WO2021238867A1 - 一种钕铁硼磁体及其制备方法和应用 - Google Patents

一种钕铁硼磁体及其制备方法和应用 Download PDF

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WO2021238867A1
WO2021238867A1 PCT/CN2021/095528 CN2021095528W WO2021238867A1 WO 2021238867 A1 WO2021238867 A1 WO 2021238867A1 CN 2021095528 W CN2021095528 W CN 2021095528W WO 2021238867 A1 WO2021238867 A1 WO 2021238867A1
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magnet
iron boron
neodymium iron
boron magnet
content
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PCT/CN2021/095528
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English (en)
French (fr)
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史丙强
刘磊
马丹
宿云婷
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烟台正海磁性材料股份有限公司
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Priority to EP21814433.5A priority Critical patent/EP4156209A4/en
Priority to KR1020227042249A priority patent/KR102670670B1/ko
Priority to JP2022573291A priority patent/JP7443570B2/ja
Priority to US17/999,989 priority patent/US20230207165A1/en
Publication of WO2021238867A1 publication Critical patent/WO2021238867A1/zh

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    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/34—Sputtering
    • C23C14/35—Sputtering by application of a magnetic field, e.g. magnetron sputtering
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    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
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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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    • H01F1/053—Alloys characterised by their composition containing rare earth metals
    • H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
    • H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
    • H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
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Definitions

  • the invention belongs to the field of neodymium iron boron magnets, and specifically relates to a neodymium iron boron magnet and a preparation method and application thereof.
  • Sintered NdFeB magnets as the fourth-generation permanent magnet materials, are called "magnet kings" with their excellent magnetic properties. They are widely used in many fields such as automobiles, wind power, compressors, elevators, and industrial automation.
  • the sintered NdFeB magnets in the motor are exposed to a high-temperature environment due to the heat generated by the windings and iron cores, and thermal demagnetization is prone to occur due to the action of the opposite direction magnetic field from the windings.
  • Dy and/or Tb instead of Nd (neodymium) to form Dy-Fe-B or Tb-Fe-B
  • the magnetic polarization of the two is significantly lower than that of Nd-Fe-B, resulting in a decrease in the remanence of the magnet That is, the final magnetic field strength that the magnet can provide is reduced, resulting in a decrease in the power of the motor or the need to increase the use of magnets in the motor to ensure the power output of the motor; at the same time, heavy rare earths are very expensive due to their reserves and excellent characteristics. The cost of magnets will also increase substantially as the amount of heavy rare earths used increases.
  • the fine-grain technology is to reduce the size of the crystal grains to form single domain crystals as much as possible, reduce the number of magnetic domains inside a single magnet crystal grain, reduce internal defects of the crystal grain, and achieve the purpose of improving the coercive force of the magnet.
  • Diffusion technology is to accurately put in heavy rare earth elements such as Dy and/or Tb to diffuse from the surface of the magnet into the inside of the magnet and enrich it at the grain boundary to improve the coercive force of the magnet.
  • the grain boundary diffusion technology can use a small amount of heavy rare earths, the coercive force can be greatly improved, and the remanence will not drop significantly, and it has been widely recognized and applied in the industry.
  • the grain boundary diffusion technology is another innovative development of the classic diffusion theory in the NdFeB industry. Its main principle is that under high temperature conditions, heavy rare earth elements such as Dy and/or Tb move along the grain boundary phase from the surface of the magnet to the center of the magnet.
  • Diffusion and enrichment on the grain boundary phase replacing the Nd in the outer edge layer of the main phase grains, forming a layer of Dy or Tb enriched shell-like structure on the outer edge of the main phase grains, improving the outer edge of the grains Anisotropic field, so as to achieve the effect of greatly improving the coercivity.
  • the concentration difference of Dy and/or Tb after it penetrates into the magnet, the concentration difference of Dy and/or Tb will be formed from the surface to the inside of the magnet, which will lead to the Hcj from the magnet. From the surface to the inside, there is also a phenomenon of gradient distribution.
  • the embedded assembly of magnets for high-speed running motors such as the magnets used in automobile drive motors or the magnets used in air-conditioning compressor motors, does not occur uniformly throughout the entire motor due to the increase in the temperature of the entire motor during actual use. It often occurs at the corners, especially the four edges in contact with the silicon steel sheet of the motor. However, other areas of the magnet are less prone to demagnetization. Grain boundary diffusion technology has been widely recognized and applied in high-speed embedded assembly motors due to its unique Hcj distribution law.
  • Nd-Fe-B sintered magnet records that Nd-Fe-B magnets are diffused in different directions, and their diffusion effects are inconsistent. Among them, diffusion along the magnetizing direction has the best effect. The material can diffuse deeper into the magnet; instead of the magnetization direction, the diffusion depth of the diffused material is limited, mainly concentrated on the surface of the material. Correspondingly, this also determines that the magnet uses the magnetizing direction to diffuse. When its Hcj increases significantly, its Br will decrease slightly. When using the non-magnetized direction to diffuse, because the diffusion material is mostly concentrated on the surface of the magnet, The internal structure of the magnet is uneven and the squareness is poor, which in turn affects the magnet's ability to withstand demagnetization.
  • the patent document CN 101939804A describes that the magnet surface is coated with 4 surfaces parallel to the magnetizing direction.
  • the magnet can obtain a high coercive force. Especially at the edge of the magnet, it is not easy to demagnetize even at high temperature. It is suitable for permanent magnet type. Rotating motor.
  • This patent document effectively combines the actual operating state of the motor with the special law of the diffused magnet, and effectively maintains the magnetic flux of the magnet on the basis of ensuring the magnet's ability to withstand demagnetization.
  • the four surfaces of the magnet parallel to the magnetizing direction are coated with diffusion materials, the internal structure of the magnet is not uniform, and the problem of poor squareness has not been solved. Although its resistance to demagnetization has been improved, the improvement is limited.
  • Coating 4 surfaces parallel to the magnetizing direction When using the dipping method, it is necessary to isolate the two opposite surfaces perpendicular to the magnetizing direction, and the diffusion material will be unevenly distributed on the magnet surface due to gravity; magnetron sputtering is required
  • the diffusion material can be attached to all 4 surfaces after multiple treatments, which results in low production efficiency and high mass production costs.
  • the present invention provides a neodymium iron boron magnet and a preparation method and application thereof in order to improve the above technical problems and difficulties in actual mass production.
  • a neodymium iron boron magnet which is represented by the chemical formula R1-R2-Fe-M-B, the neodymium iron boron magnet has a composite structure of a high coercivity region and a high remanence region;
  • R1 is a rare earth element containing at least Nd
  • R2 is a heavy rare earth element containing at least Dy and/or Tb
  • M is a transition metal element containing at least Co.
  • the content of R2 in the neodymium iron boron magnet is less than or equal to 1.0 wt%, for example, less than or equal to 0.8 wt%, preferably less than or equal to 0.5 wt%.
  • the neodymium iron boron magnet has a high coercive force region with a high R2 content and a high remanence region with a low R2 content.
  • the distribution of the high coercivity area and the high remanence area is basically as shown in FIG. 1.
  • the R2 concentration difference between the surface layer of the high remanence region and the inside of the magnet at about 1mm is ⁇ 1 ⁇ 0.1%
  • the R2 concentration difference between the surface layer of the high coercive force region and the interior of the neodymium iron boron magnet is about 1 mm ⁇ 2 ⁇ 0.15%.
  • the width of the high coercivity area is 1-5 mm, preferably 1.5-4 mm, and the central area has a high remanence area, which can effectively avoid the reduction of the magnetic flux of the magnet.
  • the high coercive force region is defined as extending from the surface layer to the inside of the magnet, and when the concentration difference of R2 is 1%, it is the width of the high coercive force region.
  • the neodymium iron boron magnet has a structure basically as shown in FIG. 1.
  • the R1 may also contain lanthanum (La), cerium (Ce), praseodymium (Pr), promethium (Pm), samarium (Sm), europium (Eu) and scandium. At least one of (Sc).
  • the content of R1 in the neodymium iron boron magnet is 28-32wt%, for example 29-31wt%, exemplarily 28wt%, 29wt%, 30wt%, 31wt%, 32wt%.
  • the R2 may also contain gadolinium (Gd), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium ( At least one of Lu) and yttrium (Y).
  • Gd gadolinium
  • Ho holmium
  • Er erbium
  • Tm thulium
  • Yb ytterbium
  • Lu yttrium
  • the M may also contain at least one of Cu, Ga, Zr, Ti, Al, Mn, Zn, and W; for example, M is selected from Co, Al, Cu And at least one of Ga.
  • the content of Co in the neodymium iron boron magnet is 1-3wt%, for example 1.5-2.5wt%, exemplarily 1wt%, 1.5wt%, 2wt%, 2.5wt%, 3wt% .
  • the content of the transition metal elements in the NdFeB magnet other than Co in M is ⁇ 2wt%, for example, ⁇ 1.5wt%, or ⁇ 1wt%, exemplarily 0.1wt%, 0.15wt%, 0.2wt%, 0.3wt%, 0.35wt%, 0.4wt%, 0.5wt%, 0.6wt%, 0.7wt%, 0.8wt%, 0.9wt%, 1.0wt%.
  • the content of B in the neodymium iron boron magnet is 0.5-1.3wt%, for example 0.8-1.05wt%, exemplarily 0.8wt%, 0.9wt%, 0.98wt%, 1.0wt% , 1.05wt%.
  • the neodymium iron boron magnet also contains inevitable impurities, such as at least one of C, N and the like.
  • the neodymium iron boron magnet has excellent demagnetization resistance.
  • the squareness of the neodymium iron boron magnet is ⁇ 0.9.
  • the demagnetization resistance of the magnet mainly depends on the demagnetization resistance of the magnet itself and the working load point of the motor.
  • the squareness of the magnet at the working temperature determines the matching relationship between the magnet's own demagnetization resistance and the motor's working load point. The higher the squareness, the higher the magnet's own demagnetization resistance, which is affected by the motor's working load point. The smaller.
  • the present invention also provides a preparation method of the above-mentioned neodymium iron boron magnet, which includes the following steps:
  • the base magnet of the R1-Fe-MB base structure make the heavy rare earth element R2 containing at least Dy and/or Tb form a film on the two opposite sides of the base magnet surface, and then carry out the diffusion treatment, the R2 element is along the base
  • the grain boundary of the magnet diffuses from the surface of the magnet to the inside, and is enriched at the grain boundary to obtain the neodymium iron boron magnet;
  • R1, R2, M and B all have the meaning and content as described above.
  • the base magnet can be prepared by methods known in the art, for example, by smelting, powdering, pressing, and heat treatment.
  • the raw material powder is prepared according to the above element content.
  • the raw material powder is heated (for example, 1400-1520°C) and melted into molten steel. After rapid cooling, it nucleates and crystallizes, and gradually grows to form alloy flakes.
  • the powder milling adopts a jet mill grinding method to obtain jet mill powder with an average particle size of 1-5 ⁇ m, preferably 2-4 ⁇ m.
  • a lubricant known in the art is added to the jet mill powder, and after the materials are fully mixed, the powder is pressed into molding under the action of an external magnetic field.
  • the temperature of the heat treatment is 1050-1100°C, exemplarily 1070°C and 1075°C; the heat preservation time of the heat treatment is 200-400min, exemplarily 270min, 300min.
  • the base magnet is a regular hexahedron.
  • the two opposite faces are two opposite faces that are not perpendicular to the magnetic direction of the base magnet and not perpendicular to the pressing direction (ie, the magnetizing direction) when the base magnet is formed.
  • the details are shown in Figure 2.
  • the R2 element is formed into a film on these two opposite surfaces, which can more effectively increase the effective utilization rate of diffused heavy rare earth elements, avoid the waste of heavy rare earth elements, and avoid the influence of the reduction of magnet remanence to the greatest extent.
  • the method for forming a film of the R2 element on the surface of the base magnet can be a method known in the art, including but not limited to methods such as vacuum evaporation, magnetron sputtering, and coating.
  • vacuum evaporation, magnetron sputtering or coating of the same amount of R2 element For example, on the two opposite sides of the base magnet, vacuum evaporation, magnetron sputtering or coating of the same amount of R2 element.
  • the amount of R2 element is ⁇ 0.5wt%, such as 0.4wt%, 0.2wt%.
  • the vacuum degree of the diffusion treatment is ⁇ 10 -2 Pa.
  • the first temperature rise and then heat preservation are carried out, and then the temperature is rapidly cooled down, and then the second temperature rise and heat preservation are carried out to complete the diffusion treatment.
  • the temperature to which the temperature is raised for the first time is 850-950°C, such as 880-930°C, exemplarily 900°C.
  • the time for the first heat preservation is 500-700 min, such as 550-650 min, exemplarily 600 min.
  • the temperature to which the rapid cooling is reached is 15-40°C, such as 20-35°C, exemplarily 25°C (room temperature).
  • the rapid cooling rate is 5-30°C/min, such as 10-20°C/min, exemplarily 5°C/min, 10°C/min, 15°C/min, 20°C/min, 25°C/min min, 30°C/min.
  • the temperature to which the temperature is raised for the second time is 500-600°C, such as 520-580°C, exemplarily 550°C.
  • the time for the second heat preservation is 200-300 min, such as 220-270 min, exemplarily 240 min.
  • the invention also provides the neodymium iron boron magnet prepared by the above method.
  • the invention also provides the application of the above-mentioned neodymium iron boron magnets in embedded motors.
  • the present invention also provides a magnetic steel containing the neodymium iron boron magnet.
  • the present invention also provides an embedded motor, which contains the above-mentioned neodymium iron boron magnet and/or magnetic steel.
  • the neodymium iron boron magnet and/or the magnetic steel are embedded in the motor.
  • the neodymium iron boron magnet of the present invention can use a small amount of Dy/Tb, greatly improve the high-temperature resistance demagnetization ability of the magnet, and suppress the reduction of the magnetic flux of the magnet, and is suitable for embedded high-speed motors.
  • the method for preparing the magnet can also greatly improve the utilization rate of the material and the production efficiency, and has the feasibility of mass production.
  • the area that is prone to demagnetization is only on the outermost layer, and there is almost no demagnetization inside.
  • the heavy rare earth elements diffused into the magnet are wasteful, and In the process of diffusion, it will inevitably diffuse into the main phase crystal grains, resulting in a reduction in the remanence of the magnet and affecting the output power of the motor.
  • the inventor further found that when the heavy rare earth film is formed and diffused on the surface perpendicular to the pressing direction of the magnet, the diffusion depth is very shallow and the coercive force increase is lower than that of the magnetization direction.
  • the squareness range at working temperature is less than 0.9, which greatly affects the magnet's ability to withstand demagnetization when the motor is running.
  • the coercivity of the magnet is The force increase is between the diffusion in the compression direction of the magnet and the diffusion in the magnetization direction, and the squareness at the working temperature is ⁇ 0.9.
  • the main phase crystal grains When it is pressed in magnetization, the main phase crystal grains are deflected under the action of a magnetic field, and then when it is pressed, it appears that there is no grain boundary phase or polarity between the crystal grains perpendicular to the pressing direction.
  • the grain boundary phase is thin, and the grain boundary phase between the grains parallel to the pressing direction is thick.
  • the thicker grain boundary phase will melt into the liquid phase, which acts as a flux to promote the growth of the main phase grains; or fills the adjacent two main phase grains to form the grain boundary through the principle of capillary tension Phase; or the formation of a larger triangular grain boundary phase or a thicker binary grain boundary phase, due to the active nature of RE elements, it is easy to form impurity compounds such as rare earth oxides in it. Therefore, the uniformity of the grain boundary phase parallel to the pressing direction is poor, and there are many impurities, and it is not easy to react with displacement diffusion, resulting in a small increase in the coercive force of the magnet diffused along the pressing direction and low squareness.
  • the grain boundary phase is repaired by the liquefaction and filling of the grain boundary phase parallel to the pressing direction during sintering, and a continuous uniform fineness is formed.
  • the thin grain boundary phase is prone to displacement diffusion reaction, but it is perpendicular to the magnet C axis, and its diffusion depth and effect are slightly inferior to the orientation direction diffusion.
  • the diffusion depth and diffusion effect are highly coincident with the actual easy demagnetization area of the magnet when the motor is running, achieving the efficient application of heavy rare earths, and the squareness can be ensured ⁇ 0.9, ensuring the resistance of the magnet Demagnetization ability.
  • the heavy rare earth film is not formed on the surface of the magnet perpendicular to the magnetizing direction, the content of heavy rare earth is relatively low in most of the surface perpendicular to the magnetizing direction, and the reduction of its remanence is significantly suppressed, effectively ensuring Maintain the magnetic flux of the magnet.
  • the present invention only performs film formation and diffusion on the two opposite surfaces of the magnet, which not only simplifies
  • the production process has been reduced, the use of heavy rare earths has been reduced, the feasibility of industrial production has been greatly improved, and it is suitable for embedded high-speed motor applications, because the embedded high-speed motor is operating at high temperature at high speed, its easy demagnetization area is the magnet
  • the position of the edge in contact with the silicon steel sheet component of the motor When the edge has a high coercivity, it can effectively resist the high-temperature thermal demagnetization phenomenon of the magnetic steel.
  • the magnetic steel in the embedded motor has a small surface area where demagnetization occurs; the high coercivity area obtained by its diffusion corresponds to the easy demagnetization area of the magnet (as shown in Figure 3).
  • the embedded assembly method shown in Figure 3 can effectively improve the magnet's resistance to demagnetization and significantly suppress the reduction of the magnetic flux of the magnet.
  • Fig. 1 is a schematic diagram of the high remanence area and the high coercive force area of the neodymium iron boron magnet of the present invention.
  • Figure 2 is a schematic diagram of the diffusion surface of the neodymium iron boron magnet of the present invention.
  • Figure 3 is a schematic diagram of the structure of the embedded motor (a) and the magnet (b).
  • Figure 4 is a graph showing the relationship between coercivity and diffusion depth.
  • the raw materials and reagents used in the following examples are all commercially available products, or can be prepared by known methods.
  • High coercivity area define the side of this area away from the high remanence area as the surface layer, from the surface layer and extending into the inside of the magnet, each processing 1*1*1mm small test piece, after acid soaking and melting the whole, adopt the spectroscopic method to test
  • the difference between R2 content and R2 content is ⁇ 2.
  • the squareness involved in the present invention takes the final magnet as the standard size of the sample and is tested by a magnetic measuring instrument.
  • the gradient distribution of the coercive force involved in the present invention is tested by processing a 1*1*1mm test piece on a magnet and using a strong pulse PFM06 equipment.
  • R1-Fe-MB based magnets Prepare raw alloys according to the following composition ratios.
  • R1 is Nd with a content of 30.5wt%; Co content is 1.5wt%; M is Al, Cu and Ga, with a content of 0.1wt. %, 0.1wt% and 0.15wt%; B content is 0.95%, the balance is Fe and unavoidable impurities, such as C, N and so on.
  • the specific preparation process of the neodymium iron boron base magnet is as follows:
  • a) Melting Using a vacuum induction melting furnace, put the above-equipped raw materials into a crucible and heat it to 1480°C. The raw materials are melted into molten steel, and the fully dissolved molten steel is poured onto the quench roll, and the temperature is rapidly reduced. It nucleates, crystallizes, and gradually grows to form alloy scales.
  • Pulverization The alloy flakes are subjected to HD crushing treatment, and then subjected to jet milling to obtain jet milling powder with an average particle size of SMD of 3.0 ⁇ m.
  • the substrate magnet was processed into small pieces of 10-10 mm to 10 mm, and the Dy metal sputter coating was performed on the surface of the substrate magnet according to Table 1 using the magnetron sputtering method.
  • experiments 1, 2, 3, 4 comprehensively compare the coercive force, squareness and magnetic moment indicators.
  • Experiment 4 has the highest comprehensive performance, and the width of the high coercive force area is 2.4mm, which can cover the high speed of the motor. The area is easy to demagnetize during operation.
  • the test piece was processed according to the diffusion direction to test the relationship between the coercivity and the diffusion depth, as shown in FIG. 4.
  • experiment 2 diffuses along the magnetizing direction, the average value of the coercive force is the highest, and the fluctuation along the diffusion depth is the smallest;
  • experiment 3 diffuses along the pressing direction, its coercive force forms a sharp peak on the diffusion surface and enters the magnet At 1mm inside, the coercive force drops sharply, and the coercive force at the center position is almost equivalent to that of the undiffused magnet;
  • Experiment 4 the coercive force decreases stepwise at 0-3mm on the surface of the magnet, the outermost layer
  • the coercive force is due to the diffusion of the magnetizing direction in Experiment 2, that is, the demagnetization resistance of its outermost layer is better than that in Experiment 2, and it gradually becomes flat at> 3mm, and the coercive force is about 250kA/m higher than that of the non-diffused magnet. , Its resistance to demagnetization has also been improved.
  • R1-Fe-MB based magnets Prepare R1-Fe-MB based magnets and prepare raw alloys according to the following composition ratios, where R1 is Nd with a content of 31wt%; Dy content is 0.5wt%, Co content is 2.0wt%; M is Al, Cu and Ga, The content is respectively 0.15wt%, 0.15wt% and 0.1wt%; the B content is 0.98%, the balance is Fe and inevitable impurities, such as C, N and so on.
  • the specific preparation process of the neodymium iron boron base magnet is as follows:
  • a) Melting Using a vacuum induction melting furnace, put the above-equipped raw materials into a crucible and heat it to 1460°C. The raw materials are melted into molten steel, and the fully dissolved molten steel is poured onto the quench roller, and the temperature is rapidly reduced. It nucleates, crystallizes, and gradually grows to form alloy scales.
  • Pulverization The alloy flakes are subjected to HD crushing treatment, and then subjected to jet milling to obtain jet milling powder with an average particle size of SMD of 2.8 ⁇ m.
  • the substrate magnet is processed into 40-8-20 and 40-8-2.5 square pieces (20 and 2.5 directions are the thickness in the magnetizing direction), and the surface of the substrate magnet is coated with Tb metal according to the coating method according to Table 3. .
  • the coercivity at 3mm is slightly lower in experiment 6, but the coercivity of the outermost layer is 156kA/m higher than that in experiment 7, which can effectively resist the demagnetization effect of the external magnetic field on the magnet; at the same time, the magnetic moment is higher. 0.6%, effectively avoiding the reduction of the magnetic moment, and ensuring the high-efficiency output of the magnet's magnetic field.

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Abstract

一种钕铁硼磁体及其制备方法和应用。所述钕铁硼磁体以化学式R1-R2-Fe-M-B表示，所述钕铁硼磁体具有高矫顽力区域和高剩磁区域的复合结构；其中，R1为至少含有Nd的稀土元素，R2为至少含有Dy和/或Tb的重稀土元素，M为至少含有Co的过渡金属元素。该磁体可以采用少量的Dy/Tb，大幅提高磁体的高温耐减磁能力，且抑制磁体磁通的降低，可适用于嵌入式的高速电机。制备该磁体的方法还可以大幅提高材料的利用率以及生产效率，具备量产可行性。

Description

一种钕铁硼磁体及其制备方法和应用
本申请要求申请人下述在先申请的优先权：于2020年5月27日向中国国家知识产权局提交的专利申请号为202010464304.9，发明名称为“一种钕铁硼磁体及其制备方法和应用”的在先申请的优先权。所述在先申请的全文通过引用的方式结合于本申请中。
技术领域
本发明属于钕铁硼磁体领域，具体涉及一种钕铁硼磁体及其制备方法和应用。
背景技术
烧结钕铁硼磁体作为第四代永磁材料，以其优良的磁性能被称为“磁王”，被广泛应用于汽车、风电、压缩机、电梯，以及工业自动化等众多领域。
高速电机在运转时，由于绕组和铁芯产生的热量，使得电机中的烧结钕铁硼磁体暴露于高温环境中，并且由于来自绕组的反方向磁场的作用而容易发生热减磁。这就需要高速电机用钕铁硼磁体具有一定的矫顽力来提供足够的耐热减磁能力，来保证磁体在高温下也能稳定输出磁场，确保电机的功率输出。
传统技术中，为了提高磁体的矫顽力，往往通过在钕铁硼磁体中添加Dy(镝)和/或Tb(铽)等重稀土元素来提高磁体的各向异性，达到提高磁体的矫顽力的目的。但是由于Dy和/或Tb的添加替代Nd(钕)，形成Dy-Fe-B或Tb-Fe-B，两者的磁极化强度要明显低于Nd-Fe-B，导致磁体的剩磁降低，即，最终磁体可以提供的磁场强度减小，导致电机功率降低或者需要增加电机中磁钢的使用量来保证电机的功率输出；同时，重稀土由于储量及优良特性的关系，价格非常昂贵， 磁体的成本也会随着重稀土的使用量的增加而大幅提升。
近年来，降低重稀土的使用量，提高磁体的矫顽力指标成为众多学者的研究热点之一。其中，细晶技术和扩散技术是目前公认的最有效的两种方法。细晶技术是将晶粒的尺寸降低，尽可能地形成单畴晶，降低单个磁体晶粒内部的磁畴数量，减少晶粒内部缺陷，达到提高磁体矫顽力的目的。但是通过细晶技术获得的矫顽力提升效果有限，且随着晶粒尺寸的降低，磁体不可避免的氧化活性提高，以及晶粒尺寸降低带来的不易充磁的问题，对目前的设备工装的精度及可靠性都提出更为苛刻的要求，工业化量产难度极大。扩散技术是将Dy和/或Tb等重稀土元素进行精准投放，使其由磁体表面扩散进入到磁体内部，并在晶界处进行富集，提高磁体的矫顽力。
晶界扩散技术因可以采用很少量的重稀土，使矫顽力得到大幅提升，而剩磁不会发生显著下降，得到了行业内的普遍认可及应用。晶界扩散技术，是经典的扩散理论在钕铁硼行业的再次创新发展，其主要原理为，在高温条件下，Dy和/或Tb等重稀土元素沿晶界相，由磁体表面向磁体中心扩散，在晶界相上富集存在，置换出主相晶粒外缘层的Nd，在主相晶粒外缘形成一层Dy或Tb富集的壳状结构，提高晶粒外缘处的各向异性场，从而达到大幅提高矫顽力的效果。晶界扩散技术因其扩散推动力为Dy和/或Tb的浓度差，因此其深入到磁体内部后，会在磁体表面到内部形成Dy和/或Tb的浓度差，进而导致其Hcj从磁体的表面到内部，也是呈现出梯度分布的现象。
高速运转电机嵌入式组装的磁钢，如汽车驱动电机用磁钢或空调压缩机电机用磁钢，在实际运用过程中因整个电机温度升高而发生的热减磁并不是整体均匀发生的，往往发生在边角部位，尤其是与电机硅钢片接触的4个棱边。而磁体其他区域反而不易发生退磁。晶界扩散技术因其独特的Hcj的分布规律，在高速运转的嵌入式装配电机中得到了普遍认可和应用。
文献《Anisotropic diffusion mechanism in grain boundary diffusion processed  Nd-Fe-B sintered magnet》记载了钕铁硼磁体，不同方向上进行扩散处理，其扩散效果不一致，其中，沿充磁方向扩散其效果最佳，扩散材料可以向更深的磁体内部扩散；而非充磁方向，扩散材料的扩散深度有限，主要集中在材料的表层位置。这相应地也决定了磁体采用充磁方向扩散，其Hcj大幅增加的同时，其Br的降幅也会略大；而采用非充磁方向扩散时，由于扩散材料大部分集中在磁体的表层位置，磁体内部结构不均匀，方形度较差，进而影响磁体的耐减磁能力。
通常，行业内大部分企业或学者都是在研究充磁方向上的扩散，或者是磁体的六个面都进行扩散，这样通过保证至少充磁方向的扩散，以获得最优秀的扩散效果，达到Hcj的大幅提升。
专利文献CN 101939804A记载了在磁体表面涂覆与充磁方向平行的4个面，磁体可以获得较高的保磁力，特别在磁体的边缘处，即使是高温下也不易退磁，适用于永磁式旋转电机。该专利文献将电机实际运行状态和扩散磁体的特殊规律进行了有效结合，在保证了磁体耐减磁能力的基础上，有效保持了磁体的磁通。但是，在磁体的平行与充磁方向4个表面涂覆扩散材料，其磁体的内部结构不均匀，方形度差的问题仍未解决，其耐减磁能力虽有提升但是提升有限。涂覆平行于充磁方向的4个面，采用浸渍法时，需要隔绝两个垂直于充磁方向的对面，且扩散材料在磁体表面因重力作用会分布不均匀；采用磁控溅射则需要多次处理才能把4个面全部附着扩散材料，生产效率低，量产成本高。
发明内容
本发明为改善上述技术问题和实际量产的难点，提供了一种钕铁硼磁体及其制备方法和应用。
一种钕铁硼磁体，其以化学式R1-R2-Fe-M-B表示，所述钕铁硼磁体具有高矫顽力区域和高剩磁区域的复合结构；
其中，R1为至少含有Nd的稀土元素，R2为至少含有Dy和/或Tb的重稀土元素，M为至少含有Co的过渡金属元素。
优选地，R2在所述钕铁硼磁体中的含量≤1.0wt％，例如≤0.8wt％，优选≤0.5wt％。
根据本发明的实施方案，所述钕铁硼磁体具有R2含量高的高矫顽力区域和具有R2含量低的高剩磁区域。例如，所述高矫顽力区域和高剩磁区域的分布基本如图1所示。
其中，所述高剩磁区域的表层及磁体内部约1mm处的R2浓度差△1≤0.1％，
其中，所述高矫顽力区域的表层及与所述钕铁硼磁体内部约1mm处的R2浓度差△2≥0.15％。
其中，所述△2/△1≥1.5，优选△2/△1≥2，示例性△2/△1＝5.5、6.33、7.4。
根据本发明的实施方案，所述高矫顽力区域的宽度为1-5mm，优选1.5-4mm，且中心区域具有高剩磁区域，可以有效避免磁体磁通的降低。其中，所述高矫顽力区域定义为自表层至磁体内部延伸，R2的浓度差值为1％时，即为高矫顽力区域的宽度。
根据本发明的实施方案，所述钕铁硼磁体具有基本如图1所示的结构。
根据本发明的实施方案，所述R1除含Nd元素外，还可以含有镧(La)、铈(Ce)、镨(Pr)、钷(Pm)、钐(Sm)、铕(Eu)和钪(Sc)中的至少一种。
根据本发明的实施方案，所述R1在钕铁硼磁体中的含量为28-32wt％，例如29-31wt％，示例性为28wt％、29wt％、30wt％、31wt％、32wt％。
根据本发明的实施方案，所述R2除含有Dy和/或Tb元素外，还可以含有钆(Gd)、钬(Ho)、铒(Er)、铥(Tm)、镱(Yb)、镥(Lu)和钇(Y)中的至少一种。
根据本发明的实施方案，所述M除含有Co外，还可以含有Cu、Ga、Zr、Ti、Al、Mn、Zn和W等中的至少一种；例如，M选自Co、Al、Cu和Ga中的至少一种。
根据本发明的实施方案，所述Co在钕铁硼磁体中的含量为1-3wt％，例如1.5-2.5wt％，示例性为1wt％、1.5wt％、2wt％、2.5wt％、3wt％。
根据本发明的实施方案，除Co之外的M中其余的过渡金属元素在钕铁硼磁体中的含量≤2wt％，例如≤1.5wt％，又如≤1wt％，示例性为0.1wt％、0.15wt％、0.2wt％、0.3wt％、0.35wt％、0.4wt％、0.5wt％、0.6wt％、0.7wt％、0.8wt％、0.9wt％、1.0wt％。
根据本发明的实施方案，所述B在钕铁硼磁体中的含量为0.5-1.3wt％，例如0.8-1.05wt％，示例性为0.8wt％、0.9wt％、0.98wt％、1.0wt％、1.05wt％。
根据本发明的实施方案，所述钕铁硼磁体中还含有不可避免的杂质，如C、N等中的至少一种。
根据本发明的实施方案，所述钕铁硼磁体具有优异的耐减磁能力。例如，在磁钢的工作温度下，钕铁硼磁体的方形度≥0.9。磁体的耐减磁能力，主要取决于磁体自身的耐减磁能力和电机的工作负载点。磁体在工作温度下的方形度，决定了磁体的自身耐减磁能力和电机工作负载点的匹配关系，方形度越高，磁体的自身的耐减磁能力越高，受电机工作负载点的影响越小。
本发明还提供上述钕铁硼磁体的制备方法，包括如下步骤：
制备或准备R1-Fe-M-B基结构的基体磁体，使至少含有Dy和/或Tb的重稀土元素R2在所述基体磁体表面的2个对面上成膜，然后进行扩散处理，R2元素沿基体磁体晶界由磁体表面向内部扩散，并在晶界处富集，得到所述钕铁硼磁体；
其中，所述R1、R2、M和B均具有如上文所述的含义和含量。
根据本发明的实施方案，所述基体磁体可以采用本领域已知方法制备得到，例如通过熔炼、制粉、压型和热处理等步骤制备得到。
例如，按照如上各元素含量配备原料粉体，原料粉体经加热(例如1400-1520℃)熔化为钢液，急冷降温后，成核、结晶，逐渐长大至形成合金鳞片。
例如，所述制粉采用气流磨研磨方式，得到平均粒径为1-5μm、优选2-4μm 的气流磨粉。
例如，压型之前，向所述气流磨粉中添加本领域已知润滑剂，充分混料后，在外磁场作用下，将粉体压制成型。
例如，所述热处理的温度为1050-1100℃，示例性为1070℃、1075℃；所述热处理的保温时间为200-400min，示例性为270min、300min。
根据本发明的实施方案，所述基体磁体为规则的六面体。
根据本发明的实施方案，所述2个对面为非垂直于基体磁体磁方向且非垂直于基体磁体成型时压制方向(即充磁方向)的2个对面。具体如图2所示。R2元素在这2个对面成膜，可以更有效地提高扩散重稀土元素的有效使用率，避免重稀土元素的浪费，且最大程度地避免磁体剩磁降低的影响。
根据本发明的实施方案，所述R2元素在基体磁体表面成膜的方式可以选用本领域已知方式，包括但不限于真空蒸镀、磁控溅射、涂覆等方法。例如，在所述基体磁体的2个对面上，真空蒸镀、磁控溅射或涂覆等量的R2元素。示例性地，每个面中，R2元素的用量为≤0.5wt％，比如为0.4wt％、0.2wt％。
根据本发明的实施方案，所述扩散处理的真空度＜10 -2Pa。
根据本发明的实施方案，所述扩散处理时先进行第一次升温后保温，然后急冷降温，再进行第二次升温和保温后，完成扩散处理。例如，所述第一次升温至的温度为850-950℃，例如880-930℃，示例性为900℃。例如，所述第一次保温的时间为500-700min，例如550-650min，示例性为600min。例如，所述急冷降温至的温度为15-40℃，例如20-35℃，示例性为25℃(室温)。例如，所述急冷降温的速率为5-30℃/min，比如10-20℃/min，示例性为5℃/min、10℃/min、15℃/min、20℃/min、25℃/min、30℃/min。例如，所述第二次升温至的温度为500-600℃，例如520-580℃，示例性为550℃。例如，所述第二次保温的时间为200-300min，例如220-270min，示例性为240min。
本发明还提供由上述方法制备得到的钕铁硼磁体。
本发明还提供上述钕铁硼磁体在嵌入式电机中的应用。
本发明还提供一种磁钢，所述磁钢中含有所述钕铁硼磁体。
本发明还提供一种嵌入式电机，其含有上述钕铁硼磁体和/或磁钢。优选地，所述钕铁硼磁体和/或磁钢以嵌入式装配于所述电机中。
本发明的有益效果：
本发明钕铁硼磁体可以采用少量的Dy/Tb，大幅提高磁体的高温耐减磁能力，且抑制磁体磁通的降低，可适用于嵌入式的高速电机。制备该磁体的方法还可以大幅提高材料的利用率以及生产效率，具备量产可行性。
发明人发现，当重稀土元素的扩散方向与磁体C轴平行时，重稀土元素在沿平行于磁体充磁方向上的扩散深度是最大的，且扩散效果最佳，重稀土元素可以扩散至磁体内部，由磁体表面至磁体中心区域，形成矫顽力的梯度分布。但是在嵌入式电机中应用的磁体，其易发生退磁的区域仅在最表面的一层，内部几乎不发生退磁，如图3所示，即磁体内部扩散进去的重稀土元素是浪费的，且在扩散过程中不可避免地向主相晶粒内部的扩散，导致磁体的剩磁降低，影响了电机的输出功率大小。
发明人进一步发现，当在垂直于磁体的压制方向的表面上进行重稀土的成膜、扩散时，相比于充磁方向扩散，扩散深度很浅，矫顽力的增幅较低，且在磁体工作温度下的方形度极差＜0.9，极大地影响了磁体在电机运行时的耐减磁能力。而在非垂直与磁体的压制方向，且非垂直与充磁方向的磁体的2个对面上进行重稀土的成膜、扩散时，虽然重稀土元素的扩散深度同样较小，但是磁体的矫顽力增幅介于磁体压制方向扩散和充磁方向扩散之间，且在工作温度下的方形度≥0.9。
熔炼工序鳞片冷却结晶生长时，主相晶粒由接触面向自由面生长时，是垂直于C轴生长的，表现为鳞片的截面上，主相的C轴垂直于相邻的两个晶界相。 当鳞片进行HD破碎时，从晶界处断裂，即主相晶粒表面被C轴指向的前端和后端，均附带有部分的晶界相。经过气流磨粉碎为细小粉末，在充磁中进行压制时，主相晶粒在磁场作用下偏转，然后进行压制时，表现为在垂直于压制方向上的晶粒间无晶界相或有极细薄的晶界相，而平行于压制方向上的晶粒间的晶界相较厚。在固液烧结阶段，较厚的晶界相会熔融为液相，起到助熔作用促进主相晶粒的长大；或者通过毛细管张力原理向紧邻的两主相晶粒间填充形成晶界相；或者形成较大的三角晶界相或较为厚实的二元晶界相，由于RE元素的活泼属性，易在其中形成稀土氧化物等杂质化合物。因此，在平行于压制方向上的晶界相均匀性较差，杂质多，不易与发生置换扩散反应，导致沿压制方向扩散的磁体矫顽力增幅小，方形度低。而在垂直于压制方向上，由于无晶界相或晶界相较为细薄，在烧结时经由平行于压制方向上的晶界相的液化填充，晶界相得到了修复，形成了连续均匀细薄的晶界相，容易发生置换扩散反应，但与磁体C轴垂直，其扩散深度及效果要略差于取向方向扩散。因此同时垂直于压制方向和扩散方向的扩散，其扩散深度及扩散效果与磁体在电机运行时实际易退磁区域高度重合，达到重稀土的高效应用，且方形度可以确保≥0.9，保证磁体的耐减磁能力。
由于不在磁体的垂直于充磁方向的表面进行重稀土的成膜，在垂直于充磁方向的表面的大部分区域重稀土含量较低，其剩磁的降低得到了显著抑制，有效地保证了维持了磁体的磁通大小。相比于专利文献CN 101939804A在磁体的除了与磁化方向相垂直的表面之外的磁体块的4个表面进行成膜、扩散，本发明仅在磁体的两个对面进行成膜、扩散，不仅简化了生产工序，降低了重稀土的使用量，工业化生产的可行性大幅提升，而且适用于嵌入式高速电机应用领域，因嵌入式的高速电机在工作温度高速运转时，其易退磁区域即为磁体与电机硅钢片组件接触的棱边位置，棱边具有高矫顽力时，可有效抵御磁钢的高温热减磁现象发生。嵌入式电机中的磁钢发生退磁的表层区域范围较小；其扩散所获 得的高矫顽力区域对应于磁体的易退磁区域(如图3所示)。图3所示的嵌入式装配方式，可有效提高磁体的耐减磁能力，且显著抑制磁体磁通的降低。
附图说明
图1为本发明钕铁硼磁体的高剩磁区域和高矫顽力区域示意图。
图2为本发明钕铁硼磁体扩散面示意图。
图3为嵌入式电机(a)及磁钢(b)的结构示意图。
图4为矫顽力与扩散深度的关系图。
具体实施方式
下文将结合具体实施例对本发明的技术方案做更进一步的详细说明。应当理解，下列实施例仅为示例性地说明和解释本发明，而不应被解释为对本发明保护范围的限制。凡基于本发明上述内容所实现的技术均涵盖在本发明旨在保护的范围内。
除非另有说明，以下实施例中使用的原料和试剂均为市售商品，或者可以通过已知方法制备。
实施例中重稀土元素的浓度差的测量方法为：
高剩磁区域：自磁体垂直于充磁方向的面的中心位置的表层及延伸入磁体内部，各加工1*1*1mm的小试片，酸浸泡整体熔融后，采用光谱法测试其R2含量及R2含量差△1。
高矫顽力区域：定义该区域远离高剩磁区域的一个侧面为表层，自表层及延伸入磁体内部，各加工1*1*1mm的小试片，酸浸泡整体熔融后，采用光谱法测试其R2含量及R2含量差△2。
本发明所涉及的方形度是以最终磁体作为样品标准尺寸，通过磁测仪测试。本发明所涉及的矫顽力的梯度分布是以磁体上加工1*1*1mm的试片，采用强脉冲PFM06设备测试。
实施例1
制备R1-Fe-M-B基磁体，依照如下组分配比制备原料合金，其中，R1为Nd，含量为30.5wt％；Co含量为1.5wt％；M为Al、Cu和Ga，含量分别为0.1wt％，0.1wt％和0.15wt％；B含量为0.95％，余量为Fe和不可避免的杂质，如C、N等。钕铁硼基材磁体具体制备过程如下：
a)熔炼：采用真空感应熔炼炉，将上述配备好的原材料放入坩埚中，加热至1480℃，原材料熔化为钢液，将溶解充分的钢液倾倒至急冷辊上，急速降温，在辊面上形核、结晶，并逐渐长大，形成合金鳞片。
b)制粉：所的合金鳞片进行HD破碎处理，然后进行气流磨研磨，获得平均粒径SMD为3.0μm的气流磨粉。
c)压型：向气流磨粉中添加0.3wt％的润滑剂，采用混料机混料120min后，倒入到压机的膜腔中，在2.5T的外加磁场作用下，压制成型。
d)烧结，将压制成的坯体放入到烧结炉中，在1075℃保温300min，然后按照20℃/min的冷却速度急冷达到室温，制成烧结钕铁硼基材磁体。
将基材磁体加工10-10-10mm的小片，采用磁控溅射法，按照表1进行基材磁体表面的Dy金属溅射涂布。
表1 磁体表面Dy金属不同涂覆位置示意表
Figure PCTCN2021095528-appb-000001
然后将采用表1方式处理的磁体分别放入至扩散炉设备中扩散处理，充真空度达到＜10 -2Pa，然后升温至900℃，保温600min，15℃/min的速率急冷至室温后再升温至550℃，保温240min，得到磁体成品。测试其成品磁性能和成分，测 试结果如表2。
表2磁体成品的性能和成分汇总表
Figure PCTCN2021095528-appb-000002
对比上述实验，实验1、2、3、4相比，综合比较矫顽力和方形度及磁矩指标，实验4综合性能最高，且高矫顽力区域的宽度为2.4mm，可以覆盖电机高速运转时易退磁区域。进一步的，按照扩散方向加工试片，测试矫顽力与扩散深度的关系，如图4所示。可以看出，实验2沿充磁方向扩散，其矫顽力平均值最高，且沿扩散深度的波动变化最小；实验3沿压制方向扩散，其矫顽力在扩散表面形成尖锐峰值，进入到磁体内部1mm处，其矫顽力存在急剧下降现象，且中心位置的矫顽力几近与未扩散磁体相当；实验4，其矫顽力在磁体表层0-3mm处性能阶梯状下降，最外层的矫顽力要由于实验2充磁方向扩散，即其最表层的耐减磁能力要优于实验2，在＞3mm处逐渐趋于平缓，且矫顽力较未扩散磁体高约250kA/m，其耐减磁能力也有一定的提升。
实施例2
制备R1-Fe-M-B基磁体，依照如下组分配比制备原料合金，其中，R1为Nd，含量为31wt％；Dy含量0.5wt％，Co含量为2.0wt％；M为Al、Cu和Ga，含量分别为0.15wt％，0.15wt％和0.1wt％；B含量为0.98％，余量为Fe和不可避免的杂质，如C、N等。钕铁硼基材磁体具体制备过程如下：
a)熔炼：采用真空感应熔炼炉，将上述配备好的原材料放入坩埚中，加热至1460℃，原材料熔化为钢液，将溶解充分的钢液倾倒至急冷辊上，急速降温，在辊面上形核、结晶，并逐渐长大，形成合金鳞片。
b)制粉：所的合金鳞片进行HD破碎处理，然后进行气流磨研磨，获得平均粒径SMD为2.8μm的气流磨粉。
c)压型：向气流磨粉中添加0.2wt％的润滑剂，采用混料机混料180min后，倒入到压机的膜腔中，在2.5T的外加磁场作用下，压制成型。
d)烧结，将压制成的坯体放入到烧结炉中，在1070℃保温270min，然后按照10℃/min的冷却速度急冷达到室温，制成烧结钕铁硼基材磁体。
将基材磁体分别加工为40-8-20和40-8-2.5的方片(20和2.5方向为充磁方向厚度)，按照表3在基材磁体表面的按照涂覆法涂覆Tb金属。
表3 磁体表面Tb金属的不同位置处理示意表
实验编号 磁体尺寸 Tb金属施加位置
5 40-8-2.5 无
6 40-8-20 40*20的2个对面，每个单面均匀涂覆磁体0.2wt％的Tb
7 40-8-2.5 40*8的2个对面，每个单面均匀涂覆磁体0.2wt％的Tb
然后将按照表3处理后的磁体放入扩散炉设备中扩散处理，充真空度达到＜10 -2Pa，然后升温至900℃，保温600min，15℃/min的速率急冷至室温后再升温至550℃保温240min，得到磁体成品。将实验6扩散处理后的40-8-20的方片加工为40-8-2.5的试片，与实验5和实验7的试片一同测试磁性能和成分。测试结果如表4。
表4 磁体成品的性能和成分汇总表
Figure PCTCN2021095528-appb-000003
实验6相比较与实验7，其3mm处矫顽力略低，但是最表层的矫顽力较实验7高156kA/m，可以有效抵御外加磁场对磁体的退磁作用；同时磁矩较高了约0.6％，有效避免了磁矩的降低，保证了磁体磁场的高效输出。
以上，对本发明的实施方式进行了说明。但是，本发明不限定于上述实施方式。凡在本发明的精神和原则之内，所做的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (10)

  1. 一种钕铁硼磁体，其特征在于，所述钕铁硼磁体以化学式R1-R2-Fe-M-B表示，所述钕铁硼磁体具有高矫顽力区域和高剩磁区域的复合结构；
    其中，R1为至少含有Nd的稀土元素，R2为至少含有Dy和/或Tb的重稀土元素，M为至少含有Co的过渡金属元素。
  2. 根据权利要求1所述的钕铁硼磁体，其特征在于，R2在所述钕铁硼磁体中的含量≤1.0wt％，例如≤0.8wt％，优选≤0.5wt％。
  3. 根据权利要求1或2所述的钕铁硼磁体，其特征在于，所述钕铁硼磁体具有R2含量高的高矫顽力区域和具有R2含量低的高剩磁区域；优选地，所述高矫顽力区域和高剩磁区域的分布基本如图1所示。
    优选地，所述高剩磁区域的表层及磁体内部1mm处的R2浓度差△1≤0.1％，
    优选地，所述高矫顽力区域的表层及与所述钕铁硼磁体内部1mm处的R2浓度差△2≥0.15％。
    优选地，所述△2/△1≥1.5，优选△2/△1≥2。
    优选地，所述高矫顽力区域的宽度为1-5mm，优选1.5-4mm，且中心区域具有高剩磁区域；其中，所述高矫顽力区域定义为自表层至磁体内部延伸，R2的浓度差值为1％时，即为高矫顽力区域的宽度。
  4. 根据权利要求1-3任一项所述的钕铁硼磁体，其特征在于，所述R1除含Nd元素外，还含有镧(La)、铈(Ce)、镨(Pr)、钷(Pm)、钐(Sm)、铕(Eu)和钪(Sc)中的至少一种。
    优选地，所述R1在钕铁硼磁体中的含量为28-32wt％。
  5. 根据权利要求1-4任一项所述的钕铁硼磁体，其特征在于，所述R2除含有Dy和/或Tb元素外，还含有钆(Gd)、钬(Ho)、铒(Er)、铥(Tm)、镱(Yb)、镥(Lu)和钇(Y)中的至少一种。
    优选地，所述M除含有Co外，还含有Cu、Ga、Zr、Ti、Al、Mn、Zn和W中的至少一种。
    优选地，所述Co在钕铁硼磁体中的含量为1-3wt％。
    优选地，除Co之外的M中其余过渡金属元素在钕铁硼磁体中的含量≤2wt％。
    优选地，所述B在钕铁硼磁体中的含量为0.5-1.3wt％。
    优选地，所述钕铁硼磁体中还含有不可避免的杂质。
  6. 权利要求1-5任一项所述钕铁硼磁体的制备方法，其特征在于，包括如下步骤：
    制备或准备R1-Fe-M-B基结构的基体磁体，使至少含有Dy和/或Tb的重稀土元素R2在所述基体磁体表面的2个对面上成膜，然后进行扩散处理，R2元素沿基体磁体晶界由磁体表面向内部扩散，并在晶界处富集，得到所述钕铁硼磁体。
  7. 根据权利要求6所述钕铁硼磁体的制备方法，其特征在于，所述基体磁体为规则的六面体。
    优选地，所述2个对面为非垂直于磁体充磁方向且非垂直于磁体成型时压制方向-的2个对面。
    优选地，所述R2元素在磁体表面成膜的方式包括但不限于真空蒸镀、磁控溅射或涂覆方法。优选地，在磁体的2个对面上，真空蒸镀、磁控溅射或涂覆等量的R2元素。
    优选地，所述扩散处理的真空度＜10 -2Pa。
    优选地，所述扩散处理时先进行第一次升温后保温，然后急冷降温，再进行第二次升温和保温后，完成扩散处理。
  8. 权利要求1-5任一项所述钕铁硼磁体在嵌入式电机中的应用。
  9. 一种磁钢，其特征在于，所述磁钢中含有权利要求1-5任一项所述钕铁硼磁体。
  10. 一种嵌入式电机，其特征在于，所述电机含有权利要求1-5任一项钕铁 硼磁体和/或权利要求9所述的磁钢。
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