1的升温速度下限为180℃/min，而含有0.1at％以上V元素的实施例1～3，升温速度下限仅约为120～140℃/min。
图3所示为实施例1～3以及比较例1的Fe基纳米晶合金在设定的到达温度为430℃时，其α-Fe的晶粒尺寸与热处理升温速度的依赖关系曲线。如图3所示，在全部升温速度范围内，由于V的添加，α-Fe晶粒变小。因此，如图2所示，V的添加有效的降低了矫顽力，起到了晶粒细化作用。
图4(a)和(b)显示出表2中的实施例4、5和比较例2、还有比较例1的Fe基纳米晶合金的矫顽力和热处理升温速度之间的依赖关系。图4(a)和(b)中设定的到达温度(Ta)分别为420℃和430℃，这是最佳热处理温度。
如图4(a)及(b)所示升温速度在50～300℃/min条件下，含V的实施例4、5的合金与不含V的比较例1、2相比，实施例4、5的矫顽力更低。并且，如图4(a)所示，在设定的到达温度为420℃时，得到10A/m以下矫顽力的优异软磁性能时，不含V的比较例1和2的升温速度下限为160～170℃/min，而含有0.1at％以上V元素的实施例4和5合金的升温速度下限降为135℃/min。由图4(b)所示，设定的到达温度为430℃时，得到10A/m以下矫顽力的优异软磁性能时，不含V的比较例1和2的升温速度下限为150～180℃/min，而含有0.1at％以上V元素的实施例4和5，其升温速度下限仅约为125～130℃/min。
图5显示出表3中的实施例4、6和比较例2、还有比较例1的Fe基纳米晶合金的矫顽力和热处理升温速度之间的依赖关系。到达温度Ta为420℃，为最佳热处理温度。
图5所示升温速度在50～300℃/min的条件下，含V的实施例4、6合金与不含V的比较例2相比，实施例4和6的矫顽力更低。并且，得到10A/m以下矫顽力的优异软磁性能时，不含V的比较例1和2的升温速度下限为约170℃/min，而含有0.01at％以上V元素的实施例 4和6合金的升温速度下限降低到约130℃/min。
图6显示出表4中实施例7、8和比较例3、还有比较例1的Fe基纳米晶合金的矫顽力和热处理升温速度之间的依赖关系。到达温度Ta为410℃，为最佳热处理温度。
图6所示升温速度在50～300℃/min的条件下，含V的实施例7、8合金与不含V的比较例3相比，实施例7和8的矫顽力更低。不含V的比较例3在任何的升温速度下均无法得到10A/m以下矫顽力的优异软磁性能，而含有0.5at％以上V的实施例7和8合金，在约135℃/min以上的升温速度下得到10A/m以下的矫顽力。
如以上图2-6所表示的结果，由于V的添加，即使降低了热处理的升温速度，本发明的合金也能得到优异的软磁性能。
【矫顽力对热处理到达温度依赖性改善的实施例】
图7(a)和(b)显示出表1中实施例1～3及比较例1的Fe基纳米晶合金的矫顽力与热处理到达温度之间的依赖关系。如图7(a)所示，升温速度R h在300℃/min的条件下，含V的实施例1～3和不含V的比较例1相比，实施例1～3在380～440℃温度范围内具有更低的矫顽力。另外，不含V的比较例1的合金，在温度大于440℃时，矫顽力超过10A/m，软磁性能急剧恶化。与其相比，含有0.1at％以上V的实施例1～3的合金，即使在440℃时，仍然具有10A/m以下的矫顽力，软磁性能优异。由于V的添加，有效的防止了软磁性能的恶化，在高温区域也得到了高饱和磁感应强度。
如图7(b)所示，升温速度R h在150℃/min的条件下，不含V的比较例1的合金，只有在440℃时矫顽力才低于10A/m。与之相反，添加了0.5at％以上V的实施例2和3的合金，矫顽力低于10A/m的温度范围扩大到415～440℃。也就是说，由于V的添加，即使在150℃/min的慢升温速度下，也能够在更宽的温度范围内得到10A/m以下的矫顽力。这一点，可降低实际工业生产中的热处理工艺要求，具有非常重要的意义。
图8显示出表2中实施例4、5和比较例2、以及比较例1的Fe基纳米晶合金的矫顽力和热处理到达温度之间的依赖关系。如图8所示，升温速度R h在150℃/min条件下，含有0.1at％以上V的实施例4、5和不含V的比较例1、2相比，不含V的比较例1和2的合金，只有在温度440℃时矫顽力才小于10A/m，而实施例4和5矫顽力小于10A/m的温度范围扩大至405～440℃。也就是说，与图7(b)一样，由于V的添加，即使在150℃/min的慢升温速度下，也能够在更宽的温度范围内得到10A/m以下的矫顽力。
【热处理条件对于卷绕铁芯热处理后矫顽力改善的实施例】
在加热过程中，短条状材料可实现均匀加热。但对于卷绕铁芯，铁芯外部比较容易随炉升温，但材料内部升温速度就会比表面慢。这个现象，在快速热处理时更为明显。更有甚者， 到达目标温度后，引起结晶化瞬间放热，铁芯温度急速上升。这种热量与材料的体积成正比，铁芯越重，这种作用越明显。而且，升温速度越快越容易引起结晶化发热，温度上升越高。
制备实施例1以及比较例1合金的两种连续条带，各取0.1g的短条带，并且各制备重量分别为1g、10g、100g的卷绕铁芯，在升温速度100～300℃/min、到达温度420℃的条件下进行热处理。测试由于结晶发热造成的高出到达温度的温度差，并对热处理后各材料的晶粒尺寸和矫顽力进行测定，其结果在表5以及图9中表示。
表5
Figure PCTCN2019097735-appb-000005
如表5和图9中所示，比较例1只有短条带(0.1g)在升温速度为300℃/min的条件下可以得到10A/m以下的矫顽力，卷绕铁芯样品(1g、10g、100g)在任何条件下都不能得到10A/m以下的矫顽力。实施例1则在所有热处理条件下，都比比较例1的最高温度要低，在几乎任何条件下都比比较例1的结晶晶粒尺寸小。还有，实施例1在所有热处理条件下都比比较例1具有更低的矫顽力，在升温速度150℃/min的条件下，其10g的卷绕铁芯也具有10A/m以下的矫顽力。这是因为V的添加，一方面减少了矫顽力对热处理升温速度的依赖性(参考图2、4、5、6)，另一方面扩大了获得低矫顽力的热处理温度范围区间(参考图7和图8)。这些结果在本发明的Fe基纳米晶合金实际的产业化以及磁性部件中也适用。

Claims (12)

  1. 一种合金组成物，其特征在于，所述合金组成物的组成表达式为Fe aV αB bSi cP xC yCu z，其中79≤a≤91at％、5≤b≤13at％、0≤c≤8at％、1≤x≤8at％、0≤y≤5at％、0.4≤z≤1.4at％、0＜α＜5at％，以及0.08≤z/x≤0.8。
  2. 根据权利要求1所述的合金组成物，其特征在于，所述的0≤y≤3at％、0.4≤z≤1.1at％、以及0.08≤z/x≤0.55。
  3. 根据权利要求1或2所述的合金组成物，其特征在于，所述组分中3at％以下的Fe可被Ti、Zr、Hf、Nb、Ta、Mo、W、Cr、Co、Ni、Al、Mn、Ag、Zn、Sn、As、Sb、Bi、Y、N、O、Ca、Mg或者稀土类元素中的至少一种元素替代。
  4. 根据权利要求1-3中任一项所述的合金组成物，其特征在于，所述合金组成物可以为连续薄带状。
  5. 根据权利要求4所述的合金组成物，其特征在于，所述连续薄带在180度弯曲试验时可紧密地弯曲。
  6. 根据权利要求1-3中任一项所述的合金组成物，其特征在于，所述合金组成物可以为粉末形状。
  7. 根据权利要求1-6中任一项所述的合金组成物，其特征在于，所述的合金组成物在热处理时，具有第一晶化开始温度(T x1)和第二晶化开始温度(T x2)，其温度差(ΔT＝T x2-T x1)为100℃～200℃。
  8. 根据权利要求1-7中任一项所述的合金组成物，其特征在于，所述的合金组成物具有由非晶质和存在于非晶质中的初期微晶所构成的纳米异质结构；所述的初期微晶的平均粒径为0.3-10nm。
  9. 一种Fe基纳米晶合金的制造方法，其特征在于，包括以下步骤：准备根据权利要求1-8中任一项所述的合金组成物；将所述合金组成物进行结晶化热处理。
  10. 一种Fe基纳米晶合金，其特征在于，根据权利要求9所述的Fe基纳米晶合金的制造方法制备而成，并具有20A/m以下的矫顽力。
  11. 根据权利要求10所述的Fe基纳米晶合金，其特征在于，晶粒的平均粒径为5-25nm。
  12. 一种磁性部件，其特征在于，使用如权利要求10或11所述的Fe基纳米晶合金构成。
PCT/CN2019/097735 2018-08-03 2019-07-25 合金组成物、Fe基纳米晶合金及其制造方法和磁性部件 WO2020024870A1 (zh)

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