WO2022006979A1 - 软磁合金粉末及其制备方法 - Google Patents

软磁合金粉末及其制备方法 Download PDF

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WO2022006979A1
WO2022006979A1 PCT/CN2020/102630 CN2020102630W WO2022006979A1 WO 2022006979 A1 WO2022006979 A1 WO 2022006979A1 CN 2020102630 W CN2020102630 W CN 2020102630W WO 2022006979 A1 WO2022006979 A1 WO 2022006979A1
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alloy
soft magnetic
alloy powder
magnetic alloy
smelting
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French (fr)
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张航
张晓晗
李犇
余金辉
裴坤
孙欢
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瑞声声学科技(深圳)有限公司
瑞声科技（南京）有限公司
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Publication of WO2022006979A1 publication Critical patent/WO2022006979A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01F1/12—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 soft-magnetic materials
    • H01F1/14—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 soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • B22F1/0003—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/07—Alloys based on nickel or cobalt based on cobalt
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C30/00—Alloys containing less than 50% by weight of each constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/10—Ferrous alloys, e.g. steel alloys containing cobalt
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01F1/12—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 soft-magnetic materials
    • H01F1/14—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 soft-magnetic materials metals or alloys
    • H01F1/20—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 soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
    • B22F2009/043—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by ball milling
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C2202/00—Physical properties
    • C22C2202/02—Magnetic

Definitions

  • the present application relates to the technical field of soft magnetic alloys, in particular to a soft magnetic alloy powder and a preparation method thereof.
  • Soft magnetic materials are an important class of functional materials because they are easily magnetized and demagnetized under small applied magnetic fields. Generally speaking, soft magnetic materials have higher initial permeability and lower coercivity. Soft magnetic properties are critical in fields such as power generation and distribution, drives, magnetic shielding materials, data storage, and microwave communications. Commonly used soft magnetic materials in business are electrical pure iron, low carbon steel, iron silicon alloy, ferritic steel, iron nickel alloy, soft ferrite and soft magnetic amorphous alloy. The selection criteria for soft magnetic materials are based on achieving the desired saturation magnetization, permeability, coercivity, resistivity, mechanical strength, but the most important limiting factor is cost.
  • FeCo binary alloys have poor plastic deformation ability, and have large brittleness, which is not conducive to cold working deformation, and it is difficult to prepare parts with complex shapes.
  • due to the high price of Co metal the scarcity of resources, and the large loss of materials by traditional molding techniques, it is limited in industrial applications.
  • 2% of V element is currently used in the alloy, but the addition of non-magnetic element V element reduces the soft magnetic properties of the alloy.
  • the main production method of FeCo alloy powder is atomization.
  • Atomization methods include gas and water atomization methods; FeCo alloy powder produced by gas atomization method is spherical powder with high purity, but poor formability, difficult to suppress, and large equipment investment, high production cost, and expensive price; water atomization method
  • the FeCo alloy powder produced is irregular in shape, with high oxygen content, many impurities, and large particle size.
  • FeCo alloy has a certain plasticity, it is difficult to mechanically crush, and the production efficiency is low, so it cannot be mass-produced. Therefore, the comprehensive properties of iron-cobalt alloys produced by a single pulverizing method are not ideal, which directly affects the popularization and application of iron-cobalt soft magnetic alloys.
  • the purpose of this application is to provide a soft magnetic alloy powder and a preparation method thereof.
  • the soft magnetic alloy powder takes FeCo alloy as a matrix, adds at least one element of B, P, C and Si, and obtains a Soft magnetic alloy powder with high saturation magnetization, low coercivity and low eddy current loss.
  • the alloy expression of the soft magnetic alloy is Fe 47.5 Co 47.5 B 5 or Fe 46.5 Co 46.5 B 7 or Fe 47.5 Co 47.5 P 5 or Fe 47.5 Co 47.5 Si 5 .
  • the present application also provides a preparation method of the soft magnetic alloy powder as described above, the preparation method comprising:
  • the alloy raw material is subjected to vacuum arc smelting and ingot casting to obtain a master alloy
  • the master alloy is melted by induction heating, and the molten master alloy is quenched with a single roll to obtain an alloy thin strip;
  • the soft magnetic alloy powder is obtained by pulverizing the alloy ribbon by a high-energy ball milling method, a planetary ball milling method or a mechanical crushing method.
  • the vacuum arc melting conditions include: vacuum degree ⁇ 6.0 ⁇ 10 -1 Pa, and the protective atmosphere is argon with a purity of 99.999%.
  • the conditions of the single-roll spin quenching method include: the surface linear velocity of the copper roll is 20 m/s ⁇ 50 m/s, the injection pressure is 0.4 to 1.00 Pa, the thickness of the thin strip prepared is 10-350 ⁇ m.
  • the alloy raw material is smelted by vacuum arc and then cast into an ingot to obtain a master alloy, comprising: first smelting a titanium alloy ingot in a smelting furnace, then smelting the alloy raw material, and repeatedly smelting multiple times to obtain the master alloy ingot.
  • Fe, Co, SE with a purity of 99.9 wt.% are weighed according to the ratio of the alloy expression to obtain the alloy raw material, which includes: performing oxide film and impurity removal treatment on the raw material containing each element.
  • the oxide film and impurity removal treatment on the raw material containing each element includes:
  • the oxide film on the surface of the raw material is polished and removed, it is placed in anhydrous ethanol, cleaned by ultrasonic waves, and then dried.
  • the soft magnetic alloy powder of the present application has the characteristics of high saturation magnetization, low coercivity, low eddy current loss, etc., and can be applied to the working environment requiring high saturation magnetization materials, thus broadening the application of soft magnetic alloys Scope.
  • Fig. 1 is the particle size of Fe 47.5 Co 47.5 B 5 alloy powder, Fe 46.5 Co 46.5 B 7 alloy powder, Fe 47.5 Co 47.5 P 5 alloy powder and Fe 47.5 Co 47.5 Si 5 alloy powder respectively prepared in four examples of the application diameter distribution curve;
  • FIG. 2 is a scanning electron microscope (SEM) morphological view of the Fe 47.5 Co 47.5 B 5 alloy powder prepared in Example 1 of the application.
  • the present application provides a soft magnetic alloy powder.
  • the alloy expression of the soft magnetic alloy powder is Fe a Co b SE c .
  • the alloy expression of the soft magnetic alloy is Fe 47.5 Co 47.5 B 5 or Fe 46.5 Co 46.5 B 7 or Fe 47.5 Co 47.5 P5 or Fe 47.5 Co 47.5 Si 5 .
  • the present application also provides a preparation method of soft magnetic alloy powder, which mainly includes the following steps:
  • step S1 batching: according to the atomic ratio a:b:c of each element in the aforementioned soft magnetic alloy precursor alloy expression Fe a Co b SE c , the raw materials containing Fe, Co and SE elements are separately batched.
  • the raw material containing Fe and Co elements can be directly a metal element, and the raw material containing SE element can be a simple substance or a compound.
  • a raw material containing Fe, Co, and SE with a purity of 99.9 wt.% was selected, and the ingredients were prepared according to the expression of the soft magnetic alloy powder alloy described above.
  • the raw material in step S1 is subjected to oxide film and impurity removal treatment. Specifically, the oxide film on the surface of the raw material containing Fe, Co, and SE was polished and removed, and then placed in a beaker filled with absolute ethanol, ultrasonically cleaned for 250 s, and then completely dried.
  • step S2 the master alloy is smelted; the ingredients obtained in step S1 are subjected to vacuum arc smelting and then ingot is cast to obtain a master alloy ingot.
  • the prepared master alloy components are put into a water-cooled copper crucible of a non-consumable vacuum arc melting furnace, and alloy elements with high density and high melting point are placed on it.
  • the alloy is turned over with a manual cantilever overturning spoon, and the smelting is repeated 6 times to ensure that the obtained master alloy ingot has a uniform composition.
  • the titanium alloy ingot needs to be smelted before smelting the raw material of the master alloy, because under the high temperature condition during smelting, the titanium alloy can absorb the air remaining in the furnace cavity and further improve the vacuum degree in the smelting furnace cavity.
  • step S3 the precursor strip is prepared: the master alloy ingot obtained in step S2 is melted by induction heating, and after melting, it is rapidly solidified in a single-roll spin quenching system to obtain a thin strip of soft magnetic alloy.
  • the smelted master alloy is broken, it is put into a quartz tube with a circular hole at the bottom and the diameter of the hole is 0.6 mm, and then placed in the induction coil in the vacuum chamber of the quick quenching equipment and the bottom of the quartz tube is fixed.
  • the mechanical pump and diffusion pump were used to evacuate to 5.0 ⁇ 10 -3 Pa, and then argon gas with a purity of 99.999% of 0.05 MPa was filled, and then the copper roller and the cooling circulating water were turned on.
  • Induction heating power supply under the protection of high-purity argon gas and using high-frequency induction heating to melt the master alloy in the quartz tube uniformly, and then spray the molten master alloy to a high speed under the pressure difference between the inside and outside of the quartz tube is 0.05 MPa.
  • the soft magnetic Fe a Co b SE c alloy precursor thin ribbon was prepared.
  • step S4 powder preparation: the thin strip obtained in step S3 is pulverized by high-energy ball milling method, planetary ball milling method or mechanical crushing method to obtain soft magnetic alloy powder.
  • the Fe a Co b SE c alloy ribbon was put into a high-energy ball mill with a ball-to-material ratio of 5:1, added with 10 wt.
  • the soft magnetic alloy powder required for this application.
  • the soft magnetic alloy powder of the present application uses FeCo-based alloy as a precursor, and the composition in the FeCo-based alloy is wide and can be adjusted continuously; in addition, using high-energy ball milling technology, planetary ball milling technology or mechanical crushing technology, the processing technology is simple, and the process is simplified , the processing time is short, the industrial production is easy, and the soft magnetic alloy powder below 10 microns can be prepared, which solves the problem that alloys such as 1J21 and 1J22 are difficult to prepare alloy powders below 10 microns;
  • the soft magnetic alloy powder prepared in this application has the characteristics of high saturation magnetization, low coercivity, low eddy current loss, etc., and can be used in the working environment that requires high saturation magnetization materials.
  • the soft magnetic alloy powder prepared by the present application has a small particle size, a nearly spherical particle morphology, high strength, excellent soft magnetic properties, and loose preparation process conditions.
  • step S1 batching: select Fe, Co and FeB raw materials with a purity of 99.9 wt.%, and carry out batching according to the expression of Fe 47.5 Co 47.5 B 5 alloy; before weighing the raw materials, remove the oxide film on the raw materials by grinding, Afterwards, the raw materials such as Fe, Co, and FeB were put into a beaker filled with absolute ethanol, ultrasonically cleaned for 250 s, and completely dried.
  • step S2 smelting the master alloy: put the prepared master alloy components into the water-cooled copper crucible of the non-consumable vacuum arc melting furnace, put the alloy elements with high density and high melting point on it, and first use a mechanical pump to smelt the furnace cavity
  • the vacuum degree of the furnace is pumped to 4 ⁇ 10 -1 Pa, close the valve of the mechanical pump, use the diffusion pump to pump the vacuum degree of the furnace chamber to below 4 ⁇ 10 -3 Pa, then close the valve of the diffusion pump, and fill it with 0.05 MPa Argon gas with a purity of 99.999% is used as a protective gas; finally, the switch of the power supply system is turned on, and the tungsten electrode and the copper column are used to contact the arc to start the smelting.
  • the titanium alloy ingot Before smelting the raw material of the master alloy, it is necessary to smelt the titanium alloy ingot first, because the titanium alloy can absorb the air remaining in the furnace cavity under the high temperature condition during smelting, and further improve the vacuum degree in the smelting furnace cavity; After smelting once, after the alloy is completely solidified, it is turned over by the overturning spoon of the manual cantilever, and the smelting is repeated 6 times to ensure that the composition of the master alloy ingot is uniform.
  • step S3 the precursor strip is prepared: after crushing the smelted master alloy, it is put into a quartz tube with a circular hole at the bottom and the diameter of the hole is 0.6 mm, and then placed in the induction tube in the vacuum chamber of the rapid quenching equipment.
  • the coil fix the bottom of the quartz tube at a height of 0.8 mm above the copper roller, use a mechanical pump and a diffusion pump to evacuate to 5.0 ⁇ 10 -3 Pa, and then fill with 0.05 MPa of argon with a purity of 99.999%, and then turn on the flow.
  • the master alloy in the quartz tube is melted evenly, and then the pressure difference between the inside and outside of the quartz tube is 0.05 MPa.
  • the molten and uniform master alloy was sprayed onto a high-speed rotating copper roll to prepare a thin ribbon of soft magnetic Fe 47.5 Co 47.5 B 5 alloy precursor.
  • step S4 powder preparation: put the Fe 47.5 Co 47.5 B 5 alloy precursor thin ribbon into a high-energy ball mill, the ball-to-material ratio is 5:1, add 10 wt.% of anhydrous ethanol, and the rotation speed is 2000 r/min , ball milled for 1 h, taken out for vacuum drying, and Fe 47.5 Co 47.5 B 5 alloy powder can be prepared.
  • step S1 batching: select Fe, Co and FeB raw materials with a purity of 99.9 wt.%, and carry out batching according to the expression of Fe 46.5 Co 46.5 B 7 alloy; before weighing the raw materials, remove the oxide film on the raw materials by grinding, Afterwards, the raw materials such as Fe, Co, and FeB were put into a beaker filled with absolute ethanol, ultrasonically cleaned for 250 s, and completely dried.
  • step S2 smelting the master alloy: put the prepared master alloy components into the water-cooled copper crucible of the non-consumable vacuum arc melting furnace, put the alloy elements with high density and high melting point on it, and first use a mechanical pump to smelt the furnace cavity
  • the vacuum degree of the furnace is pumped to 4 ⁇ 10 -1 Pa, close the valve of the mechanical pump, use the diffusion pump to pump the vacuum degree of the furnace chamber to below 4 ⁇ 10 -3 Pa, then close the valve of the diffusion pump, and fill it with 0.05 MPa Argon gas with a purity of 99.999% is used as a protective gas; finally, the switch of the power supply system is turned on, and the tungsten electrode and the copper column are used to contact the arc to start the smelting.
  • the titanium alloy ingot Before smelting the raw material of the master alloy, it is necessary to smelt the titanium alloy ingot first, because the titanium alloy can absorb the air remaining in the furnace cavity under the high temperature condition during smelting, and further improve the vacuum degree in the smelting furnace cavity; Smelting once, after the alloy is completely solidified, turn it over with a manual cantilever overturning spoon, and repeat the smelting 6 times to ensure that the composition of the master alloy ingot is uniform.
  • step S3 the precursor strip is prepared: after crushing the smelted master alloy, it is put into a quartz tube with a circular hole at the bottom and the diameter of the hole is 0.6 mm, and then placed in the induction tube in the vacuum chamber of the rapid quenching equipment.
  • the coil fix the bottom of the quartz tube at a height of 0.8 mm above the copper roller, use a mechanical pump and a diffusion pump to evacuate to 5.0 ⁇ 10 -3 Pa, and then fill with 0.05 MPa of argon with a purity of 99.999%, and then turn on the flow.
  • the master alloy in the quartz tube is melted evenly, and then the pressure difference between the inside and outside of the quartz tube is 0.05 MPa.
  • the molten and uniform master alloy was sprayed onto a high-speed rotating copper roll to prepare the soft magnetic Fe 46.5 Co 46.5 B 7 alloy precursor thin ribbon used in the experiment.
  • step S4 the powder preparation: The Fe 46.5 Co 46.5 B 7 precursor alloy ribbon into high energy ball milling, the ball to powder ratio of 5: 1, absolute ethanol was added 10 wt%, the rotational speed of 2000 r / min. , ball milled for 1 h, taken out for vacuum drying, and Fe 46.5 Co 46.5 B 7 alloy powder can be prepared.
  • step S1 batching: select Fe, Co and FeP raw materials with a purity of 99.9 wt.%, and carry out batching according to the expression of Fe 47.5 Co 47.5 P 5 alloy; before weighing the raw materials, remove the oxide film on the raw materials by grinding, Afterwards, the raw materials such as Fe, Co, and FeP were put into a beaker filled with absolute ethanol, ultrasonically cleaned for 250 s, and completely dried.
  • step S2 smelting the master alloy: put the prepared master alloy components into the water-cooled copper crucible of the non-consumable vacuum arc melting furnace, put the alloy elements with high density and high melting point on it, and first use a mechanical pump to smelt the furnace cavity
  • the vacuum degree of the furnace is pumped to 4 ⁇ 10 -1 Pa, close the valve of the mechanical pump, use the diffusion pump to pump the vacuum degree of the furnace chamber to below 4 ⁇ 10 -3 Pa, then close the valve of the diffusion pump, and fill it with 0.05 MPa Argon gas with a purity of 99.999% is used as a protective gas; finally, the switch of the power supply system is turned on, and the tungsten electrode and the copper column are used to contact the arc to start the smelting.
  • the titanium alloy ingot Before smelting the raw material of the master alloy, it is necessary to smelt the titanium alloy ingot first, because the titanium alloy can absorb the air remaining in the furnace cavity under the high temperature condition during smelting, and further improve the vacuum degree in the smelting furnace cavity; After smelting once, after the alloy is completely solidified, it is turned over by the overturning spoon of the manual cantilever, and the smelting is repeated 6 times to ensure that the composition of the master alloy ingot is uniform.
  • step S3 the precursor strip is prepared: after crushing the smelted master alloy, it is put into a quartz tube with a circular hole at the bottom and the diameter of the hole is 0.6 mm, and then placed in the induction tube in the vacuum chamber of the rapid quenching equipment.
  • the coil fix the bottom of the quartz tube at a height of 0.8 mm above the copper roller, use a mechanical pump and a diffusion pump to evacuate to 5.0 ⁇ 10 -3 Pa, and then fill with 0.05 MPa of argon with a purity of 99.999%, and then turn on the flow.
  • the master alloy in the quartz tube is melted evenly, and then the pressure difference between the inside and outside of the quartz tube is 0.05 MPa.
  • the molten and uniform master alloy was sprayed onto a high-speed rotating copper roll to prepare the soft magnetic Fe 47.5 Co 47.5 P 5 alloy precursor thin ribbon used in the experiment.
  • step S4 powder preparation: put the Fe 47.5 Co 47.5 P 5 alloy precursor thin ribbon into a high-energy ball mill, the ball-to-material ratio is 5:1, add 10 wt.% of anhydrous ethanol, and the rotation speed is 2000 r/min , ball milled for 1 h, taken out for vacuum drying, and Fe 47.5 Co 47.5 P 5 alloy powder can be prepared.
  • step S1 batching: select Fe, Co and Si raw materials with a purity of 99.9 wt.%, and carry out batching according to the expression of Fe a Co b SE c alloy; before weighing the raw materials, remove the oxide film on the raw materials by grinding, Afterwards, the raw materials such as Fe, Co, and Si were put into a beaker filled with absolute ethanol, ultrasonically cleaned for 250 s, and completely dried.
  • step S2 smelting the master alloy: put the prepared master alloy components into the water-cooled copper crucible of the non-consumable vacuum arc melting furnace, put the alloy elements with high density and high melting point on it, and first use a mechanical pump to smelt the furnace cavity
  • the vacuum degree of the furnace is pumped to 4 ⁇ 10 -1 Pa, close the valve of the mechanical pump, use the diffusion pump to pump the vacuum degree of the furnace chamber to below 4 ⁇ 10 -3 Pa, then close the valve of the diffusion pump, and fill it with 0.05 MPa Argon gas with a purity of 99.999% is used as a protective gas; finally, the switch of the power supply system is turned on, and the tungsten electrode and the copper column are used to contact the arc to start the smelting.
  • the titanium alloy ingot Before smelting the raw material of the master alloy, it is necessary to smelt the titanium alloy ingot first, because the titanium alloy can absorb the air remaining in the furnace cavity under the high temperature condition during smelting, and further improve the vacuum degree in the smelting furnace cavity; After smelting once, after the alloy is completely solidified, it is turned over by the overturning spoon of the manual cantilever, and the smelting is repeated 6 times to ensure that the composition of the master alloy ingot is uniform.
  • step S3 the precursor strip is prepared: after crushing the smelted master alloy, it is put into a quartz tube with a circular hole at the bottom and the diameter of the hole is 0.6 mm, and then placed in the induction tube in the vacuum chamber of the rapid quenching equipment.
  • the coil fix the bottom of the quartz tube at a height of 0.8 mm above the copper roller, use a mechanical pump and a diffusion pump to evacuate to 5.0 ⁇ 10 -3 Pa, and then fill with 0.05 MPa of argon with a purity of 99.999%, and then turn on the flow.
  • the master alloy in the quartz tube is melted evenly, and then the pressure difference between the inside and outside of the quartz tube is 0.05 MPa.
  • the molten and uniform master alloy was sprayed onto the high-speed rotating copper roll to prepare the soft magnetic Fe 47.5 Co 47.5 Si 5 alloy precursor thin strip used in the experiment.
  • step S4 powder preparation: put the Fe 47.5 Co 47.5 Si 5 alloy precursor thin ribbon into a high-energy ball mill, the ball-to-material ratio is 5:1, add anhydrous ethanol 10 wt.%, and the rotation speed is 2000 r/min , ball milled for 1 h, taken out for vacuum drying, and Fe 47.5 Co 47.5 Si 5 alloy powder can be prepared.
  • Table 1 shows the saturation magnetization of Fe a Co b SE c alloy powders prepared in the above four examples.
  • Figure 1 shows the particle size distribution curves of the Fe a Co b SE c alloy powders prepared in the above four examples.
  • Figure 2 shows the scanning electron microscope (SEM) morphology of the Fe 47.5 Co 47.5 B 5 alloy powder prepared in Example 1.
  • Table 1 lists the saturation magnetization (Bs) of the four Fe a Co b SE c alloy powders prepared in Example 1, Example 2, Example 3 and Example 4 respectively. It can be seen from Table 1 that these four Fe a Co b SE c alloy powders all have high saturation magnetization.
  • the Fe 47.5 Co 47.5 B 5 alloy powder obtained in Example 1 has a higher saturation magnetization (Bs) of 2.36T.
  • the Fe 46.5 Co 46.5 B 7 alloy powder obtained in Example 2 has a higher saturation magnetization (Bs) of 2.24 T.
  • the Fe 47.5 Co 47.5 P 5 alloy powder obtained in Example 3 has a higher saturation magnetization (Bs) of 2.34T.
  • the Fe 47.5 Co 47.5 Si 5 alloy powder obtained in Example 4 has a higher saturation magnetization (Bs) of 2.33 T.
  • FIG 1 is a first embodiment, second embodiment, third embodiment and the particle size distribution curve were prepared according to a fourth four Fe a Co b SE c alloy powder embodiments, can be obtained from Figure 1, the four Fe a Co The average particle size distribution of b SE c alloy powder is relatively concentrated.
  • the Fe 47.5 Co 47.5 B 5 alloy powder obtained in Example 1 has a particle size d50 of 5.64 ⁇ m.
  • the Fe 47.5 Co 47.5 B 7 alloy powder obtained in Example 2 has a particle size d50 of 3.37 ⁇ m.
  • the Fe 47.5 Co 47.5 P 5 alloy powder obtained in Example 3 has a particle size d50 of 5.87 ⁇ m.
  • the Fe 47.5 Co 47.5 Si 5 alloy powder obtained in Example 4 has a particle size d50 of 6.11 ⁇ m.
  • Fig. 2 is a picture of Fe 47.5 Co 47.5 B 5 alloy powder obtained in Example 1 under SEM. It can be seen from Fig. 2 that the particle size distribution of Fe 47.5 Co 47.5 B 5 alloy powder is relatively concentrated, the particles are nearly spherical, and the fluidity is relatively high. good.

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Abstract

本申请提供了一种软磁合金粉末及其制备方法，所述软磁合金粉末的合金表达式为Fe aCo bSE c，所述合金表达式中，SE包括B、P、C和Si中的至少一种，满足20≤a≤80，20≤b≤80，2≤c≤15，a+b+c=100。通过上述方式，本申请的软磁合金粉末，具有高饱和磁化强度、低矫顽力、低涡流损耗等特点，可应用于要求高饱和磁化强度材料的工作环境中，拓宽了软磁合金的应用范围。

Description

软磁合金粉末及其制备方法 技术领域
本申请涉及软磁合金技术领域，具体涉及一种软磁合金粉末及其制备方法。
 背景技术
软磁材料是一类重要的功能材料，因为软磁材料在较小的外加磁场下容易磁化和退磁。一般来说，软磁材料的具有较高的初始磁导率和较低的矫顽力。软磁性能对发电和配电器、驱动器、磁屏蔽材料、数据存储和微波通信等领域至关重要。一般商业上常用的软磁材料是电工纯铁、低碳钢、铁硅合金、铁素体钢、铁镍合金、软铁氧体以及软磁非晶合金。软磁材料的选择标准是基于达到所需的饱和磁化强度、磁导率、矫顽力、电阻率、机械强度，但是最重要的限制因素是成本。现有软磁合金在磁学性能以及机械性能等方面的不断改进，再加上新材料不断被发现，导致软磁材料在特定应用领域的激烈竞争。在软磁材料中，电工钢的市场占有率最高。然而，FeCo合金在商用磁性材料中表现出最高的饱和磁化强度。此外，FeCo合金具有较高的居里温度和良好的强度，非常适合于要求高磁通密度的应用，同时可以减小电子器件尺寸，在未来电子器件小型化方面具有重要应用。
而FeCo二元合金的塑性变形能力较差，具有较大的脆性而不利于冷加工变形，难以制备出具有复杂形状零部件。此外，由于Co金属的价格昂贵，资源稀缺，传统的成型技术对材料的损耗较大，所以在工业应用中受到了一定的限制。为了改善其加工性，目前多采用在合金中加入2 %的V元素，但是非磁性元素 V元素的加入，降低了合金的软磁性能。有研究指出，FeCo 50合金中加入2% V元素后，合金的饱和磁感应强度降低4%，最大磁导率明显下降，软磁性能显著恶化。所以工业上需要一种近净成形技术来实现FeCo合金磁性器件精密化、小型化、复杂化，同时大幅节约成本和资源。因此研究FeCo合金粉体制备技术是十分必要的。
目前FeCo合金粉末主要生产方式为雾化法。雾化法有气、水雾化法；气雾化法生产的FeCo合金粉为球形粉，纯度高，但成型性差，难以压制，而且设备投资大、生产成本高，价格贵；水雾化法生产的FeCo合金粉形貌为不规则形，氧含量高，杂质多，粒度较大；同时，因为FeCo合金具有一定的塑性，难以进行机械破碎，生产效率低，无法批量生产。因此，用单一制粉方法生产的铁钴合金综合性能是不理想的，直接影响铁钴软磁合金的推广应用。
因此，为了制备高饱和磁化强度和低矫顽力的FeCo合金，有必要提供一种新的软磁合金粉末及制其备方法。
 技术问题
本申请的目的在于提供一种软磁合金粉末及其制备方法，所述软磁合金粉末以FeCo合金为基体，加入B、P、C和Si中的至少一种元素，按照规定的比例，获得高饱和磁化强度、低矫顽力、低涡流损耗的软磁合金粉末。
 技术解决方案
本申请的技术方案如下：一种软磁合金粉末，所述软磁合金粉末的合金表达式为Fe aCo bSE c，其中，所述SE包括B、P、C和Si中的至少一种，满足20≤a≤80，20≤b≤80，2≤c≤15，a+b+c=100。
优选的，所述合金表达式中，满足30≤a≤70，30≤b≤70，2≤c≤10，a+b+c=100。
优选的，所述软磁合金的合金表达式为Fe 47.5Co 47.5B 5或Fe 46.5Co 46.5B 7或Fe 47.5Co 47.5P 5或Fe 47.5Co 47.5Si 5。
本申请还提供了一种如以上所述的软磁合金粉末的制备方法，所述制备方法包括：
按照所述合金表达式的配比分别称取纯度为99.9wt.%的包含Fe、Co、SE元素的各种原料，得到合金原料；
将所述合金原料进行真空电弧熔炼后铸锭得到母合金；
采用感应加热的方法熔融所述母合金，将熔融后的母合金用单辊旋淬法制得合金薄带；
采用高能球磨法或行星球磨法或机械破碎法将所述合金薄带粉碎制得所述软磁合金粉末。
优选的，所述真空电弧熔炼的条件包括：真空度≥6.0×10 -1 Pa，保护气氛为99.999 %纯度的氩气。
优选的，所述单辊旋淬法的条件包括：铜辊表面线速度为20 m/s～50 m/s，喷射压强为0.4～1.00 Pa，制得的所述薄带厚度为10～350 μm。
优选的，所述将所述合金原料进行真空电弧熔炼后铸锭得到母合金，包括：在熔炼炉中先熔炼钛合金锭，再熔炼所述合金原料，反复熔炼多次，得到所述母合金铸锭。
优选的，所述按照所述合金表达式的配比称取纯度为99.9wt.%的Fe、Co、SE，得到合金原料，之前包括：对包含各元素的原料进行氧化膜和杂质去除处理。
优选的，所述对包含各元素的原料进行氧化膜和杂质去除处理，包括：
将所述原料表面的氧化膜打磨去除后，置于无水乙醇中利用超声波清洗后干燥。
 有益效果
本申请的有益效果在于：本申请提供了一种软磁合金粉末及其制备方法，所述软磁合金粉末的合金表达式为Fe aCo bSE c，所述合金表达式中，SE包括B、P、C和Si中的至少一种，满足20≤a≤80，20≤b≤80，2≤c≤15，a+b+c=100。通过上述方式，本申请的软磁合金粉末，具有高饱和磁化强度、低矫顽力、低涡流损耗等特点，可应用于要求高饱和磁化强度材料的工作环境中，拓宽了软磁合金的应用范围。
附图说明
图1为本申请四个实施例分别制得的Fe 47.5Co 47.5B 5合金粉末、Fe 46.5Co 46.5B 7合金粉末、Fe 47.5Co 47.5P 5合金粉末和Fe 47.5Co 47.5Si 5合金粉末的粒径分布曲线图；
图2为本申请实施例一中制得的Fe 47.5Co 47.5B 5合金粉末在扫描电子显微镜（SEM）的形貌图。
本发明的实施方式
下面结合附图和实施方式对本申请作进一步说明。
本申请提供了一种软磁合金粉末，软磁合金粉末的合金表达式为Fe aCo bSE c，在合金表达式中，SE包括B、P、C和Si中的至少一种，满足20≤a≤80，20≤b≤80，2≤c≤15，a+b+c=100。优选的，在合金表达式中，满足30≤a≤70，30≤b≤70，2≤c≤10，a+b+c=100。优选的，所述软磁合金的合金表达式为Fe 47.5Co 47.5B 5或Fe 46.5Co 46.5B 7或Fe 47.5Co 47.5P5或Fe 47.5Co 47.5Si 5。
基于以上软磁合金粉末，本申请还提供了一种软磁合金粉末的制备方法，主要包括以下步骤：
在步骤S1中，配料：按照前文软磁合金前驱体合金表达式Fe aCo bSE c中各元素的原子比例a：b：c分别对包含Fe、Co、SE元素的各种原料进行配料。在本申请实施例中，包含Fe和Co元素的原料可以直接为金属单质，而包含SE元素的原料则可以为单质也可以为化合物。
具体的，选取纯度为99.9 wt.%的包含Fe、Co、SE各元素的原料，按照前文记载的软磁合金粉末合金表达式进行配料。优选的，在步骤S1之前，对步骤S1中的原料进行氧化膜和杂质去除处理。具体的，将包含Fe、Co、SE各元素的原料表面的氧化膜打磨去除后放入盛有无水乙醇的烧杯中，进行超声波清洗250 s，之后将其完全干燥。
在步骤  S2中，熔炼母合金；将步骤S1获得的配料进行真空电弧熔炼后铸锭得到母合金铸锭。
具体的，将配制好的母合金成分放入非自耗真空电弧熔炼炉的水冷铜坩埚里，密度大且熔点高的合金元素放在上面。首先利用机械泵将炉腔的真空度抽至4×10 -1 Pa，关闭机械泵阀门，使用扩散泵将炉腔的真空度抽至4×10 -3 Pa以下，然后将扩散泵阀门关闭，充入0.05 MPa的纯度为99.999%的氩气，作为保护气体；最后，打开电源系统的开关，利用钨电极与铜柱来接触引弧，并开始熔炼。优选的，熔炼时，每熔炼一次，待合金完全凝固后，利用手动悬臂的翻转勺将其翻转过来，并反复熔炼6次保证得到的母合金铸锭成分均匀。可选的，在熔炼母合金原料之前，需要先熔炼钛合金锭，因为在熔炼时的高温条件下，钛合金可以吸附炉腔内残留的空气，进一步提高熔炼炉腔体内的真空度。
在步骤S3中，前驱体带材制备：采用感应加热的方法熔化步骤S2获得的母合金铸锭，熔化后在单辊旋淬系统中快速凝固制得软磁合金的薄带。
具体的，将熔炼好的母合金破碎后，放入底部开有圆孔且孔的直径为0.6 mm的石英管中，然后放置在快淬设备真空腔里的感应线圈中并将石英管底部固定在距离铜辊上方0.8 mm高度处，采用机械泵和扩散泵抽真空至5.0×10 -3 Pa后充入0.05 MPa的纯度为99.999%的氩气，然后开启通有冷却循环水的铜辊和感应加热电源，在高纯氩气的保护下并采用高频感应加热的方式使石英管中的母合金熔化均匀，然后在石英管内外压差为0.05 MPa下把熔融均匀的母合金喷射到高速旋转的铜辊上，制备出软磁Fe aCo bSE c合金前驱体薄带。
在步骤S4中，粉体制备：采用高能球磨法、行星球磨法或机械破碎法将步骤S3制得的薄带粉碎制得软磁合金粉末。
具体的，将Fe aCo bSE c合金薄带放入高能球磨中，球料比为5：1，加入无水乙醇10 wt.%，转速为2000 r/min，球磨1h，取出真空干燥获得本申请所需的软磁合金粉末。
本申请的软磁合金粉末，以FeCo基合金为前驱体，FeCo基合金中的成分范围广且可连续调整；另外，利用高能球磨技术、行星球磨技术或机械破碎技术，处理工艺简单，流程简化，加工时间较短，易于工业化生产，即可制备10微米级以下的软磁合金粉末，解决了1J21和1J22等牌号合金难以制备10微米级以下合金粉末的问题；本申请制备的软磁合金粉末，具有高饱和磁化强度、低矫顽力、低涡流损耗等特点，可应用于要求高饱和磁化强度材料的工作环境中。综上本申请制备的软磁合金粉末其粒径较小、颗粒形貌为近球形、强度较高、软磁性能优异、制备工艺条件宽松。
实施例一
在步骤S1中，配料：选取纯度为99.9 wt.%的Fe、Co和FeB原料，按照Fe 47.5Co 47.5B 5合金表达式进行配料；在称取原材料之前，把原材料上面的氧化膜打磨去除，后将Fe、Co和FeB等原材料放入盛有无水乙醇的烧杯中，进行超声波清洗250 s，将其完全干燥。
在步骤S2中，熔炼母合金：将配制好的母合金成分放入非自耗真空电弧熔炼炉的水冷铜坩埚里，密度大且熔点高的合金元素放在上面，首先利用机械泵将炉腔的真空度抽至4×10 -1 Pa，关闭机械泵阀门，使用扩散泵将炉腔的真空度抽至4×10 -3 Pa以下，然后将扩散泵阀门关闭，充入0.05 MPa的纯度为99.999%的氩气，作为保护气体；最后，打开电源系统的开关，利用钨电极与铜柱来接触引弧，并开始熔炼。在熔炼母合金原料之前，需要先熔炼钛合金锭，这是因为在熔炼时的高温条件下，钛合金可以吸附炉腔内残留的空气，进一步提高熔炼炉腔体内的真空度；熔炼时，每熔炼一次，待合金完全凝固后，利用手动悬臂的翻转勺将其翻转过来，并反复熔炼6次保证母合金铸锭的成分均匀。
在步骤S3中，前驱体带材制备：将熔炼好的母合金破碎后，放入底部开有圆孔且孔的直径为0.6 mm的石英管中，然后放置在快淬设备真空腔里的感应线圈中并将石英管底部固定在距离铜辊上方0.8 mm高度处，采用机械泵和扩散泵抽真空至5.0×10 -3 Pa后充入0.05 MPa的纯度为99.999%的氩气，然后开启通有冷却循环水的铜辊和感应加热电源，在高纯氩气的保护下并采用高频感应加热的方式使石英管中的母合金熔化均匀，然后在石英管内外压差为0.05 MPa下把熔融均匀的母合金喷射到高速旋转的铜辊上，制备出软磁Fe 47.5Co 47.5B 5合金前驱体薄带。
在步骤S4中，粉体制备：将Fe 47.5Co 47.5B 5合金前驱体薄带放入高能球磨中，球料比为5：1，加入无水乙醇10 wt.%，转速为2000 r/min，球磨1h，取出真空干燥，即可制备出Fe 47.5Co 47.5B 5合金粉末。
实施例二
在步骤S1中，配料：选取纯度为99.9 wt.%的Fe、Co和FeB原料，按照Fe 46.5Co 46.5B 7合金表达式进行配料；在称取原材料之前，把原材料上面的氧化膜打磨去除，后将Fe、Co和FeB等原材料放入盛有无水乙醇的烧杯中，进行超声波清洗250 s，将其完全干燥。
在步骤S2中，熔炼母合金：将配制好的母合金成分放入非自耗真空电弧熔炼炉的水冷铜坩埚里，密度大且熔点高的合金元素放在上面，首先利用机械泵将炉腔的真空度抽至4×10 -1 Pa，关闭机械泵阀门，使用扩散泵将炉腔的真空度抽至4×10 -3 Pa以下，然后将扩散泵阀门关闭，充入0.05 MPa的纯度为99.999%的氩气，作为保护气体；最后，打开电源系统的开关，利用钨电极与铜柱来接触引弧，并开始熔炼。在熔炼母合金原料之前，需要先熔炼钛合金锭，这是因为在熔炼时的高温条件下，钛合金可以吸附炉腔内残留的空气，进一步提高熔炼炉腔体内的真空度；熔炼时，每熔炼一次，待合金完全凝固后，利用手动悬臂的翻转勺将其翻转过来，并反复熔炼6次保证母合金铸锭的成分均匀。
在步骤S3中，前驱体带材制备：将熔炼好的母合金破碎后，放入底部开有圆孔且孔的直径为0.6 mm的石英管中，然后放置在快淬设备真空腔里的感应线圈中并将石英管底部固定在距离铜辊上方0.8 mm高度处，采用机械泵和扩散泵抽真空至5.0×10 -3 Pa后充入0.05 MPa的纯度为99.999%的氩气，然后开启通有冷却循环水的铜辊和感应加热电源，在高纯氩气的保护下并采用高频感应加热的方式使石英管中的母合金熔化均匀，然后在石英管内外压差为0.05 MPa下把熔融均匀的母合金喷射到高速旋转的铜辊上，制备出实验所用的软磁Fe 46.5Co 46.5B 7合金前驱体薄带。
在步骤S4中，粉体制备：将Fe 46.5Co 46.5B 7合金前驱体薄带放入高能球磨中，球料比为5：1，加入无水乙醇10 wt.%，转速为2000 r/min，球磨1h，取出真空干燥，即可制备出Fe 46.5Co 46.5B 7合金粉末。
实施例三
在步骤S1中，配料：选取纯度为99.9 wt.%的Fe、Co和FeP原料，按照Fe 47.5Co 47.5P 5合金表达式进行配料；在称取原材料之前，把原材料上面的氧化膜打磨去除，后将Fe、Co和FeP等原材料放入盛有无水乙醇的烧杯中，进行超声波清洗250 s，将其完全干燥。
在步骤S2中，熔炼母合金：将配制好的母合金成分放入非自耗真空电弧熔炼炉的水冷铜坩埚里，密度大且熔点高的合金元素放在上面，首先利用机械泵将炉腔的真空度抽至4×10 -1 Pa，关闭机械泵阀门，使用扩散泵将炉腔的真空度抽至4×10 -3 Pa以下，然后将扩散泵阀门关闭，充入0.05 MPa的纯度为99.999%的氩气，作为保护气体；最后，打开电源系统的开关，利用钨电极与铜柱来接触引弧，并开始熔炼。在熔炼母合金原料之前，需要先熔炼钛合金锭，这是因为在熔炼时的高温条件下，钛合金可以吸附炉腔内残留的空气，进一步提高熔炼炉腔体内的真空度；熔炼时，每熔炼一次，待合金完全凝固后，利用手动悬臂的翻转勺将其翻转过来，并反复熔炼6次保证母合金铸锭的成分均匀。
在步骤S3中，前驱体带材制备：将熔炼好的母合金破碎后，放入底部开有圆孔且孔的直径为0.6 mm的石英管中，然后放置在快淬设备真空腔里的感应线圈中并将石英管底部固定在距离铜辊上方0.8 mm高度处，采用机械泵和扩散泵抽真空至5.0×10 -3 Pa后充入0.05 MPa的纯度为99.999%的氩气，然后开启通有冷却循环水的铜辊和感应加热电源，在高纯氩气的保护下并采用高频感应加热的方式使石英管中的母合金熔化均匀，然后在石英管内外压差为0.05 MPa下把熔融均匀的母合金喷射到高速旋转的铜辊上，制备出实验所用的软磁Fe 47.5Co 47.5P 5合金前驱体薄带。
在步骤S4中，粉体制备：将Fe 47.5Co 47.5P 5合金前驱体薄带放入高能球磨中，球料比为5：1，加入无水乙醇10 wt.%，转速为2000 r/min，球磨1h，取出真空干燥，即可制备出Fe 47.5Co 47.5P 5合金粉末。
实施例四
在步骤S1中，配料：选取纯度为99.9 wt.%的Fe、Co和Si原料，按照Fe aCo bSE c合金表达式进行配料；在称取原材料之前，把原材料上面的氧化膜打磨去除，后将Fe、Co和Si等原材料放入盛有无水乙醇的烧杯中，进行超声波清洗250 s，将其完全干燥。
在步骤S2中，熔炼母合金：将配制好的母合金成分放入非自耗真空电弧熔炼炉的水冷铜坩埚里，密度大且熔点高的合金元素放在上面，首先利用机械泵将炉腔的真空度抽至4×10 -1 Pa，关闭机械泵阀门，使用扩散泵将炉腔的真空度抽至4×10 -3 Pa以下，然后将扩散泵阀门关闭，充入0.05 MPa的纯度为99.999%的氩气，作为保护气体；最后，打开电源系统的开关，利用钨电极与铜柱来接触引弧，并开始熔炼。在熔炼母合金原料之前，需要先熔炼钛合金锭，这是因为在熔炼时的高温条件下，钛合金可以吸附炉腔内残留的空气，进一步提高熔炼炉腔体内的真空度；熔炼时，每熔炼一次，待合金完全凝固后，利用手动悬臂的翻转勺将其翻转过来，并反复熔炼6次保证母合金铸锭的成分均匀。
在步骤S3中，前驱体带材制备：将熔炼好的母合金破碎后，放入底部开有圆孔且孔的直径为0.6 mm的石英管中，然后放置在快淬设备真空腔里的感应线圈中并将石英管底部固定在距离铜辊上方0.8 mm高度处，采用机械泵和扩散泵抽真空至5.0×10 -3 Pa后充入0.05 MPa的纯度为99.999%的氩气，然后开启通有冷却循环水的铜辊和感应加热电源，在高纯氩气的保护下并采用高频感应加热的方式使石英管中的母合金熔化均匀，然后在石英管内外压差为0.05 MPa下把熔融均匀的母合金喷射到高速旋转的铜辊上，制备出实验所用的软磁Fe 47.5Co 47.5Si 5合金前驱体薄带。
在步骤S4中，粉体制备：将Fe 47.5Co 47.5Si 5合金前驱体薄带放入高能球磨中，球料比为5：1，加入无水乙醇10 wt.%，转速为2000 r/min，球磨1h，取出真空干燥，即可制备出Fe 47.5Co 47.5Si 5合金粉末。
软磁合金粉末性能检测结果
请参阅表1、图1和图2。表1展示了以上四个实施例中制得的Fe aCo bSE c合金粉末饱和磁化强度。图1展示了以上四个实施例中制得的Fe aCo bSE c合金粉末的粒径分布曲线。图2展示了实施例一中制得的Fe 47.5Co 47.5B 5合金粉末在扫描电子显微镜（SEM）的形貌图。
表1列出了实施例一、实施例二、实施例三和实施例四分别制得的四种Fe aCo bSE c合金粉末的饱和磁化强度（Bs），由表1可见，这四种Fe aCo bSE c合金粉末均具有较高的饱和磁化强度。实施例一制得的Fe 47.5Co 47.5B 5合金粉末，其具有2.36T的较高饱和磁化强度（Bs）。实施例二制得的Fe 46.5Co 46.5B 7合金粉末，其具有2.24 T较高的饱和磁化强度（Bs）。实施例三制得的Fe 47.5Co 47.5P 5合金粉末，其具有2.34T较高的饱和磁化强度（Bs）。实施例四制得的Fe 47.5Co 47.5Si 5合金粉末，其具有2.33 T较高的饱和磁化强度（Bs）。
表1：Fe aCo bSE c合金粉末饱和磁化强度
合金 饱和磁化强度 d 50粒径
Fe 47.5Co 47.5B 5 2.36 T 5.64 μm
Fe 46.5Co 46.5B 7 2.24 T 3.37 μm
Fe 47.5Co 47.5P 5 2.34 T 5.87 μm
Fe 47.5Co 47.5Si 5 2.33 T 6.11 μm
图1为实施例一、实施例二、实施例三和实施例四分别制得的四种Fe aCo bSE c合金粉末的粒径分布曲线，由图1可得，这四种Fe aCo bSE c合金粉末的均粒径分布均较为集中。实施例一制得的Fe 47.5Co 47.5B 5合金粉末，其粒径d50为5.64 μm。实施例二制得的Fe 47.5Co 47.5B 7合金粉末，其粒径d50为3.37 μm。实施例三制得的Fe 47.5Co 47.5P 5合金粉末，其粒径d50为5.87 μm。实施例四制得的Fe 47.5Co 47.5Si 5合金粉末，其粒径d50为6.11 μm。
图2为实施例一制得的Fe 47.5Co 47.5B 5合金粉末在SEM下的图片，由图2可见，Fe 47.5Co 47.5B 5合金粉末粒径分布较为集中，颗粒为近球形，流动性较好。
以上所述的仅是本申请的实施方式，在此应当指出，对于本领域的普通技术人员来说，在不脱离本申请创造构思的前提下，还可以做出改进，但这些均属于本申请的保护范围。

Claims (9)

1、一种软磁合金粉末，其特征在于，所述软磁合金粉末的合金表达式为Fe aCo bSE c，其中，所述SE包括B、P、C和Si中的至少一种，满足20≤a≤80，20≤b≤80，2≤c≤15，a+b+c=100。
2、根据权利要求1所述的软磁合金粉末，其特征在于，所述合金表达式中，满足30≤a≤70，30≤b≤70，2≤c≤10，a+b+c=100。
3、根据权利要求1所述的软磁合金粉末，其特征在于，所述软磁合金的合金表达式为Fe 47.5Co 47.5B 5或Fe 46.5Co 46.5B 7或Fe 47.5Co 47.5P 5或Fe 47.5Co 47.5Si 5。
4、一种如权利要求1-3任一所述的软磁合金粉末的制备方法，其特征在于，所述制备方法包括：
按照所述合金表达式的配比分别称取纯度为99.9wt.%的包含Fe、Co、SE元素的各种原料，得到合金原料；
将所述合金原料进行真空电弧熔炼后铸锭得到母合金；
采用感应加热的方法熔融所述母合金，将熔融后的母合金用单辊旋淬法制得合金薄带；
采用高能球磨法或行星球磨法或机械破碎法将所述合金薄带粉碎制得所述软磁合金粉末。
5、如权利可要求4所述的软磁合金粉末的制备方法，其特征在于，
所述真空电弧熔炼的条件包括：真空度≥6.0×10 -1 Pa，保护气氛为99.999 %纯度的氩气。
6、如权利可要求4所述的软磁合金粉末的制备方法，其特征在于，
所述单辊旋淬法的条件包括：铜辊表面线速度为20 m/s～50 m/s，喷射压强为0.4～1.00 Pa，制得的所述薄带厚度为10～350 μm。
7、如权利可要求4所述的软磁合金粉末的制备方法，其特征在于，所述将所述合金原料进行真空电弧熔炼后铸锭得到母合金，包括：在熔炼炉中先熔炼钛合金锭，再熔炼所述合金原料，反复熔炼多次，得到所述母合金铸锭。
8、如权利可要求4所述的软磁合金粉末的制备方法，其特征在于，所述按照所述合金表达式的配比称取纯度为99.9wt.%的Fe、Co、SE，得到合金原料，之前包括：对包含各元素的原料进行氧化膜和杂质去除处理。
9、如权利可要求4所述的软磁合金粉末的制备方法，其特征在于，所述对包含各元素的原料进行氧化膜和杂质去除处理，包括：
将所述原料表面的氧化膜打磨去除后，置于无水乙醇中利用超声波清洗后干燥。
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