WO2020184724A1 - 準安定単結晶希土類磁石微粉及びその製造方法 - Google Patents
準安定単結晶希土類磁石微粉及びその製造方法 Download PDFInfo
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- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
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- H01F1/04—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 hard-magnetic materials metals or alloys
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Definitions
- the present invention provides a rare earth anisotropic magnet material suitable for use in a high-characteristic permanent magnet suitable for use in a wide range of fields such as electronics, telecommunications, medical care, machine tool fields, and industrial / automobile motors. Regarding rare earth magnet materials.
- the magnetic compound used for the highest performance magnet is the Nd 2 Fe 14 B compound. This is the main phase of the Nd-Fe-B magnet invented in 1982, the crystal structure was determined in 1984, and it is currently used as the strongest permanent magnet material.
- Non-Patent Document 1 Having a TbCu 7 structure (SmZr) (FeCo) 10 N x is anisotropic Nd 2 Fe 14 B equivalent, the saturation magnetization is 1 approximately 10% higher value than the Nd 2 Fe 14 B (Non-Patent Document 1).
- this compound is known to be a metastable phase, and the production method is limited.
- powder synthesis has been successful only by the liquid quenching method, the mechanical alloying method, and the HDDR method. (See Non-Patent Documents 2 and 3 and Patent Document 1).
- Non-Patent Document 1 Non-Patent Document 1
- Patent Document 1 the report by Takagi et al.
- Patent Document 1 isotropic samples, and are single crystal powders or crystal directions that are raw materials for possible high-performance magnet materials. We have not yet synthesized a complete powder.
- Nd-Fe-B magnets it has been reported that even if the raw material powder is an isotropic powder, a powder having the same crystal orientation or a magnet molded body can be obtained by performing hot processing or HDDR treatment. However, even if the same treatment is applied to the magnet material of Sm-Fe, Nd-Fe or Sm-Fe-N, Nd-FeN based (see Patent Documents 2 and 3), crystals do not align.
- Non-Patent Document 4 the only method for obtaining a sample with crystal orientation is the sputtering method.
- the sputtering method requires a lot of time and cost to obtain the powder, which is not realistic as a method for synthesizing the powder. (See Non-Patent Document 4).
- the present inventor has a TbCu 7 structure, which is a metastable phase in the process of raising the temperature of the raw material metal to make it a gas phase and then cooling it to room temperature, with an average of 30-300 nm. It has been found that a single crystal powder having a particle size can be obtained, and the present invention has been completed.
- R is at least one element selected from the group consisting of Nd and Sm).
- M is at least one element selected from the group consisting of Zr, Y and Ce, T is at least one element selected from the group consisting of Fe and Co, and x is 7.0.
- ⁇ x ⁇ 10.0, y is 1.0 ⁇ y ⁇ 2.0, and z is 0.0 ⁇ z ⁇ 0.3), and is characterized by having a crystal structure of TbCu 7 .
- Single crystal powders having an average particle size of 30-300 nm are provided.
- the method for synthesizing a single crystal powder is a mixed powder or alloy of at least one element of Sm and Nd, at least one element of Zr, Y and Ce, and at least one element of Fe and Co.
- a group consisting of (R 1-z M z ) T x (in the formula, R is Nd and Sm), which is obtained in the process of mixing the powder, making it into a gas phase by raising the temperature of the raw material powder, and then cooling it to room temperature.
- At least one element selected from, M is at least one element selected from the group consisting of Zr, Y and Ce
- T is at least one element selected from the group consisting of Fe and Co.
- a production method characterized by synthesizing a single crystal powder which is an element and x is 7.0 ⁇ x ⁇ 10.0 and z is 0.0 ⁇ z ⁇ 0.3).
- the method for synthesizing a single crystal powder is a mixed powder or alloy of at least one element of Sm and Nd, at least one element of Zr, Y and Ce, and at least one element of Fe and Co. From the group consisting of (R 1-z M z ) T x (in the formula, R is Nd and Sm) obtained in the process of mixing the powder, raising the temperature of the raw metal to make it a gas phase, and then cooling it to room temperature. At least one element to be selected, M is at least one element selected from the group consisting of Zr, Y and Ce, and T is at least one element selected from the group consisting of Fe and Co.
- the present invention it is possible to provide single crystal particles or powder having a metastable TbCu 7 structure.
- the method for synthesizing a single crystal powder material of the present invention there is a method capable of synthesizing single crystal magnet material particles or powder in the process of raising the temperature of the raw material metal to temporarily bring it into a gas phase and then cooling it to room temperature. Can be provided.
- (A) is a scanning transmission electron microscope image of NdFe x particles having a TbCu 7 structure as one embodiment of the present invention
- (B) is a transmission electron microscope image of NdFe x particles
- (C) is (B).
- (D) is an electron diffraction image of (C). It is the measurement result of (A) XRD and (B) SEM image of the SmFe x powder having the TbCu 7 structure as one embodiment of the present invention.
- Embodiments of the present invention will be described below.
- Each crystal structure can be obtained by replacing the rare earth element in the Ca site of the basic CaCu 5 structure with a pair of iron, so-called "dumbbell iron: Fe-Fe".
- the TbCu 7 structure is a structure in which the rare earth and dumbbell iron are randomly replaced, and therefore the Fe or Co content can have a range of 87.50-90.91 at% with respect to the rare earth element (Fig.). 1).
- the “metastable crystal structure” in the present invention is a crystal structure of a metastable phase, and the “metastable phase” is a phase that is unstable in thermal equilibrium and does not appear in the phase diagram.
- Sm- In the case of a binary alloy of Fe, a compound having a ThMn 12 structure, a TbCu 7 structure, and a CaCu 5 structure is known as a metastable phase.
- the "single crystal particle” in the present invention refers to a particle whose crystal axis direction does not change regardless of the position of one particle in the particle. However, since it is difficult to completely prevent the oxidation of the particle surface, it is determined that the target particle is a single crystal particle even if the oxide layer on the particle surface is present.
- the “single crystal powder” in the present invention is a state in which the above “single crystal particles” are in a large number without becoming a polycrystalline state.
- TbCu 7 single crystal is comprehensively determined by composition analysis by powder X-ray diffraction method (hereinafter XRD), energy dispersive X-ray spectroscopy (hereinafter EDX), and electron diffraction method. It is not possible to distinguish between single crystal and polycrystal only from XRD, and it is very difficult to distinguish from other stable phases, for example, Th 2 Zn 17 , only from the electron diffraction pattern. Because there is. Therefore, specifically, from the XRD result, it was confirmed that the alloy phase of R and Fe was only the TbCu 7 structure, and further, from the EDX measurement, x of (R 1-z M z ) T x was 7.0 ⁇ .
- XRD powder X-ray diffraction method
- EDX energy dispersive X-ray spectroscopy
- the method for determining "TbCu 7 single crystal” in the present invention can also be determined by taking out one particle and performing crystal structure analysis while randomly changing the orientation.
- Uniaxial anisotropy is a magnetic property that easily magnetizes a magnetic material in a specific crystal axis direction, and that direction is one direction. This uniaxial anisotropy is necessary to have high energy as a permanent magnet material.
- Step factor is a physical quantity related to the electrification density (shape) of 4f electrons in the inner shell of rare earth elements. If this is negative, it will be a shape that contracts with respect to the axis of symmetry, and if it is positive, it will be a shape that extends from spherical symmetry. Since the 4f electron cloud receives a crystal field from surrounding ions and its stable direction is determined, the shape of the electron cloud determines the direction of magnetic anisotropy.
- Rare earth magnets are materials that combine the excellent properties of large magnetocrystalline anisotropes exhibited by rare earth elements with the high magnetization and high Curie temperature exhibited by iron group transition metals, and can be easily replaced even if alternative research on rare earth elements progresses. Not an excellent industrial material.
- the rare earth element that controls the crystal magnetic anisotropy has a flat 4f electron spatial distribution (that is, the Stevens factor is negative) with respect to the quantization axis of the full-angle momentum of the 4f electron, and along the quantization axis. It is divided into Sm having a spatial distribution of 4f electrons (that is, the Stevens factor is positive).
- the Stevens factor has uniaxial anisotropy regardless of whether it is positive or negative due to the structure in which the above dumbbell iron is randomly inserted. Further, when nitriding, a compound having uniaxial anisotropy loses its effect, and a compound having no uniaxial anisotropy can obtain an effect having uniaxial anisotropy. Therefore, the compounds of the present invention (R 1-z M z ) T x and (R 1-z M z ) T x N y (in the formula, R is at least one element selected from the group consisting of Nd and Sm).
- M is at least one element selected from the group consisting of Zr, Y and Ce
- T is at least one element selected from the group consisting of Fe and Co
- x is 7.0.
- y is 1.0 ⁇ y ⁇ 2.0
- z is 0.0 ⁇ z ⁇ 0.3
- the "average particle size" in the present invention means that when 300 or more particles are randomly selected and a histogram of the particle size is drawn from the appearance image of the particles, where the longest diameter is the particle size of the particles. Equation: Fitting to the lognormal distribution function represented by, It is a value represented by. ⁇ and ⁇ are constants.
- the laser diffraction method also measures the so-called secondary particle size in which clusters are formed, the meaning is different from the average particle size in the present invention.
- the average value of the particle size obtained from the cross-sectional image tends to be smaller than the average value of the particle size obtained from the appearance image, this is also different from the average particle size in the present invention.
- Na, Al, Mn, V, Cr, Ni, Cu, La, Pr, Hf, and Mo elements may be contained as slight impurities of 0.0-1.0 at% or less. Since it cannot be completely excluded due to the limit of purity of the raw material, it is rational to consider that it is within the scope of the present invention even if it is contained.
- the single crystal particles of the present invention can be synthesized as follows.
- a mixed powder or alloy powder of at least one element of Sm and Nd, at least one element of Zr, Y and Ce, and at least one element of Fe and Co is used as a raw material powder. It is obtained in the process of raising the temperature of the raw material metal to make it a vapor phase and then cooling it to room temperature.
- the raw material powder may be a hydride of the above metal.
- the method for evaporating the raw material powder is not particularly limited, but for example, the RF thermal plasma method, the DC arc discharge method, and the arc plasma method can be considered.
- single crystal particles or powder can be produced by lowering the temperature to room temperature under an inert gas atmosphere, for example, an argon or helium atmosphere.
- an inert gas atmosphere for example, an argon or helium atmosphere.
- the powder is recovered in an inert gas atmosphere, for example, in an atmosphere of argon or helium having an oxygen concentration of 100 ppm or less, preferably an oxygen concentration of 10 ppm.
- the TbCu 7 structure is stable even if heat treatment is performed to promote crystallization.
- Example 1 The Nd powder was prepared by a known gas atomization method, then classified by a sieve of mesh # 500, and Nd having an average particle size of 21 ⁇ m calculated by a laser diffraction method and Fe having an average particle size of 3 ⁇ m purchased from a high-purity chemical laboratory were atomized. The mixture was mixed at a ratio of 2: 3, and the mixed powder was used as the raw material powder.
- FIG. 2 is a schematic diagram of a thermal plasma system.
- a thermal plasma system Using JEOL's TP-4002NPS, an input power of 6 kW and a frequency of 13.56 MHz are applied to the plasma generation coil (Fig. 2, 102), and G1 grade Ar is flowed at 35 L / min while the upper part of the chamber is controlled to 100 kPa.
- a powder feeder (Fig. 2, 100) JEOL TP-99010FDR, the powder was fed at a supply rate of about 0.3 g / min, and the powder was supplied into the generated thermal plasma.
- XRD performed incident energy at 14 KeV at Aichi Synchrotron Optical Center BL5S2.
- the sample was filled in a quartz capillary having a diameter of 300 ⁇ m in a glove box and sealed with an epoxy resin to prevent oxidation.
- FIG. 3 (A) shows the XRD result of the NdFe x sample having the TbCu 7 structure.
- AsTP is a sample that has been subjected to thermal plasma treatment. After that, heat treatment was performed by holding in an infrared heating furnace from 400 ° C. to 800 ° C. in increments of 100 ° C. in a vacuum of 10-2 Pa or less for 5 minutes at each temperature, as shown in FIG. 3 (A). Shown.
- the heat treatment temperature is less than 700 ° C.
- the superlattice peak peculiar to the Th 2 Zn 17 structure that appears near 21.4 ° is not observed, and therefore it can be seen that the TbCu 7 structure does not include the Th 2 Zn 17 structure, but 700 ° C. above the heat treatment temperature it can be seen that a powder containing Th 2 Zn 17 structure because the superlattice peak derived from Th 2 Zn 17 structure can be identified around 21.4 °.
- FIG. 3B shows the XRD results of the NdFe x N sample having the TbCu 7 structure. 1 L / min. The results of heat treatment are shown by holding the heat treatment at 300, 400, and 600 ° C. for 15 minutes at each temperature in an infrared heating furnace under the nitrogen air flow condition of. Under all conditions, a low angle shift of the peak derived from the TbCu 7 structure was observed, and its volume expanded by about 5.98 ⁇ 0.6% in all samples compared to the NdFe x sample having the TbCu 7 structure. From this, it can be seen that the nitrogen atom invaded in the range of 1.0 ⁇ y ⁇ 2.0.
- FIG. 4 (A) is an SEM image of an NdFe x sample having a TbCu 7 structure.
- (B) is a histogram of particle diameters prepared by randomly selecting 300 particles. From this, the average particle size was calculated to be 96 nm.
- (A) of NdFe x particles having a TbCu 7 structure is a transmission electron microscope image
- (B) is a high-resolution transmission electron microscope image
- (C) is an electron diffraction image. From this result, it can be confirmed that it is a single crystal.
- this XRD was performed with Aichi Synchrotron BL5S2, and the energy was measured after enclosing the powder in a quartz capillary of 14 keV and 300 ⁇ m in a glove box.
- Example 2 Sm metal is heat-treated at 500 ° C. in a hydrogen atmosphere to obtain SmH 3, and then SmH 3 crushed to 100 ⁇ m or less and Fe with an average particle size of 3 ⁇ m purchased from the Institute of High Purity Chemistry are mixed at an atomic ratio of 2: 3. And the mixed powder was used as a raw material powder.
- the thermal plasma process conditions are the same as in Example 1 above.
- FIG. 6A shows the XRD results of SmFe x particles having a TbCu 7 structure. Further, FIG. 6 (A) also shows the result of heat treatment by holding the heat in an Ar stream from 400 ° C. to 700 ° C. in 100 ° C. increments for 5 minutes at each temperature in an infrared heating furnace. At asTP, 400 ° C., the peak derived from the TbCu 7 structure is shifted to the low angle side because hydrides are formed by hydrogen contained in the raw material during the thermal plasma treatment, but the heat treatment temperature is 500 ° C. In the above, dehydrogenation has progressed, and a spectrum matching the peak position of SmFe x having a TbCu 7 structure has been obtained.
- the superlattice peak peculiar to the Th 2 Zn 17 structure that appears near 21.4 ° is not observed, and therefore it can be seen that the structure is TbCu 7 , but at a heat treatment temperature of 800 ° C. or higher, Th 2 is around 21.4 °. A superlattice peak derived from the Zn 17 structure can be confirmed.
- this XRD was performed with Aichi Synchrotron BL5S2, and the energy was measured after encapsulating the powder in a quartz capillary of 14 keV and 300 ⁇ m in a glove box.
- JSM-7800F manufactured by JEOL was used for the observation.
- the rare earth anisotropic magnet material of the present invention is suitable for use in a wide range of fields such as electronics, telecommunications, medical care, machine tool fields, industrial and automobile motors, and is suitable for use in high-characteristic permanent magnets. is there.
- fields such as electronics, telecommunications, medical care, machine tool fields, industrial and automobile motors
- permanent magnets with even higher characteristics are required.
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Abstract
Description
本発明の単結晶粉末材料の合成方法によれば、原料金属の温度を上げることにより一旦気相にし、その後室温まで冷える過程で単結晶の磁石材料粒子または粉末を合成することが可能な方法が提供できる。
R-Fe系の高Fe濃度の二元化合物には、CaCu5構造を基本とする多くの結晶相が存在する。それぞれの結晶構造は、基本であるCaCu5構造のCaサイトにある希土類元素を1対の鉄、いわゆる「ダンベル鉄:Fe-Fe」に置き換えていくことで得られる。TbCu7構造はその希土類とダンベル鉄がランダムに置き換わった構造であり、それ故、FeもしくはCoの含有量が希土類元素に対して87.50-90.91at%の幅を持つことができる(図1参照)。
で表される対数正規分布関数へフィッティングし、次式:
で表される値である。θ、μは定数である。ここで、レーザー回折法ではクラスターをつくったいわゆる二次粒子径をも測定してしまうため、本発明における平均粒径とは意味合いが異なる。また、断面像から得られる粒径の平均値は、外観像から得られる粒径の平均値よりも小さい傾向にあることから、これも本発明における平均粒径とは異なる。
Sm及びNdの少なくとも1種類の元素とZr及びY及びCeの少なくとも1種類の元素とFe、Coの少なくとも1種類の元素の混合粉もしくは合金粉を原料粉とし、原料金属の温度を上げることにより一旦気相にし、その後室温まで冷える過程で得られる。原料粉は上記金属の水素化物でも構わない。
得られた単結晶材料を例えば窒素雰囲気化、アンモニア、アンモニアと水素の混合気体、アンモニアと窒素の混合気体雰囲気中で200-600℃、好ましくは350-450℃で熱処理を10-600分行うことで一般式:RTxNyのyは1.0≦y≦2.0の範囲になり、単結晶材料を得ることができる。
Nd粉は公知のガスアトマイズ法で作製し、その後メッシュ#500のふるいで分級し、レーザー回折法で算出した平均粒径21μmのNdと高純度化学研究所から購入した平均粒径3μmのFeを原子比で2:3で混合し、その混合粉を原料粉とした。
Sm金属を水素雰囲気中で500℃熱処理をすることでSmH3とし、その後、100μm以下に粉砕したSmH3と高純度化学研究所から購入した平均粒径3μmのFeを原子比2:3の割合で混合し、その混合粉を原料粉とした。熱プラズマプロセス条件は上記実施例1と同様である。
Claims (9)
- RがNdであることを特徴とする請求項1に記載の単結晶粉末。
- RがSmであることを特徴とする請求項1に記載の単結晶粉末。
- RがNdであることを特徴とする請求項4に記載の単結晶粉末。
- RがSmであることを特徴とする請求項4に記載の単結晶粉末。
- 永久磁石材料として用いることを特徴とする請求項1~6のいずれか一項に記載の単結晶粉末。
- 請求項1~3のいずれか一項に記載の単結晶粉末を製造する方法であって、
R(RはNd及びSmからなる群から選択される少なくとも1種類の元素である。)とM(MはZr及びY及びCeからなる群から選択される少なくとも1種類の元素である。)とT(TはFe及びCoからなる群から選択される少なくとも1種類の元素である。)の混合粉もしくは合金粉を原料粉とし、原料金属粉を蒸発させる、単結晶粉末の製造方法。
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