WO2021244321A1 - 钕铁硼磁体材料、原料组合物、制备方法、应用 - Google Patents

钕铁硼磁体材料、原料组合物、制备方法、应用 Download PDF

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WO2021244321A1
WO2021244321A1 PCT/CN2021/095094 CN2021095094W WO2021244321A1 WO 2021244321 A1 WO2021244321 A1 WO 2021244321A1 CN 2021095094 W CN2021095094 W CN 2021095094W WO 2021244321 A1 WO2021244321 A1 WO 2021244321A1
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mas
main alloy
mass percentage
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alloy
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French (fr)
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骆溁
师大伟
廖宗博
陈志庆
黄佳莹
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厦门钨业股份有限公司
福建省长汀金龙稀土有限公司
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Definitions

  • the invention specifically relates to a neodymium iron boron magnet material, a raw material composition, a preparation method and an application.
  • NdFeB rare earth magnet materials have the characteristics of high remanence, high coercivity and high energy product, they are widely used in power electronics, communications, information, motors, transportation, office automation, medical equipment, military and other fields, and make The market application of some small, highly integrated high-tech products is possible, such as voice coil motors (VCM) for hard drives, hybrid vehicles (HEV), electric vehicles, etc.
  • VCM voice coil motors
  • HEV hybrid vehicles
  • Tb 2 Fe 14 B and Dy 2 Fe 14 B which have high magnetocrystalline anisotropy field (HA), and directly add pure metals of Tb and Dy during alloy smelting, or contain Tb , Dy alloy to improve the coercivity of neodymium iron boron magnets, but due to the formation of Tb, Dy elements Tb 2 Fe 14 B, Dy 2 Fe 14 B saturation magnetization (Ms) is much lower than Nd 2 Fe 14 B, It will cause the remanence of the magnet to be significantly reduced, and the addition of Tb and Dy heavy rare earth elements in this process is relatively large, and the cost of the raw material composition is high.
  • HA magnetocrystalline anisotropy field
  • the dual alloy method is a method to increase the coercivity by improving the microstructure of the magnet and the boundary structure of the magnetic phase.
  • the existing dual alloy method generally uses alloys rich in heavy rare earth elements as the auxiliary phase, and the main phase alloy The composition is close to the stoichiometric ratio of Nd 2 Fe 14 B; then the main and auxiliary phases are mixed and then pressed, sintered, and annealed to obtain a magnet.
  • This method is not limited by the size of the permanent magnet, but due to the need to use heavy rare earth metals in the auxiliary alloy, it causes a waste of heavy rare earth metals.
  • the technical problem to be solved by the present invention is to overcome the need to use heavy rare earth metals in the existing double alloy method, and heavy rare earth metals are expensive and rare defects, and provide a neodymium iron boron magnet material, raw material composition, preparation method, and application .
  • TRE is less than 29mas%, magnet sintering becomes difficult, and the prepared magnet has a low degree of densification.
  • the microstructure of NdFeB magnets with lower rare earth concentration (TRE is less than 29mas%) is mainly the main phase, with very few rare earth-rich phases; while the microstructure of NdFeB magnets with higher rare earth concentration
  • the structure in addition to the main phase, there are more rare-earth-rich phases; after the two are mixed, the rare-earth-rich phase in the neodymium-iron-boron magnet with high rare-earth concentration can be better than the rare-earth-rich phase in the single alloy.
  • the main phase melts in the subsequent sintering process and is continuously wrapped around the main phase crystal grains; at the same time, in conjunction with the N element of the present application, it can reduce the area of the grain boundary triangle area and improve the densification degree and grain boundary of the magnet Continuity, thereby improving remanence and coercivity.
  • One of the objectives of the present invention is to provide a raw material composition of a neodymium iron boron magnet material, which comprises a main alloy A, a main alloy B and a rare earth metal R1; R1, 0.2-1 mas%,
  • the main Alloy A in percentage by mass, which comprises a rare earth metal R A, and R A comprises Nd, R A, 27.5 ⁇ 28.5mas %; N1,0 ⁇ 0.3mas%; B, 0.94 ⁇ 1.1mas%; Fe, 60 ⁇ 71.5mas%; the sum of each component is 100mas%; mas% refers to the mass percentage in the main alloy A;
  • main alloy B in terms of mass percentage, it includes rare earth metal R B , and R B includes Nd, R B , 29-31mas%; N2, 0-0.3mas%; B, 0.85-1mas%; Fe, 60 ⁇ 70mas%; the sum of each component is 100mas%, and mas% refers to the mass percentage in the main alloy B;
  • N1 and N2 are not 0 at the same time;
  • both N1 and N2 include one or more of Bi, Sn, Zn, Cu, Ga, In, Au, Ag, and Pb;
  • the mass ratio of the main alloy A and the main alloy B is 50:50 to 95:5.
  • R A is the content range is preferably 27.59 ⁇ 28.2mas%, e.g. 28.1mas%, mas% refers to the mass percentage A of the main alloy.
  • the Nd content can range from 27.5 to 28.5 mas%, preferably 27.5 to 28 mas%, for example, 27.5 mas%, and mas% refers to the mass percentage in the main alloy A.
  • said R A does not contain heavy rare earth metal. More preferably, R A comprises a Nd only.
  • the R A may further comprise one or more of Pr, La, Ce, Dy and Tb.
  • the R A comprises one or more Pr, Dy and Tb.
  • mas% refers to the mass percentage A of the main alloy.
  • range of the content of Pr is preferably 0 ⁇ 1mas%, not 0, e.g. 0.01mas% or 0.5mas%, mas% means that the main Alloy A The mass percentage in.
  • the Dy content is preferably the range is 0 ⁇ 0.1mas%, not 0, e.g. 0.05mas%, mas% by mass in the main means of Alloy A percentage.
  • said Tb is preferably an amount ranging for 0 ⁇ 0.1mas%, not 0, e.g. 0.03mas%, mas% by mass in the main means of Alloy A percentage.
  • the ratio of the mass of Pr, the Dy or Tb and the conventional art may be, for example, 1: 5: 3.
  • the ratio of the mass of Pr, the Dy or Tb and the conventional art may be, for example, 1: 5: 3.
  • the content of N1 is preferably 0.07-0.3 mas%, and mas% refers to the mass percentage in the main alloy A.
  • the type of N1 preferably includes one or more of Cu, Ga, Zn and Bi. More preferably, the type of N1 includes Cu and/or Ga. More preferably, the type of N1 is Cu and/or Ga.
  • the content of Cu is preferably 0.05 to 0.15 mas%, such as 0.07 mas% or 0.1 mas%, and mas% refers to the mass percentage in the main alloy A .
  • the content of Ga is preferably 0.1-0.2 mas%, such as 0.15 mas%, and mas% refers to the mass percentage in the main alloy A.
  • the content of Zn is preferably 0.1-0.2 mas%, and mas% refers to the mass percentage in the main alloy A.
  • the content of Bi is preferably 0.1-0.2 mas%, such as 0.15 mas%, 0.1 mas% or 0.02 mas%, and mas% refers to the content in the main alloy A The mass percentage in.
  • the mass ratio of Cu and Ga may be conventional in the art, such as 2:3.
  • the mass ratio of Zn and Bi may be conventional in the art, such as 2:3 or 2:1.
  • the mass ratio of Ga and Bi may be conventional in the art, such as 5:1.
  • the content of B in the main alloy A is preferably 0.97-1.1 mas%, such as 1 mas%, and mas% refers to the mass percentage in the main alloy A.
  • the content of R B in the main alloy B preferably ranges from 30 to 31 mas%, such as 30.09 mas% or 30.2 mas%, and mas% refers to the mass percentage in the main alloy B .
  • the content of Nd in the main alloy B is preferably 28.9 to 31 mas%, such as 30 mas%, 29.5 mas% or 30.2 mas%, and mas% refers to the content in the main alloy B The mass percentage.
  • said R B free of heavy rare earth metal. More preferably, the R B contains only Nd.
  • the R B may further comprise one or more of Pr, La, Ce, Dy and Tb.
  • the R B comprises one or more Pr, Dy and Tb.
  • R B rare earth elements other than Nd is preferably used in an amount not more than 0.1mas%
  • mas% refers to the percentage by mass of the master alloy B is.
  • the content of the Pr preferably ranges from 0 to 1 mas% and is not 0, such as 0.01 mas% or 0.5 mas%, and mas% refers to the content in the main alloy B The mass percentage in.
  • the content of the Dy is preferably in the range of 0 to 0.1 mas%, and not 0, for example, 0.05 mas%, and mas% refers to the mass in the main alloy B percentage.
  • the content of the Tb is preferably in the range of 0-0.1 mas% and not 0, such as 0.03 mas%, and mas% refers to the mass in the main alloy B percentage.
  • R B comprises Pr, Dy and Tb
  • the ratio of the mass of Pr, the Dy or Tb and the conventional art may be, for example, 1: 5: 3.
  • the content of N2 is preferably 0.07-0.3 mas%, and mas% refers to the mass percentage in the main alloy B.
  • the type of N2 preferably includes one or more of Cu, Ga, Zn and Bi. More preferably, the type of N2 includes Cu and/or Ga. More preferably, the type of N2 is Cu and/or Ga.
  • the content of Cu is preferably 0.05-0.15 mas%, such as 0.07 mas% or 0.1 mas%, and mas% refers to the mass percentage in the main alloy B .
  • the content of Ga is preferably 0.1-0.2 mas%, for example 0.15 mas%, and mas% refers to the mass percentage in the main alloy B.
  • the content of Zn is preferably 0.1-0.2 mas%, and mas% refers to the mass percentage in the main alloy B.
  • the content of Bi is preferably 0.1-0.2 mas%, such as 0.15 mas%, 0.1 mas% or 0.02 mas%, and mas% refers to the content in the main alloy B The mass percentage in.
  • the mass ratio of Cu and Ga may be conventional in the art, such as 2:3.
  • the mass ratio of Zn and Bi may be conventional in the art, such as 2:3 or 2:1.
  • the mass ratio of Ga and Bi may be conventional in the art, such as 5:1.
  • the content of B is preferably in the range of 0.95 to 1 mas%, and mas% refers to the mass percentage in the main alloy B.
  • the difference between the total content of R A and R B of the absolute value of preferably 0.5 to 3.5%, more preferably from 0.5% to 2.5%.
  • the main alloy A and/or the main alloy B preferably further includes M, and the M includes Ti, Co, Ni, V, Nb, Ta, Cr, Mo, W, Mn, Zr and One or more of Hf.
  • the content of M is in the range of 0.08% to 0.48%.
  • the type of M includes one or more of Zr, Ti, Nb, and Co.
  • the content of the Zr is preferably 0.1-0.2 mas%, for example 0.15 mas%, and mas% refers to the mass percentage in the main alloy A.
  • the content of Ti is preferably 0.1-0.2 mas%, and mas% refers to the mass percentage in the main alloy A.
  • the content of the Nb is preferably 0-0.05 mas% and not 0, for example, 0.02 mas%.
  • the mas% refers to the mass percentage in the main alloy A.
  • the content of Co is preferably 0-0.5 mas% and not 0, more preferably 0-0.4 mas% and not 0, such as 0.05 mas% or 0.25mas%, mas% refers to the mass percentage in the main alloy A.
  • the content of Zr is preferably 0.1-0.2 mas%, such as 0.15 mas%, and mas% refers to the mass percentage in the main alloy B.
  • the content of Ti is preferably 0.1-0.2 mas%, and mas% refers to the mass percentage in the main alloy B.
  • the content of Nb is preferably 0-0.05 mas% and not 0, such as 0.02 mas%. mas% refers to the mass percentage in the main alloy B.
  • the content of Co is preferably 0-0.5 mas% and not 0, more preferably 0-0.4 mas% and not 0, such as 0.05 mas% or 0.25mas%, mas% refers to the mass percentage in the main alloy B.
  • the content of R1 is preferably 0.2 to 0.6 mas% or 0.5 to 0.9 mas%, such as 0.25 mas%, 0.5 mas%, 0.81 mas% or 0.7 mas%.
  • the mass percentage in the raw material composition of the iron-boron magnet material is preferably 0.2 to 0.6 mas% or 0.5 to 0.9 mas%, such as 0.25 mas%, 0.5 mas%, 0.81 mas% or 0.7 mas%.
  • the type of R1 may include one or more of Pr, Dy, Tb, Ho, and Gd.
  • the type of R1 includes one or more of Pr, Tb and Dy. More preferably, the type of R1 is Tb and/or Dy.
  • the content of the Pr preferably ranges from 0 to 0.1 mas%, and is not 0, for example, 0.05 mas%.
  • the mas% refers to the raw material of the neodymium iron boron magnet material.
  • the Pr is added in the form of a PrCu alloy.
  • the percentage of Cu in the PrCu is 0.1-17mas%.
  • the content of Dy preferably ranges from 0 to 0.5 mas% and is not 0, such as 0.2 mas% or 0.3 mas%, and mas% refers to the content of the neodymium iron boron The mass percentage in the raw material composition of the magnet material.
  • the content of Tb preferably ranges from 0.2 to 0.6 mas%, such as 0.5 mas%, and mas% refers to the mass in the raw material composition of the neodymium iron boron magnet material percentage.
  • the mass ratio of the Pr and the Dy may be conventional in the art, for example, 1:4.
  • the mass ratio of Tb and Dy may be conventional in the art, such as 2:3 or 3:5.
  • the mass ratio of the Pr, the Tb, and the Dy may be conventional in the art, for example, 1:50:30.
  • the quality of the main alloy A and the main alloy B is preferably 50:50 to 80:20, such as 60:40 or 75:25.
  • the raw material composition of the neodymium iron boron magnet material can be any one of the following numbers 1-11 (mas%):
  • the main alloy A is any one of the following numbers 1-6 (mas%):
  • the main alloy B is any one of the following numbers 1-7 (mas%):
  • the second objective of the present invention is to provide a method for preparing a neodymium iron boron magnet material, which comprises the following steps: melting the main alloy A and the main alloy B in the raw material composition of the neodymium iron boron magnet material The liquid is melted and casted separately to obtain the main alloy flakes A and the main alloy flakes B; the mixture of the main alloy flakes A and the main alloy flakes B through hydrogen crushing and pulverization is subjected to forming and sintering treatments, and then subjected to the R1 grain boundary diffusion treatment is sufficient.
  • the preparation method includes the following steps: separately casting the melts of the main alloy A and the main alloy B in the raw material composition of the neodymium iron boron magnet material to obtain the main alloy Flake A and main alloy flake B; the mixture of the main alloy flake A and the main alloy flake B is subjected to hydrogen crushing, fine pulverization, forming and sintering treatment, and then the R1 grain boundary diffusion treatment is required;
  • the preparation method includes the following steps: separately casting the melts of the main alloy A and the main alloy B in the raw material composition of the neodymium iron boron magnet material to obtain the main alloy flakes A and the main alloy Sheet B; the main alloy sheet A and the main alloy sheet B are respectively subjected to hydrogen crushing, and then the mixture of the main alloy sheet A and the main alloy sheet B is subjected to fine pulverization, forming and sintering treatment, and then subjected to The R1 grain boundary diffusion treatment is sufficient;
  • the preparation method includes the following steps: separately casting the melts of the main alloy A and the main alloy B in the raw material composition of the neodymium iron boron magnet material to obtain the main alloy flakes A and the main alloy Sheet B; the main alloy sheet A and the main alloy sheet B are respectively subjected to hydrogen crushing and fine pulverization, the mixture of the main alloy sheet A and the main alloy sheet B is formed and sintered, and then subjected to the The R1 grain boundary diffusion treatment is sufficient.
  • the melting temperature may be 1300-1700°C.
  • the smelting equipment is generally a high-frequency vacuum smelting furnace, such as a high-frequency vacuum induction quick-setting ribbon spinning furnace.
  • the operation and conditions of the hydrogen crushing can be conventional pulverizing processes in the field, and the hydrogen crushing generally includes hydrogen absorption, dehydrogenation and cooling treatment.
  • the temperature of the hydrogen absorption is generally 20-200°C.
  • the temperature of the dehydrogenation is generally 400-650°C.
  • the pressure of the hydrogen absorption is generally 50-600 kPa.
  • the operation and conditions of the fine pulverization can be conventional powder milling processes in the field.
  • the fine pulverization is generally achieved by air-jet milling, and the air-jet milling powder is generally carried out under the conditions of 0.1-2 MPa, preferably 0.5-0.7 MPa.
  • the gas stream in the gas stream milling powder can be, for example, nitrogen gas and/or argon gas.
  • the efficiency of the air jet milling powder may vary according to different equipment, for example, it may be 30-400 kg/h, and for example 200 kg/h.
  • the forming operation and conditions can be conventional forming processes in the field.
  • the magnetic field forming method for example, the magnetic field forming method.
  • the magnetic field strength of the magnetic field shaping method is generally above 1.5T.
  • the sintering operation and conditions can be conventional sintering processes in the field, such as vacuum sintering process and/or inert atmosphere sintering process.
  • the vacuum sintering process or the inert atmosphere sintering process are conventional operations in the art.
  • an inert atmosphere sintering process is used, the initial stage of the sintering can be performed under the condition of a vacuum degree of less than 5 ⁇ 10 ⁇ 1 Pa.
  • the inert atmosphere may be a conventional atmosphere containing inert gas in the art, and is not limited to helium and argon.
  • the sintering temperature may be 1000-1200°C, preferably 1030-1090°C.
  • the sintering time may be 0.5-10h, preferably 2-8h.
  • the grain boundary diffusion treatment can be processed according to a conventional process in the field, for example, the grain boundary diffusion treatment can be realized by an R1 metal coating operation, a vapor phase physical precipitation operation, or an evaporation operation.
  • the R1 is generally coated in the form of fluoride or a low melting point alloy, such as fluoride of Tb.
  • Dy is further contained, it is preferable that Dy is coated in the form of fluoride of Dy.
  • Pr is also contained, it is preferable to add Pr in the form of a PrCu alloy.
  • the R1 contains Pr and Pr participates in the grain boundary diffusion in the form of a PrCu alloy
  • Cu is added during the grain boundary diffusion in the preparation method, or is added during the smelting and grain boundary diffusion steps at the same time
  • the content of Cu is preferably 0.03 ⁇ 0.15mas%
  • mas% is the mass percentage of the element in the raw material composition; wherein the Cu accounts for the PrCu The percentage is 0.1-17mas%.
  • the fluoride of the heavy rare earth metal used or other elements introduced in the alloy are not included in the category of the raw material composition.
  • the temperature of the grain boundary diffusion may be 800-1000°C, for example, 900°C.
  • the time for the grain boundary diffusion may be 12-90h, such as 24h.
  • heat treatment is also performed according to the conventional practice in the art.
  • the temperature of the heat treatment may be 480°C-700°C.
  • the heat treatment time may be 2-4 hours, for example, 3 hours.
  • lubricants, etc. are generally added during the preparation process, and the content of carbon impurities introduced is conventional in the field, and is generally below 1000 ppm, which is not included in the scope of the raw material composition.
  • the means for controlling the oxygen content can be conventional in the field and not included in the scope of the raw material composition.
  • the third objective of the present invention is to provide a neodymium iron boron magnet material, which is prepared according to the above-mentioned preparation method.
  • the grain boundary continuity in the phase structure of the neodymium iron boron magnet material is 98% or more, such as 99.5%, 98.23%, 98.9%, 98.52%, 98.41%, 99.37%, 98.95%, 99.52%, 98.84%, 98.65% or 99.31%, more preferably 99% or more.
  • the calculation method of grain boundary continuity refers to the ratio of the length occupied by phases other than voids in the grain boundary (for example, the B-rich phase and the rare earth-rich phase are equal) to the total grain boundary length. Grain boundary continuity exceeding 96% can be called continuous channel.
  • the phase structure of the neodymium iron boron magnet material includes a grain boundary triangular region, and the area of the grain boundary triangular region accounts for 1 to 2.5%, such as 2.03%, 1.32%, 1.56%, 1.33%, 1.34%, 1.24%, 1.19%, 1.42%, 1.45%, 1.48% or 1.39%, more preferably 1.2 to 1.5%.
  • the grain boundary triangle area generally refers to the place where three or more grain boundary phases intersect, and there are B-rich phases, rare earth-rich phases, rare earth oxides, rare earth carbides and cavities distributed.
  • the calculation method of the area ratio of the grain boundary triangle area refers to the ratio of the area of the grain boundary triangle area to the total area (main phase + grain boundary).
  • the density of NdFeB magnetic material is preferably 7.54 ⁇ 8g / cm 3, for example 7.55g / cm 3, 7.56g / cm 3 or 7.57g / cm 3.
  • the fourth object of the present invention is to provide an application of neodymium iron boron magnet material in a motor.
  • the reagents and raw material compositions used in the present invention are all commercially available.
  • the grain boundary continuity of the neodymium iron boron magnet material of the present invention is increased to more than 98%;
  • the area of the triangular area in the phase structure of the neodymium iron boron magnet material of the present invention can be reduced to 1 to 2.5%;
  • the absolute value of the Br temperature coefficient of the neodymium iron boron magnet material of the present invention from 20 to 120°C can be as low as 0.101 to 0.105%/°C.
  • Br of the neodymium iron boron magnet material of the present invention is greater than or equal to 14.9kGs, and Hcj can reach more than 25kOe;
  • the adaptability of the sintering temperature of the neodymium iron boron magnet material of the present invention is better, which can reach 25-30°C.
  • Figure 1 is the FE-EPMA diagram of Example 3 NdFeB magnet material.
  • the preparation method of neodymium iron boron permanent magnet material is as follows:
  • Airflow milling process Under the nitrogen atmosphere, the hydrogen crushed powder is pulverized by airflow under the condition of 0.65MPa in the crushing chamber (the efficiency of airflow milling may vary depending on the equipment. For example, it can be 200kg/h) to obtain fine powder.
  • each molded body is moved to a sintering furnace for sintering, sintered under a vacuum of less than 0.5 Pa, and sintered at 1050°C for 6 hours to obtain a neodymium iron boron permanent magnet material matrix.
  • composition and content of the neodymium iron boron permanent magnet materials in Table 4 below are nominal compositions calculated from the data in Tables 1 to 3, ignoring losses.
  • Figure 1 is the FE-EPMA diagram of Example 3 NdFeB magnet material, in which 1 is the main phase, 2 is the grain boundary phase, and 3 is the grain boundary triangle region.
  • Temperature stability is generally expressed by the temperature variation coefficient of various magnetic properties, which refers to the percentage of change in magnetic properties for every temperature change of 1°C, which characterizes the magnetic properties of permanent magnet materials in the external temperature field.
  • the temperature coefficient of remanence of the neodymium-iron-boron magnet material of the present invention is equivalent to that of the comparative example, or even better; when the same type of heavy rare-earth metal is used for diffusion, the coercive force is significantly higher than that of the comparative example (Examples 2-11); That is, compared to the comparative example, the rare earth-rich phase can be better evenly distributed around each main phase, melted in the subsequent sintering process, and continuously wrapped around the main phase crystal grains; at the same time, it can cooperate with the N element of the present application , Can reduce the area of the grain boundary triangle area, improve the density of the magnet and the continuity of the grain boundary, thereby increasing the remanence and coercivity.

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Abstract

本发明公开了钕铁硼磁体材料、其原料组合物、其制备方法和应用。原料组合物包括R1，0.2～1mas％，主合金A中，其包括R A、且R A包括Nd，R A，27.5～28.5mas％；N1，0～0.3mas％；B，0.94～1.1mas％；Fe，60～71.5mas％；各组分之和为100mas％；主合金B中，其包括R B、且R B包括Nd，R B，29～31mas％；N2，0～0.3mas％；B，0.85～1mas％；Fe，60～70mas％；N1和N2的含量不同时为0；主合金A和主合金B的质量比为50:50～95:5。由该原料组合物制得的钕铁硼磁体材料的晶界连续性提高、三角区面积减少、温度系数降低。

Description

钕铁硼磁体材料、原料组合物、制备方法、应用 技术领域
本发明具体涉及一种钕铁硼磁体材料、原料组合物、制备方法、应用。
背景技术
由于钕铁硼稀土磁体材料具有高剩磁、高矫顽力和高磁能积的特点，广泛应用于电力电子、通讯、信息、电机、交通运输、办公自动化、医疗器械、军事等领域，并使一些小型、高度集成的高新技术产品的市场应用成为可能，例如硬盘用音圈电机(VCM)，混合动力汽车(HEV)，电动车等。要满足以上市场需求，需要以更低的成本制备出同时具备高剩磁和高矫顽力的钕铁硼磁体。
目前，现有技术中制备钕铁硼永磁体的方式主要有以下两种：
1)单合金制备工艺：利用Tb 2Fe 14B、Dy 2Fe 14B具有较高的磁晶各向异性场(HA)，直接在合金熔炼过程中添加Tb、Dy的纯金属，或者含Tb、Dy的合金以提高钕铁硼磁体的矫顽力，但由于Tb、Dy元素形成的Tb 2Fe 14B、Dy 2Fe 14B的饱和磁化强度(Ms)大大低于Nd 2Fe 14B，会造成磁体的剩磁明显降低，且该工艺Tb、Dy重稀土元素的添加量比较大，原料组合物成本很高。
2)双合金法是一种通过改善磁体的微观组织和磁性相的边界结构来提高矫顽力的方法，现有的双合金法一般以富含重稀土元素的合金作为辅相，主相合金成分接近Nd 2Fe 14B化学成分计量比；然后将主辅相混合后经压制、烧结、退火制得磁体。此方法不受永磁体尺寸限制，但由于辅合金中需要使用重稀土金属，造成对重稀土金属的浪费。
发明内容
本发明要解决的技术问题是克服现有的双合金法中需要使用重稀土金 属、而重稀土金属昂贵且稀有的缺陷，而提供一种钕铁硼磁体材料、原料组合物、制备方法、应用。
在常规的钕铁硼磁体制造技术中，TRE小于29mas％，磁体烧结变得困难，且所制备的磁体致密化程度低。发明人经过创造性的劳动发现，较低稀土浓度(TRE小于29mas％)的钕铁硼磁体的微观结构中主要是主相，富稀土相很少；而较高稀土浓度的钕铁硼磁体的微观结构中，除了主相，还有较多富稀土相；两者混合后，高稀土浓度的钕铁硼磁体中的富稀土相可以比单合金中的富稀土相，更好地均匀分布在各个主相周围，在后续的烧结过程中熔化，并连续包裹分布在主相晶粒周围；同时与本申请的N元素配合，能够减少晶界三角区的面积，提高磁体的致密化程度和晶界连续性，从而提高剩磁和矫顽力。
本发明是通过以下技术方案来解决上述技术问题的：
本发明的目的之一，提供一种钕铁硼磁体材料的原料组合物，其包括主合金A、主合金B和稀土金属R1；R1，0.2～1mas％，
所述主合金A中，以质量百分比计，其包括稀土金属R A、且R A包括Nd，R A，27.5～28.5mas％；N1，0～0.3mas％；B，0.94～1.1mas％；Fe，60～71.5mas％；各组分之和为100mas％；mas％是指在所述主合金A中的质量百分比；
所述主合金B中，以质量百分比计，其包括稀土金属R B、且R B包括Nd，R B，29～31mas％；N2，0～0.3mas％；B，0.85～1mas％；Fe，60～70mas％；各组分之和为100mas％，mas％是指在所述主合金B中的质量百分比；
所述N1和N2的含量不同时为0；
所述主合金A和所述主合金B中，N1和N2均包括Bi、Sn、Zn、Cu、Ga、In、Au、Ag和Pb中的一种或多种；
所述主合金A和所述主合金B的质量比为50:50～95:5。
本发明中，较佳地，所述R A的含量范围较佳地为27.59～28.2mas％，例如28.1mas％，mas％是指在所述主合金A中的质量百分比。
本发明中，所述Nd的含量范围可为27.5～28.5mas％，较佳地为27.5～28mas％，例如27.5mas％，mas％是指在所述主合金A中的质量百分比。
本发明中，较佳地，所述R A不含重稀土金属。更佳地，所述R A仅包含Nd。
本发明中，所述R A还可包括Pr、La、Ce、Dy和Tb中的一种或多种。较佳地，所述R A包括Pr、Dy和Tb中的一种或多种。
其中，所述R A中除Nd之外的稀土元素用量较佳地不超过0.1mas％，mas％是指在所述主合金A中的质量百分比。
其中，当所述R A包括Pr时，所述Pr的含量范围较佳地为0～1mas％、且不为0，例如0.01mas％或者0.5mas％，mas％是指在所述主合金A中的质量百分比。
其中，当所述R A包括Dy时，所述Dy的含量范围较佳地为0～0.1mas％、且不为0，例如0.05mas％，mas％是指在所述主合金A中的质量百分比。
其中，当所述R A包括Tb时，所述Tb的含量范围较佳地为0～0.1mas％、且不为0，例如0.03mas％，mas％是指在所述主合金A中的质量百分比。
其中，当所述R A包括Pr、Dy和Tb时，所述Pr、所述Dy和所述Tb的质量比例可为本领域常规，例如1:5:3。
其中，当所述R A包括Pr、Dy和Tb时，所述Pr、所述Dy和所述Tb的质量比例可为本领域常规，例如1:5:3。
本发明中，所述N1的含量较佳地为0.07～0.3mas％，mas％是指在所述主合金A中的质量百分比。
本发明中，所述N1的种类较佳地包括Cu、Ga、Zn和Bi中的一种或多种。更佳地，所述N1的种类包括Cu和/或Ga。更佳地，所述N1的种类为Cu和/或Ga。
其中，当所述N1的种类包含Cu时，所述Cu的含量较佳地为0.05～0.15mas％，例如0.07mas％或者0.1mas％，mas％是指在所述主合金A中的质量百分比。
其中，当所述N1的种类包含Ga时，所述Ga的含量较佳地为0.1～0.2mas％，例如0.15mas％，mas％是指在所述主合金A中的质量百分比。
其中，当所述N1的种类包含Zn时，所述Zn的含量较佳地为0.1～0.2mas％，mas％是指在所述主合金A中的质量百分比。
其中，当所述N1的种类包含Bi时，所述Bi的含量较佳地为0.1～0.2mas％，例如0.15mas％、0.1mas％或者0.02mas％，mas％是指在所述主合金A中的质量百分比。
其中，当所述N1的种类包含Cu和Ga时，所述Cu和所述Ga的质量比例可为本领域常规，例如2:3。
其中，当所述N1的种类包含Zn和Bi时，所述Zn和所述Bi的质量比例可为本领域常规，例如2:3或者2:1。
其中，当所述N1的种类包含Ga和Bi时，所述Ga和所述Bi的质量比例可为本领域常规，例如5:1。
本发明中，所述主合金A中B含量较佳地为0.97～1.1mas％，例如1mas％，mas％是指在所述主合金A中的质量百分比。
本发明中，所述主合金B中，所述R B的含量范围较佳地为30～31mas％，例如30.09mas％或者30.2mas％，mas％是指在所述主合金B中的质量百分比。
本发明中，所述主合金B中，所述Nd的含量范围较佳地为28.9～31mas％，例如30mas％、29.5mas％或者30.2mas％，mas％是指在所述主合金B中的质量百分比。
本发明中，较佳地，所述R B不含重稀土金属。更佳地，所述R B仅包含Nd。
本发明中，所述R B还可包括Pr、La、Ce、Dy和Tb中的一种或多种。较佳地，所述R B包括Pr、Dy和Tb中的一种或多种。
其中，所述R B中除Nd之外的稀土元素用量较佳地不超过0.1mas％，mas％是指在所述主合金B中的质量百分比。
其中，当所述R B包括Pr时，所述Pr的含量范围较佳地为0～1mas％、且不为0，例如0.01mas％或者0.5mas％，mas％是指在所述主合金B中的质量百分比。
其中，当所述R B包括Dy时，所述Dy的含量范围较佳地为0～0.1mas％、且不为0，例如0.05mas％，mas％是指在所述主合金B中的质量百分比。
其中，当所述R B包括Tb时，所述Tb的含量范围较佳地为0～0.1mas％、且不为0，例如0.03mas％，mas％是指在所述主合金B中的质量百分比。
其中，当所述R B包括Pr、Dy和Tb时，所述Pr、所述Dy和所述Tb的质量比例可为本领域常规，例如1:5:3。
本发明中，所述N2的含量较佳地为0.07～0.3mas％，mas％是指在所述主合金B中的质量百分比。
本发明中，所述N2的种类较佳地包括Cu、Ga、Zn和Bi中的一种或多种。更佳地，所述N2的种类包括Cu和/或Ga。更佳地，所述N2的种类为Cu和/或Ga。
其中，当所述N2的种类包含Cu时，所述Cu的含量较佳地为0.05～0.15mas％，例如0.07mas％或者0.1mas％，mas％是指在所述主合金B中的质量百分比。
其中，当所述N2的种类包含Ga时，所述Ga的含量较佳地为0.1～0.2mas％，例如0.15mas％，mas％是指在所述主合金B中的质量百分比。
其中，当所述N2的种类包含Zn时，所述Zn的含量较佳地为0.1～0.2mas％，mas％是指在所述主合金B中的质量百分比。
其中，当所述N2的种类包含Bi时，所述Bi的含量较佳地为0.1～0.2mas％，例如0.15mas％、0.1mas％或者0.02mas％，mas％是指在所述主合金B中的质量百分比。
其中，当所述N2的种类包含Cu和Ga时，所述Cu和所述Ga的质量比例可为本领域常规，例如2:3。
其中，当所述N2的种类包含Zn和Bi时，所述Zn和所述Bi的质量比 例可为本领域常规，例如2:3或者2:1。
其中，当所述N2的种类包含Ga和Bi时，所述Ga和所述Bi的质量比例可为本领域常规，例如5:1。
本发明中，所述合金B中，所述B的含量范围较佳地为0.95～1mas％，mas％是指在所述主合金B中的质量百分比。
本发明中，所述R A和R B的含量之差的绝对值较佳地为0.5-3.5％，更佳地为0.5～2.5％。
本发明中，所述主合金A和/或所述主合金B较佳地还包括M，所述M包括Ti、Co、Ni、V、Nb、Ta、Cr、Mo、W、Mn、Zr和Hf中的一种或多种。
其中，较佳地，所述M的含量范围为0.08～0.48％。
其中，较佳地，所述M的种类包括Zr、Ti、Nb和Co中的一种或多种。
当所述主合金A包含Zr时，所述Zr的含量较佳地为0.1～0.2mas％，例如0.15mas％，mas％是指在所述主合金A中的质量百分比。
当所述主合金A包含Ti时，所述Ti的含量较佳地为0.1～0.2mas％，mas％是指在所述主合金A中的质量百分比。
当所述主合金A包含Nb时，所述Nb的含量较佳地为0～0.05mas％、且不为0，例如0.02mas％，mas％是指在所述主合金A中的质量百分比。
当所述主合金A包含Co时，所述Co的含量较佳地为0～0.5mas％、且不为0，更佳地为0～0.4mas％、且不为0，例如0.05mas％或者0.25mas％，mas％是指在所述主合金A中的质量百分比。
当所述主合金B包含Zr时，所述Zr的含量较佳地为0.1～0.2mas％，例如0.15mas％，mas％是指在所述主合金B中的质量百分比。
当所述主合金B包含Ti时，所述Ti的含量较佳地为0.1～0.2mas％，mas％是指在所述主合金B中的质量百分比。
当所述主合金B包含Nb时，所述Nb的含量较佳地为0～0.05mas％、且不为0，例如0.02mas％，mas％是指在所述主合金B中的质量百分比。
当所述主合金B包含Co时，所述Co的含量较佳地为0～0.5mas％、且不为0，更佳地为0～0.4mas％、且不为0，例如0.05mas％或者0.25mas％，mas％是指在所述主合金B中的质量百分比。
本发明中，所述R1的含量较佳地为0.2～0.6mas％或者0.5～0.9mas％，例如0.25mas％、0.5mas％、0.81mas％或者0.7mas％，mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比。
本发明中，所述R1的种类可包括Pr、Dy、Tb、Ho和Gd中的一种或多种。较佳地，所述R1的种类包括Pr、Tb和Dy中的一种或多种。更佳地，所述R1的种类为Tb和/或Dy。
其中，当所述R1包括Pr时，所述Pr的含量范围较佳地为0～0.1mas％、且不为0，例如0.05mas％，mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比。较佳地，所述Pr以PrCu合金的形式添加。其中所述Cu占所述PrCu的百分比为0.1～17mas％。
其中，当所述R1包括Dy时，所述Dy的含量范围较佳地为0～0.5mas％、且不为0，例如0.2mas％或者0.3mas％，mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比。
其中，当所述R1包括Tb时，所述Tb的含量范围较佳地为0.2～0.6mas％，例如0.5mas％，mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比。
其中，当所述R1包括Pr和Dy时，所述Pr和所述Dy的质量比例可为本领域常规，例如1:4。
其中，当所述R1包括Tb和Dy时，所述Tb和所述Dy的质量比例可为本领域常规，例如2:3或者3:5。
其中，当所述R1包括Pr、Tb和Dy时，所述Pr、所述Tb和所述Dy的质量比例可为本领域常规，例如1:50:30。
本发明中，所述主合金A和所述主合金B的质量比较佳地为50:50～80:20，例如60:40或者75:25。
在本发明较佳实施方式中，所述钕铁硼磁体材料的原料组合物可为下述编号1-11中的任意一种(mas％)：
Figure PCTCN2021095094-appb-000001
其中主合金A分别为下述编号1-6中的任意一种(mas％)：
Figure PCTCN2021095094-appb-000002
其中主合金B分别为下述编号1-7中的任意一种(mas％)：
Figure PCTCN2021095094-appb-000003
本发明的目的之二，提供一种钕铁硼磁体材料的制备方法，其包括以下步骤：将前述钕铁硼磁体材料的原料组合物中的所述主合金A和所述主合金B的熔融液分别进行熔炼和铸造，即得主合金片A和主合金片B；将所述主合金片A和所述主合金片B经氢破碎、微粉碎的混合物进行成形和烧结处 理，之后经所述R1晶界扩散处理即可。
本发明中，较佳地，所述制备方法包括以下步骤：将前述钕铁硼磁体材料的原料组合物中的所述主合金A和所述主合金B的熔融液分别进行铸造，即得主合金片A和主合金片B；将所述主合金片A和所述主合金片B的混合物经氢破碎、微粉碎、成形和烧结处理，之后经所述R1晶界扩散处理即可；
或者，所述制备方法包括以下步骤：将所述钕铁硼磁体材料的原料组合物中的所述主合金A和所述主合金B的熔融液分别进行铸造，即得主合金片A和主合金片B；将所述主合金片A和所述主合金片B分别进行氢破碎，之后将所述主合金片A和所述主合金片B的混合物经微粉碎、成形和烧结处理，之后经所述R1晶界扩散处理即可；
或者，所述制备方法包括以下步骤：将所述钕铁硼磁体材料的原料组合物中的所述主合金A和所述主合金B的熔融液分别进行铸造，即得主合金片A和主合金片B；将所述主合金片A和所述主合金片B分别进行氢破碎和微粉碎，将所述主合金片A和所述主合金片B的混合物经成形和烧结处理，之后经所述R1晶界扩散处理即可。
本发明中，所述熔炼的温度可为1300-1700℃。
本发明中，所述熔炼的设备一般为高频真空熔炼炉，例如高频真空感应速凝甩带炉。
本发明中，所述氢破碎的操作和条件可为本领域常规制粉工艺，所述氢破碎一般包括吸氢、脱氢和冷却处理。所述吸氢的温度一般为20-200℃。所述脱氢的温度一般为400-650℃。所述吸氢的压力一般为50-600kPa。
本发明中，所述微粉碎的操作和条件可为本领域常规制粉工艺。所述微粉碎一般通过气流磨制粉实现，所述气流磨制粉一般在0.1-2MPa，优选0.5-0.7MPa的条件下进行气流磨制粉。所述气流磨制粉中的气流例如可为氮气和/或氩气。所述气流磨制粉的效率可根据设备不同有所差别，例如可为30-400kg/h，再例如200kg/h。
本发明中，所述成形的操作和条件可为本领域常规的成形工艺。例如磁场成形法。所述的磁场成形法的磁场强度一般在1.5T以上。
本发明中，所述烧结的操作和条件可为本领域常规的烧结工艺，例如真空烧结工艺和/或惰性气氛烧结工艺。所述真空烧结工艺或所述惰性气氛烧结工艺均为本领域常规操作。当采用惰性气氛烧结工艺时，所述烧结开始阶段可在真空度低于5×10 -1Pa的条件下进行。所述惰性气氛可为本领域常规的含有惰性气体的气氛，不限于氦气、氩气。
本发明中，所述烧结的温度可为1000～1200℃，优选为1030-1090℃。所述烧结的时间可为0.5～10h，优选为2-8h。
本发明中，所述晶界扩散处理可按本领域常规的工艺进行处理，例如通过R1金属涂覆操作、气相物理沉淀操作或蒸镀操作实现晶界扩散处理。
其中，所述R1一般是以氟化物或低熔点合金的形式涂覆，例如Tb的氟化物。当还包含Dy时，较佳地，Dy以Dy的氟化物的形式涂覆。另外，当还包含Pr时，较佳地，Pr以PrCu合金的形式添加。
当所述R1包含Pr且Pr以PrCu合金的形式参与晶界扩散时，较佳地，Cu在所述制备方法中的添加方式为晶界扩散时添加，或者为熔炼和晶界扩散步骤同时添加；当所述Cu在晶界扩散时添加，所述Cu的含量较佳地为0.03～0.15mas％，mas％为元素占所述原料组合物的质量百分比；其中所述Cu占所述PrCu的百分比为0.1～17mas％。
其中，所采用的重稀土金属的氟化物或者合金中引入的其他元素不计入原料组合物的范畴。
本发明中，所述晶界扩散的温度可为800-1000℃，例如900℃。
本发明中，所述晶界扩散的时间可为12-90h，例如24h。
本发明中，所述晶界扩散之后，按照本领域常规还进行热处理。
本发明中，所述热处理的温度可为480℃-700℃。
本发明中，所述热处理的时间可为2-4小时，例如3小时。
本发明中，在制备工艺中一般会添加润滑剂等，引入的碳杂质含量为本 领域常规，一般为1000ppm以下，不计入原料组合物的范畴。
本发明中，在制备工艺中一般需要控制氧含量至1300ppm以下，控制氧含量的手段可为本领域常规，不计入原料组合物的范畴。
本发明的目的之三，提供了一种钕铁硼磁体材料，其按照上述制备方法制得。
本发明中，较佳地，所述钕铁硼磁体材料的相结构中晶界连续性为98％以上，例如99.5％、98.23％、98.9％、98.52％、98.41％、99.37％、98.95％、99.52％、98.84％、98.65％或99.31％，更佳地为99％以上。
本发明中，晶界连续性的计算方式是指晶界中除空洞外的物相占据的长度(例如富B相、富稀土相等)与总晶界长度的比值。晶界连续性超过96％即可称为连续通道。
本发明中，较佳地，所述钕铁硼磁体材料的相结构包括晶界三角区，所述晶界三角区的面积占比为1～2.5％，例如2.03％、1.32％、1.56％、1.33％、1.34％、1.24％、1.19％、1.42％、1.45％、1.48％或1.39％，更佳地为1.2～1.5％。
本发明中，所述晶界三角区一般是指三条或以上的晶界相交叉的地方，分布有富B相、富稀土相、稀土氧化物、稀土碳化物和空洞。所述晶界三角区面积占比的计算方式是指晶界三角区的面积与总面积(主相+晶界)之比。
本发明中，所述钕铁硼磁体材料的密度较佳地为7.54～8g/cm 3，例如7.55g/cm 3、7.56g/cm 3或者7.57g/cm 3。
本发明的目的之四，提供了一种钕铁硼磁体材料在电机的应用。
本发明所用试剂和原料组合物均市售可得。
本发明的积极进步效果在于：
(1)本发明钕铁硼磁体材料的晶界连续性提高到了98％以上；
(2)本发明钕铁硼磁体材料的相结构中三角区面积占比可降低至1～2.5％；
(3)本发明钕铁硼磁体材料的20～120℃Br温度系数的绝对值可低至0.101～0.105％/℃。
(4)本发明钕铁硼磁体材料的Br≥14.9kGs，Hcj可达25kOe以上；
(5)本发明钕铁硼磁体材料的烧结温度的适应性较好，可达25～30℃。
附图说明
图1为实施例3钕铁硼磁体材料的FE-EPMA图。
具体实施方式
下面通过实施例的方式进一步说明本发明，但并不因此将本发明限制在所述的实施例范围之中。下列实施例中未注明具体条件的实验方法，按照常规方法和条件，或按照商品说明书选择。
本发明实施例1～11和对比例1～7的钕铁硼磁体材料的原料组合物以及配比如下表1～3所示。
表1 钕铁硼磁体材料的原料组合物配方主合金A组分(mas％)
Figure PCTCN2021095094-appb-000004
“/”表示不含有该元素。
表2 钕铁硼磁体材料的原料组合物配方主合金B组分(mas％)
Figure PCTCN2021095094-appb-000005
“/”表示不含有该元素。
表3
Figure PCTCN2021095094-appb-000006
“/”表示不含有该元素。
钕铁硼永磁材料的制备方法如下：
本发明的实施例和对比例中，引入的碳杂质和氧杂质含量为本领域常规。
(1)熔炼和铸造过程：按照表1和2中的配方以及表3中的比例，取相应配比的组合物放入真空熔炼炉在5×10 -2Pa的真空中以1500℃的温度分别进行真空熔炼；之后通过薄带连铸法将熔炼所得的熔融液分别进行铸造，制得主合金片A和主合金片B。
(2)氢破制粉过程：在室温下，将步骤(1)中的主合金片A和主合金片B放置氢破用炉中，抽真空，而后向氢破用炉内通入纯度为99.9％的氢气，维持氢气的压力90kPa，充分吸氢后，边抽真空边升温，充分脱氢，之后进行冷却，取出氢破粉碎后的粉末。其中，吸氢的温度为室温，脱氢的温度为550℃。
(3)气流磨制粉过程：在氮气气氛下，在粉碎室压力为0.65MPa的条 件下对氢破粉碎后的粉末进行气流磨粉碎(气流磨制粉的效率可根据设备不同有所差别，例如可为200kg/h)，得到细粉。
(4)成形过程：将经气流磨之后的粉末在1.5T以上的磁场强度中压制成型。
(5)烧结过程：将各成型体搬至烧结炉中进行烧结，烧结在低于0.5Pa的真空下，以1050℃烧结6h，得钕铁硼永磁材料的基体。
(6)晶界扩散过程：钕铁硼永磁材料的基体表面净化后，按照表3中R1的组分进行扩散(实施例1和10中的R1中Pr以PrCu形式添加，实施例1和10中的Cu在晶界扩散步骤添加的含量为0.0085mas％和0.0017mas％，)，并以900℃的温度扩散24h，之后冷却至室温，再以580℃的温度进行热处理3h，即得钕铁硼永磁材料。
下表4中的钕铁硼永磁材料的组分和含量为忽略损耗，通过表1～3数据进行计算所得的名义成分。
表4 钕铁硼磁体材料的组分(mas％)
Figure PCTCN2021095094-appb-000007
Figure PCTCN2021095094-appb-000008
“/”表示不含有该元素。
效果实施例
分别取实施例1～10以及对比例1～7中钕铁硼磁体材料，测定其性能和成分。
(1)磁性能评价：钕铁硼磁体材料使用英国Hirst公司的PFM-14磁性能测量仪进行磁性能检测；下表5所示为磁性能检测结果。
图1为实施例3钕铁硼磁体材料的FE-EPMA图，其中1为主相，2为晶界相，3为晶界三角区。
(2)温度稳定性能的测试：温度稳定性一般用各项磁性能的温度变化系数来表示，是指温度每变化1℃，磁性能变化的百分数，表征永磁材料的磁性能在外部温度场下保持不变的能力，其绝对值越小越好；温度系数绝对值的计算公式为：
Figure PCTCN2021095094-appb-000009
计算结果如表5所示。
(3)烧结温度的适应性：烧结温度的适应性是指烧结温度在某一温度范围，磁体的密度和性能均达到最佳，则称该温度范围为温度适应性范围。例如烧结温度为1050℃-1080℃，密度和性能均能达到最佳，则称温度适应性为30℃(1080-1050＝30(℃))。
表5 钕铁硼磁体材料的性能
Figure PCTCN2021095094-appb-000010
Figure PCTCN2021095094-appb-000011
“Br”是指剩余磁通密度，“Hcj”是指矫顽力。
1)本发明钕铁硼磁体材料的剩磁温度系数均与对比例相当，甚至更好；在采用同类型重稀土金属扩散时的矫顽力明显高于对比例(实施例2～11)；也就是，相对于对比例，富稀土相能够更好地均匀分布在各个主相周围，在后续的烧结过程中熔化，并连续包裹分布在主相晶粒周围；同时与本申请的N元素配合，能够减少晶界三角区的面积，提高磁体的致密化程度和晶界连续性，从而提高剩磁和矫顽力。
2)基于本申请的配方，若采用相当组分含量的单合金，晶界连续降低、三角区面积较大，并且剩磁和矫顽力偏低，温度适应性范围降低(对比例1)。
3)基于本申请的配方，若不含有低熔点金属，也就是N元素，晶界连续降低、三角区面积明显增大，并且剩磁和矫顽力明显降低、磁体密度偏低，温度适应性范围降低(对比例2)。
4)基于本申请的配方，若低熔点金属含量较高，晶界连续降低、三角区面积明显增大，并且剩磁和矫顽力明显降低、磁体密度偏低，温度适应性范围降低(对比例3和对比例4)。
5)基于本申请的配方，若主合金A和主合金B的比例不在本申请限定的范围，也会导致晶界连续降低、三角区面积明显增大，并且剩磁和矫顽力明显降低、磁体密度偏低、且高温性能也会偏低，温度适应性范围降低(对比例5～7)。

Claims (10)

  1. 一种钕铁硼磁体材料的原料组合物，其特征在于，其包括主合金A、主合金B和稀土金属R1；R1，0.2～1mas％，mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    所述主合金A中，以质量百分比计，其包括稀土金属R A、且R A包括Nd，R A，27.5～28.5mas％；N1，0～0.3mas％；B，0.94～1.1mas％；Fe，60～71.5mas％；各组分之和为100mas％；mas％是指在所述主合金A中的质量百分比；
    所述主合金B中，以质量百分比计，其包括稀土金属R B、且R B包括Nd，R B，29～31mas％；N2，0～0.3mas％；B，0.85～1mas％；Fe，60～70mas％；各组分之和为100mas％，mas％是指在所述主合金B中的质量百分比；
    所述N1和N2的含量不同时为0；
    所述主合金A和所述主合金B中，N1和N2独立地包括Bi、Sn、Zn、Cu、Ga、In、Au、Ag和Pb中的一种或多种；
    所述主合金A和所述主合金B的质量比为50:50～95:5。
  2. 根据权利要求1所述的钕铁硼磁体材料的原料组合物，其特征在于，所述R A的含量范围为27.59～28.2mas％，例如28.1mas％，mas％是指在所述主合金A中的质量百分比；
    和/或，所述Nd的含量范围为27.5～28.5mas％，较佳地为27.5～28mas％，例如27.5mas％，mas％是指在所述主合金A中的质量百分比；
    和/或，所述R A的种类为类别一或者类别二：
    类别一：所述R A不含重稀土金属；较佳地，所述R A仅包含Nd；
    类别二：所述R A还包括Pr、La、Ce、Dy和Tb中的一种或多种；较佳地，所述R A包括Pr、Dy和Tb中的一种或多种；
    当所述R A包括Pr时，所述Pr的含量范围较佳地为0～1mas％、且不为0，例如0.01mas％或者0.5mas％，mas％是指在所述主合金A中的质量百分比；
    当所述R A包括Dy时，所述Dy的含量范围较佳地为0～0.1mas％、且不 为0，例如0.05mas％，mas％是指在所述主合金A中的质量百分比；
    当所述R A包括Tb时，所述Tb的含量范围较佳地为0～0.1mas％、且不为0，例如0.03mas％，mas％是指在所述主合金A中的质量百分比；
    较佳地，所述R A中除Nd之外的稀土元素用量不超过0.1mas％，mas％是指在所述主合金A中的质量百分比。
  3. 根据权利要求1所述的钕铁硼磁体材料的原料组合物，其特征在于，所述主合金A中B含量为0.97～1.1mas％，例如1mas％，mas％是指在所述主合金A中的质量百分比；
    和/或，所述N1的含量为0.07～0.3mas％，mas％是指在所述主合金A中的质量百分比；
    较佳地，所述N1的种类包括Cu、Ga、Zn和Bi中的一种或多种；
    更佳地，所述N1的种类包括Cu和/或Ga；更佳地，所述N1的种类为Cu和/或Ga；
    当所述N1的种类包含Cu时，所述Cu的含量较佳地为0.05～0.15mas％，例如0.07mas％或者0.1mas％，mas％是指在所述主合金A中的质量百分比；
    当所述N1的种类包含Ga时，所述Ga的含量较佳地为0.1～0.2mas％，例如0.15mas％，mas％是指在所述主合金A中的质量百分比；
    当所述N1的种类包含Zn时，所述Zn的含量较佳地为0.1～0.2mas％，mas％是指在所述主合金A中的质量百分比；
    当所述N1的种类包含Bi时，所述Bi的含量较佳地为0.1～0.2mas％，例如0.15mas％、0.1mas％或者0.02mas％，mas％是指在所述主合金A中的质量百分比。
  4. 根据权利要求1所述的钕铁硼磁体材料的原料组合物，其特征在于，
    所述主合金B中，所述R B的含量范围为30～31mas％，例如30.09mas％或者30.2mas％，mas％是指在所述主合金B中的质量百分比；
    和/或，所述主合金B中，所述Nd的含量范围为28.9～31mas％，例如30mas％、29.5mas％或者30.2mas％，mas％是指在所述主合金B中的质量百 分比；
    和/或，所述R B的种类为类别一或者类别二：
    类别一：所述R B不含重稀土金属；较佳地，所述R B仅包含Nd；
    类别二：所述R B还包括Pr、La、Ce、Dy和Tb中的一种或多种；较佳地，所述R B包括Pr、Dy和Tb中的一种或多种；
    当所述R B包括Pr时，所述Pr的含量范围较佳地为0～1mas％、且不为0，例如0.01mas％或者0.5mas％，mas％是指在所述主合金B中的质量百分比；
    当所述R B包括Dy时，所述Dy的含量范围较佳地为0～0.1mas％、且不为0，例如0.05mas％，mas％是指在所述主合金B中的质量百分比；
    当所述R B包括Tb时，所述Tb的含量范围较佳地为0～0.1mas％、且不为0，例如0.03mas％，mas％是指在所述主合金B中的质量百分比；
    较佳地，所述R B中除Nd之外的稀土元素用量不超过0.1mas％，mas％是指在所述主合金B中的质量百分比；
    和/或，所述合金B中，所述B的含量范围为0.95～1mas％，mas％是指在所述主合金B中的质量百分比；
    和/或，所述N2的含量为0.07～0.3mas％，mas％是指在所述主合金B中的质量百分比；
    和/或，所述N2的种类包括Cu、Ga、Zn和Bi中的一种或多种；较佳地，所述N2的种类包括Cu和/或Ga；更佳地，所述N2的种类为Cu和/或Ga；
    当所述N2的种类包含Cu时，所述Cu的含量为0.05～0.15mas％，例如0.07mas％或者0.1mas％，mas％是指在所述主合金B中的质量百分比；
    当所述N2的种类包含Ga时，所述Ga的含量为0.1～0.2mas％，例如0.15mas％，mas％是指在所述主合金B中的质量百分比；
    当所述N2的种类包含Zn时，所述Zn的含量为0.1～0.2mas％，mas％是指在所述主合金B中的质量百分比；
    当所述N2的种类包含Bi时，所述Bi的含量为0.1～0.2mas％，例如0.15mas％、0.1mas％或者0.02mas％，mas％是指在所述主合金B中的质量百分比。
  5. 根据权利要求1所述的钕铁硼磁体材料的原料组合物，其特征在于，所述R A和R B的含量之差的绝对值为0.5-3.5％，较佳地为0.5～2.5％；
    和/或，所述主合金A和/或所述主合金B还包括M，所述M包括Ti、Co、Ni、V、Nb、Ta、Cr、Mo、W、Mn、Zr和Hf中的一种或多种；
    和/或，所述M的含量范围为0.08～0.48％；
    较佳地，所述M的种类包括Zr、Ti、Nb和Co中的一种或多种；
    当所述主合金A包含Zr时，所述Zr的含量较佳地为0.1～0.2mas％，例如0.15mas％，mas％是指在所述主合金A中的质量百分比；
    当所述主合金A包含Ti时，所述Ti的含量较佳地为0.1～0.2mas％，mas％是指在所述主合金A中的质量百分比；
    当所述主合金A包含Nb时，所述Nb的含量较佳地为0～0.05mas％、且不为0，例如0.02mas％，mas％是指在所述主合金A中的质量百分比；
    当所述主合金A包含Co时，所述Co的含量较佳地为0～0.5mas％、且不为0，更佳地为0～0.4mas％、且不为0，例如0.05mas％或者0.25mas％，mas％是指在所述主合金A中的质量百分比；
    当所述主合金B包含Zr时，所述Zr的含量较佳地为0.1～0.2mas％，例如0.15mas％，mas％是指在所述主合金B中的质量百分比；
    当所述主合金B包含Ti时，所述Ti的含量较佳地为0.1～0.2mas％，mas％是指在所述主合金B中的质量百分比；
    当所述主合金B包含Nb时，所述Nb的含量较佳地为0～0.05mas％、且不为0，例如0.02mas％，mas％是指在所述主合金B中的质量百分比；
    当所述主合金B包含Co时，所述Co的含量较佳地为0～0.5mas％、且不为0，更佳地为0～0.4mas％、且不为0，例如0.05mas％或者0.25mas％，mas％是指在所述主合金B中的质量百分比。
  6. 根据权利要求1所述的钕铁硼磁体材料的原料组合物，其特征在于，所述R1的含量为0.2～0.6mas％或者0.5～0.9mas％，例如0.25mas％、0.5mas％、0.81mas％或者0.7mas％，mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    和/或，所述R1的种类包括Pr、Dy、Tb、Ho和Gd中的一种或多种；较佳地，所述R1的种类包括Pr、Tb和Dy中的一种或多种；更佳地，所述R1的种类为Tb和/或Dy；
    当所述R1包括Pr时，所述Pr的含量范围较佳地为0～0.1mas％、且不为0，例如0.05mas％，mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；更佳地，所述Pr以PrCu合金的形式添加，其中所述Cu占所述PrCu的百分比为0.1～17mas％；
    当所述R1包括Dy时，所述Dy的含量范围较佳地为0～0.5mas％、且不为0，例如0.2mas％或者0.3mas％，mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    当所述R1包括Tb时，所述Tb的含量范围较佳地为0.2～0.6mas％，例如0.5mas％，mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    和/或，所述主合金A和所述主合金B的质量比为50:50～80:20，例如60:40或者75:25。
  7. 根据权利要求1所述的钕铁硼磁体材料的原料组合物，其特征在于，以质量百分比计，所述钕铁硼磁体材料的原料组合物由以下组分组成：
    所述主合金A中：Nd，28.5mas％；Cu，0.07mas％；B，1.1mas％；余量为Fe，mas％是指在所述主合金A中的质量百分比；
    所述主合金B中：Nd，31mas％；Cu，0.07mas％；B，0.85mas％；余量为Fe，mas％是指在所述主合金B中的质量百分比；
    所述主合金A和所述主合金B的质量比为60:40；所述R1中：Pr，0.05mas％；Dy，0.2mas％；mas％是指在所述钕铁硼磁体材料的原料组合物中的 质量百分比；
    或者，所述主合金A中：Nd，27.5mas％；Pr，0.01mas％；Dy，0.05mas％；Tb，0.03mas％；Cu，0.3mas％；B，0.94mas％；余量为Fe；mas％是指在所述主合金A中的质量百分比；
    所述主合金B中：Nd，30mas％；Pr，0.01mas％；Dy，0.05mas％；Tb，0.03mas％；Cu，0.3mas％；B，1mas％；余量为Fe；mas％是指在所述主合金B中的质量百分比；
    所述主合金A和所述主合金B的质量比为95:5；所述R1中：Dy，0.3mas％；Tb，0.2mas％；mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    或者，所述主合金A中：Nd，28mas％；Tb，0.1mas％；Cu，0.1mas％；Ga，0.15mas％；Zr，0.15mas％；B，0.97mas％；余量为Fe；mas％是指在所述主合金A中的质量百分比；
    所述主合金B中：Nd，28.9mas％；Tb，0.1mas％；Cu，0.1mas％；Ga，0.15mas％；Zr，0.15mas％；B，0.95mas％；余量为Fe；mas％是指在所述主合金B中的质量百分比；
    所述主合金A和所述主合金B的质量比为60:40；所述R1中：Tb，0.5mas％；mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    或者，所述主合金A中：Nd，28mas％；Tb，0.1mas％；Cu，0.1mas％；Ga，0.15mas％；Zr，0.15mas％；B，0.97mas％；余量为Fe；mas％是指在所述主合金A中的质量百分比；
    所述主合金B中：Nd，28.9mas％；Tb，0.1mas％；Cu，0.1mas％；Ga，0.15mas％；Zr，0.15mas％；B，0.95mas％；余量为Fe；mas％是指在所述主合金B中的质量百分比；
    所述主合金A和所述主合金B的质量比为75:25；所述R1中：Tb，0.5mas％；mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    或者，所述主合金A中：Nd，28mas％；Tb，0.1mas％；Cu，0.1mas％； Ga，0.15mas％；Zr，0.15mas％；B，0.97mas％；余量为Fe；mas％是指在所述主合金A中的质量百分比；
    所述主合金B中：Nd，28.9mas％；Tb，0.1mas％；Cu，0.1mas％；Ga，0.15mas％；Zr，0.15mas％；B，0.95mas％；余量为Fe；mas％是指在所述主合金B中的质量百分比；
    所述主合金A和所述主合金B的质量比为50:50；所述R1中：Tb，0.5mas％；mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    或者，所述主合金A中：Nd，27.5mas％；Pr，0.01mas％；Dy，0.05mas％；Tb，0.03mas％；Ti，0.3mas％；B，0.94mas％；余量为Fe；mas％是指在所述主合金A中的质量百分比；
    所述主合金B中：Nd，28.9mas％；Tb，0.1mas％；Cu，0.1mas％；Ga，0.15mas％；Zr，0.15mas％；B，0.95mas％；余量为Fe；mas％是指在所述主合金B中的质量百分比；
    所述主合金A和所述主合金B的质量比为60:40；所述R1中：Dy，0.3mas％；Tb，0.2mas％；mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    或者，所述主合金A中：Nd，28mas％；Tb，0.1mas％；Cu，0.1mas％；Ga，0.15mas％；Zr，0.15mas％；B，0.97mas％；余量为Fe；mas％是指在所述主合金A中的质量百分比；
    所述主合金B中：Nd，30mas％；Pr，0.01mas％；Dy，0.05mas％；Tb，0.03mas％；Ti，0.3mas％；B，1mas％；余量为Fe；mas％是指在所述主合金B中的质量百分比；
    所述主合金A和所述主合金B的质量比为60:40；所述R1中：Dy，0.3mas％；Tb，0.2mas％；mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    或者，所述主合金A中：Nd，28mas％；Tb，0.1mas％；Zn，0.1mas％；Bi，0.15mas％；Zr，0.15mas％；B，0.97mas％；余量为Fe；mas％是指在 所述主合金A中的质量百分比；
    所述主合金B中：Nd，28.9mas％；Tb，0.1mas％；Zn，0.1mas％；Bi，0.15mas％；Zr，0.15mas％；B，0.95mas％；余量为Fe；mas％是指在所述主合金B中的质量百分比；
    所述主合金A和所述主合金B的质量比为60:40；所述R1中：Tb，0.5mas％；mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    或者，所述主合金A中：Nd，28mas％；Tb，0.1mas％；Zn，0.1mas％；Bi，0.15mas％；Zr，0.15mas％；B，0.97mas％；余量为Fe；mas％是指在所述主合金A中的质量百分比；
    所述主合金B中：Nd，28.9mas％；Tb，0.1mas％；Zn，0.1mas％；Bi，0.15mas％；Zr，0.15mas％；B，0.95mas％；余量为Fe；mas％是指在所述主合金B中的质量百分比；
    所述主合金A和所述主合金B的质量比为60:40；所述R1中：Tb，0.5mas％；mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    或者，所述主合金A中：Nd，27.7mas％；Pr，0.5mas％；Zn，0.2mas％；Bi，0.1mas％；Zr，0.1mas％；Ti，0.1mas％；Nb，0.02mas％；Co，0.05mas％；B，1mas％；余量为Fe；mas％是指在所述主合金A中的质量百分比；
    所述主合金B中：Nd，29.5mas％；Pr，0.5mas％；Zn，0.2mas％；Bi，0.1mas％；Zr，0.1mas％；Ti，0.1mas％；Nb，0.02mas％；Co，0.05mas％；B，1mas％；余量为Fe；mas％是指在所述主合金B中的质量百分比；
    所述主合金A和所述主合金B的质量比为60:40；所述R1中：Pr，0.01mas％；Dy，0.5mas％；Tb，0.3mas％；mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比；
    或者，所述主合金A中：Nd，28mas％；Ga，0.1mas％；Bi，0.02mas％；Co，0.25mas％；B，0.97mas％；余量为Fe；mas％是指在所述主合金A中的质量百分比；
    所述主合金B中：Nd，30.2mas％；Ga，0.1mas％；Bi，0.02mas％；Co， 0.25mas％；B，0.97mas％；余量为Fe；mas％是指在所述主合金B中的质量百分比；
    所述主合金A和所述主合金B的质量比为80:20；所述R1中：Dy，0.1mas％；Tb，0.6mas％；mas％是指在所述钕铁硼磁体材料的原料组合物中的质量百分比。
  8. 一种钕铁硼磁体材料的制备方法，其特征在于，其包括以下步骤：将如权利要求1～7任一项所述的钕铁硼磁体材料的原料组合物中的所述主合金A和所述主合金B的熔融液分别进行熔炼和铸造，即得主合金片A和主合金片B；将所述主合金片A和所述主合金片B经氢破碎、微粉碎的混合物进行成形和烧结处理，之后经所述R1晶界扩散处理即可；
    较佳地，所述制备方法包括以下步骤：将前述钕铁硼磁体材料的原料组合物中的所述主合金A和所述主合金B的熔融液分别进行铸造，即得主合金片A和主合金片B；将所述主合金片A和所述主合金片B的混合物经氢破碎、微粉碎、成形和烧结处理，之后经所述R1晶界扩散处理即可；
    或者，所述制备方法包括以下步骤：将所述钕铁硼磁体材料的原料组合物中的所述主合金A和所述主合金B的熔融液分别进行铸造，即得主合金片A和主合金片B；将所述主合金片A和所述主合金片B分别进行氢破碎，之后将所述主合金片A和所述主合金片B的混合物经微粉碎、成形和烧结处理，之后经所述R1晶界扩散处理即可；
    或者，所述制备方法包括以下步骤：将所述钕铁硼磁体材料的原料组合物中的所述主合金A和所述主合金B的熔融液分别进行铸造，即得主合金片A和主合金片B；将所述主合金片A和所述主合金片B分别进行氢破碎和微粉碎，将所述主合金片A和所述主合金片B的混合物经成形和烧结处理，之后经所述R1晶界扩散处理即可；
    当所述R1包含Pr且Pr以PrCu合金的形式进行所述晶界扩散处理时，较佳地，Cu在所述制备方法中的添加时机为晶界扩散步骤，或者在熔炼步骤和晶界扩散步骤同时添加；当所述Cu在晶界扩散时添加，所述Cu的含 量较佳地为0.03～0.15mas％，mas％为元素占所述原料组合物的质量百分比；其中所述Cu占所述PrCu的百分比为0.1～17mas％。
  9. 一种钕铁硼磁体材料，其特征在于，其按照权利要求8所述的制备方法制得；
    所述钕铁硼磁体材料的相结构中晶界连续性较佳地为98％以上，例如99.5％、98.23％、98.9％、98.52％、98.41％、99.37％、98.95％、99.52％、98.84％、98.65％或99.31％，更佳地为99％以上；
    所述钕铁硼磁体材料的相结构包括晶界三角区，所述晶界三角区的面积占比较佳地为1～2.5％，例如2.03％、1.32％、1.56％、1.33％、1.34％、1.24％、1.19％、1.42％、1.45％、1.48％或1.39％，更佳地为1.2～1.5％；
    所述钕铁硼磁体材料的密度较佳地为7.54～8g/cm 3，例如7.55g/cm 3、7.56g/cm 3或者7.57g/cm 3。
  10. 一种如权利要求9所述的钕铁硼磁体材料在电机的应用。
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