WO2023001189A1 - 一种高性能烧结钕铁硼磁体及其制备方法 - Google Patents

一种高性能烧结钕铁硼磁体及其制备方法 Download PDF

Info

Publication number
WO2023001189A1
WO2023001189A1 PCT/CN2022/106752 CN2022106752W WO2023001189A1 WO 2023001189 A1 WO2023001189 A1 WO 2023001189A1 CN 2022106752 W CN2022106752 W CN 2022106752W WO 2023001189 A1 WO2023001189 A1 WO 2023001189A1
Authority
WO
WIPO (PCT)
Prior art keywords
alloy
diffusion
preparation
magnet
temperature
Prior art date
Application number
PCT/CN2022/106752
Other languages
English (en)
French (fr)
Inventor
李志强
张婷
赵南
薛令文
Original Assignee
烟台正海磁性材料股份有限公司
南通正海磁材有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 烟台正海磁性材料股份有限公司, 南通正海磁材有限公司 filed Critical 烟台正海磁性材料股份有限公司
Priority to KR1020247002013A priority Critical patent/KR20240022643A/ko
Priority to EP22845354.4A priority patent/EP4358103A1/en
Publication of WO2023001189A1 publication Critical patent/WO2023001189A1/zh

Links

Classifications

    • 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
    • H01F1/032—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
    • 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
    • H01F1/047—Alloys characterised by their composition
    • 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
    • H01F1/0575—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 pressed, sintered or bonded together
    • H01F1/0577—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 pressed, sintered or bonded together sintered
    • 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
    • H01F1/032—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
    • 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
    • H01F1/06—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 in the form of particles, e.g. powder
    • 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
    • H01F1/032—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
    • 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
    • H01F1/06—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 in the form of particles, e.g. powder
    • H01F1/08—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 in the form of particles, e.g. powder pressed, sintered, or bound together
    • 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
    • H01F1/032—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
    • 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
    • H01F1/06—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 in the form of particles, e.g. powder
    • H01F1/08—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 in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/086—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 in the form of particles, e.g. powder pressed, sintered, or bound together sintered
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
    • H01F41/0266—Moulding; Pressing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
    • H01F41/0293—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets diffusion of rare earth elements, e.g. Tb, Dy or Ho, into permanent magnets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F7/00—Magnets
    • H01F7/02—Permanent magnets [PM]

Definitions

  • the invention belongs to the field of rare earth permanent magnet materials, and in particular relates to a high-performance sintered NdFeB magnet and a preparation method thereof.
  • NdFeB magnets As a modern permanent magnet with relatively excellent performance, NdFeB magnets have different performances, among which the most excellent performance is high-performance sintered NdFeB.
  • High-performance sintered NdFeB is obtained through quick-setting strip method, hydrogen crushing, jet milling, pressing and sintering, and adopts anaerobic process to obtain Hcj (intrinsic coercive force, KOe) and (BH)max (maximum magnetic energy product, MGOe) and sintered NdFeB permanent magnet materials with a sum greater than 60.
  • the patent application with the publication number CN101707107A discloses a manufacturing method of a high remanence and high coercivity rare earth permanent magnet material, which includes master alloy preparation, pulverization, molding, sintering to make a sintered magnet, aging treatment, machining,
  • the surface treatment process step is characterized in that after sintering the sintered magnet R1-T-B-M1 process step, the sintered magnet is embedded in heavy rare earth HR2M2 alloy powder and one or more of R3 oxide, R4 fluoride, R5 fluoride in a pre-mixed blend of powders.
  • HR2 is at least one of Dy, Ho and Tb
  • M2 is at least one of Al, Cu, Co, Ni, Mn, Ga, In, Sn, Pb, Bi, Zn and Ag
  • R3, R4, R5 is one or more of rare earth elements including Y and Sc.
  • the patent application whose publication number is CN106298219A discloses a method for preparing RTB rare earth permanent magnets, comprising the following steps, a) preparing R L u R H v Fe 100-uvwz B w M z rare earth alloy used as a diffusion source, so The above RL represents at least one element of Pr and Nd, R H represents at least one element of Dy, Tb, Ho, and M represents at least one of Co, Nb, Cu, Al, Ga, Zr, Ti Elements, this rare earth alloy contains the main phase structure of R-Fe-B tetragonal crystal, u, v, w, z are the weight percentages of each substance, u, v, w, z satisfy the following relationship, 0 ⁇ u ⁇ 10,35 ⁇ v ⁇ 70, 0.5 ⁇ w ⁇ 5, 0 ⁇ z ⁇ 5; b) pulverize R L u R H v Fe 100-uvwz B w M z rare earth alloy to form alloy powder; c)
  • the diffusion source alloy used in this invention is R-Fe-B alloy, but when the R-Fe-B alloy is used as the diffusion source and the B content in the diffusion source is too high, its melting point will be relatively high, resulting in low diffusion rate . That is to say, there are few effective components entering the substrate in the same time, and once the diffusion temperature is increased, the main phase grains will be destroyed, thereby weakening the diffusion effect. Therefore, the diffusion efficiency is poor, and the ideal performance cannot be achieved.
  • the patent application with the publication number CN107731437A discloses a method for reducing the irreversible loss of sintered NdFeB thin sheet magnets. Proportionally mixed, then put into a diffusion furnace for heat treatment at a certain speed and temperature; finally, anneal the diffused magnet at 460°C-520°C for 3-5h.
  • This invention uses light rare earth metal Nd, Pr or PrNd alloy quick-setting sheet as a diffusion source to diffuse Nd or Pr elements into the surface layer area of the bulk sintered NdFeB sheet magnet, and then repair the damage to the surface area of the sintered NdFeB sheet magnet. microstructure to improve the coercive force of sintered NdFeB flake magnets.
  • the diffusion source used in this process is light rare earth
  • the diffusion effect of light rare earth is limited, so it is relatively effective only for thin slice products, and its Hcj performance is limited (only increased by 1-3KOe), and it is improved for products with a slightly larger thickness. Hcj performance effect is not obvious.
  • the patent application with the publication number CN105321702A discloses a method for increasing the coercive force of sintered NdFeB magnets.
  • the coercive force of sintered NdFeB magnets is improved by using a grain boundary diffusion alloy material that does not contain heavy rare earth elements through the grain boundary diffusion method; the diffusion alloy
  • the composition is Re 100-xy Al x M y , Re is one or more of Ce, Pr, Nd, M is one or more of Mg, Cu, 2 ⁇ X ⁇ 33, 0 ⁇ y ⁇ 5.
  • the specific steps of the process are: vacuum smelting the diffusion alloy, preparing the diffusion alloy into powder or rapidly quenching into a thin strip, coating the diffusion alloy on the surface of the sintered NdFeB magnet, and then diffusing in a vacuum furnace at 600-1000 °C 1-10 hours, tempering at 500°C for 1-5 hours.
  • the diffusion process is to cover the diffusion source on the surface of the magnet for diffusion, which will easily cause the powder or fragments of the diffusion source to adhere to the surface of the magnet, and the lower surface will be damaged due to the gravity of the magnet itself. Dimple defects occur to varying degrees, thus affecting product size and/or appearance.
  • the patent application with the publication number CN103003899A discloses a treatment device, which is equipped with a diffusion treatment part, a separation part, and a heat treatment part.
  • the diffusion source of the metal or alloy of metal RH is rotated while rotating; the separation part selectively separates the RH diffusion source from the sintered magnet received by the diffusion processing part and the RH diffusion source; the heat treatment part is for Re- Fe-B sintered magnets are heat-treated with the RH diffusion source removed.
  • the connection parts of different cavities are prone to low temperature, and it is difficult to ensure the uniform temperature zone in the furnace;
  • the continuous treatment furnace can not play a better role in improving efficiency. For example, when there is material in the diffusion area, the separation part and the heat treatment part are in a waiting state without material, so there is no obvious advantage in separate equipment from the diffusion part, separation part and heat treatment part.
  • M 1 is preferably any two of Ti, Zr, and Al elements, and the mass ratio of the two elements is 1:1-2 :1, for example 1:1, 1.5:1, 1:2, 2:1.
  • R H is Dy
  • M 1 is two of Ti and Al
  • x 85%
  • z 0.4%
  • y 14.6%
  • the R H x M 1 y B z alloy is Dy 85% Ti 9.73% Al 4.87% B 0.4% .
  • R H is Tb
  • M 1 is two of Ti and Zr
  • x 80%
  • z 0.3%
  • y 19.7%.
  • the R H x M 1 y B z alloy is Tb 80% Ti 11.82% Zr 7.88% B 0.3% .
  • the R H x M 1 y B z alloy may be in a flake form, for example, its average thickness is ⁇ 10 mm; preferably, the average thickness is ⁇ 5 mm; exemplarily 1 mm, 1.8 mm, 2 mm, 3 mm , 4mm, 5mm.
  • the present invention also provides a method for preparing the above-mentioned R H x M 1 y B z alloy, the preparation method comprising: smelting and quick-setting raw materials including R H element, M 1 element and B element to prepare the R H x M 1 y B z alloy.
  • the R H element, the M 1 element and the B element have the meanings as described above.
  • the melting is performed in an inert atmosphere
  • the inert atmosphere may be provided by argon and/or helium, preferably by argon.
  • the temperature of the smelting is 1350°C to 1550°C, exemplarily 1350°C, 1450°C, 1480°C, 1500°C; further, the holding time of the smelting is 0 to 30min, exemplarily 5min, 10min, 20min, 30min.
  • the smelting is until the raw materials are melted to form alloy liquid, and the alloy liquid is melted.
  • the preparation method further includes cooling to the pouring temperature after the alloy liquid obtained by smelting is melted.
  • the cooling rate is 3-9°C/min, exemplarily 3°C/min, 4°C/min, 6°C/min, 8°C/min, 9°C/min.
  • the pouring temperature is 1330-1530°C, exemplarily 1340°C, 1400°C, 1430°C, 1450°C.
  • the preparation method includes: pouring the molten alloy cooled to the pouring temperature by a strip throwing method to obtain R H x M 1 y B z quick-setting alloy flakes.
  • the average thickness of the R H x M 1 y B z quick-setting alloy sheet is ⁇ 10mm; preferably, the average thickness is ⁇ 5mm; examples are 1mm, 2mm, 3mm, 4mm, 5mm.
  • the preparation method includes melting raw materials including R H elements, M elements and B elements into an alloy liquid in an inert atmosphere, and cooling to the pouring temperature after the alloy liquid is melted, Casting is carried out by strip casting method to obtain R H x M 1 y B z quick-setting alloy flakes with an average thickness of ⁇ 10 mm.
  • the present invention also provides the application of the above-mentioned R H x M 1 y B z alloy in the preparation of sintered NdFeB materials, preferably in the preparation of high-performance sintered NdFeB materials.
  • the high-performance sintered NdFeB material refers to a sintered NdFeB permanent magnet material whose sum of Hcj (intrinsic coercive force, KOe) and (BH)max (maximum magnetic energy product, MGOe) is greater than 60.
  • the above-mentioned R H x M 1 y B z alloy is used as a diffusion source in the preparation of sintered NdFeB materials.
  • the invention also provides a sintered neodymium-iron-boron magnet, which is prepared by diffusion heat treatment with R 1 m Fen B p M 2 w as base material and R H x M 1 y B z alloy as diffusion source.
  • the R H x M 1 y B z alloy has the meanings as described above.
  • the R 1 is selected from the element group of Pr, Nd, Dy, Tb, Ho, Gd, Ce, La and Y
  • Fe iron element
  • B boron element
  • M2 is selected from one of Ti, Zr, Co, V, Nb, Ni, Cu, Zr, Al and Ga element groups , two or more elements.
  • said R 1 is selected from Nd and Dy
  • said M 2 is selected from Ti, Cu, Ga and Co.
  • the preparation method of the R 1 m Fen B p M 2 w matrix material includes smelting, powder making, pressing, sintering and aging to make a magnet, and may further include mechanical processing and surface treatment steps .
  • the thickness of the orientation direction of the substrate is not more than 30 mm, for example, 1-30 mm, which can be divided into 1-8 mm, 8-15 mm, 15-20 mm, and 20-30 mm.
  • the Hcj (intrinsic coercive force) of the sintered NdFeB magnet is not less than 20kOe, preferably 21-29kOe, exemplarily 23.61kOe, 24.45kOe, 25.63kOe, 26.40kOe, 27.50 kOe, 28.89kOe.
  • the Br of the sintered NdFeB magnet is 13.8-14.6 kGs, exemplarily 13.85 kGs, 13.94 kGs, 14.1 kGs, 14.2 kGs, 14.3 kGs, 14.55 kGs.
  • the density of the sintered NdFeB magnet is 7.50-7.60 g/cm 3 , exemplarily 7.50 g/cm 3 , 7.56 g/cm 3 , 7.60 g/cm 3 , preferably 7.56 g /cm 3 .
  • the present invention also provides a preparation method of the above-mentioned sintered NdFeB magnet, the preparation method comprising the following steps:
  • the sintered NdFeB magnet is obtained by uniformly mixing the diffusion source R H x M 1 y B z alloy and the base material R 1 m Fen B p M 2 w , and performing diffusion heat treatment.
  • the mass ratio of the diffusion source R H x M 1 y B z alloy to the base material R 1 m Fe n B p M 2 w is (1-5): 1, exemplarily 1: 1, 1.5:1, 2:1, 2.3:1, 3:1, 5:1.
  • the diffusion heat treatment adopts a method of temperature rise and fall in stages.
  • a three-stage heating and cooling method is adopted.
  • the temperature in the first stage of the three-stage stepped heating and cooling method is raised to 300-650°C, exemplarily 400°C, 480°C, 550°C, 650°C; the first stage is kept for 1-8h, exemplarily 2h, 4h, 6h, 8h;
  • the temperature is raised to 750-980°C, exemplarily 800°C, 850°C, 930°C, 980°C; the second stage is kept for 7-50h, exemplarily 10h, 20h, 30h, 40h, 50h;
  • the temperature is lowered to 700-930°C, exemplarily 750°C, 800°C, 880°C, 930°C; in the third stage, the temperature is kept for 3-20h, exemplarily 5h, 10h, 15h, 20h.
  • the heating rate of each stage is 3-15°C/min, exemplarily 6°C/min, 10°C/min; the cooling rate is 5-30°C/min, exemplarily 6°C/min, 10°C/min , 20°C/min.
  • the diffusion heat treatment further includes aging treatment.
  • the aging treatment temperature is 400-680°C, exemplarily 400°C, 500°C, 520°C, 600°C, 680°C; the holding time of aging treatment is 2-10h, exemplarily 2h, 4h, 6h, 8h , 10h.
  • the diffusion heat treatment is carried out in a detachably installed diffusion device.
  • the detachable and installed material reaction barrel can be easily replaced. After one barrel of material is processed, it can be processed in the next furnace continuously, which is convenient for the continuous production of sintered NdFeB magnets.
  • the present invention uses the R H x M 1 y B z alloy as the diffusion source and uses a detachable reaction barrel for diffusion to efficiently produce cost-effective rare earth permanent magnets, thereby solving the problem of the diffusion source in the diffusion process.
  • the problem of welding and adhesion with the base material improves the Hcj of the sintered NdFeB magnet, and solves the problem of efficiency improvement in the diffusion process; and the diffusion source of the present invention can be reused to reduce the production of high-performance sintered NdFeB magnets Low cost, and can be applied to larger magnets, especially to ensure the mass production of cost-effective sintered NdFeB products with a thickness of 8-30mm in the orientation direction.
  • R H adopts one or a combination of Dy and Tb to diffuse, and when the B element content is controlled to be 0.1% ⁇ z ⁇ 0.5%, it can Appropriately increase the melting point of the R H x M 1 y B z alloy, and at the same time ensure that Dy and Tb can efficiently diffuse into the magnet during the diffusion process, and can avoid the waste of Dy and Tb due to high temperature sublimation;
  • M 1 is One or more elements selected from the element group of Ti, Zr, and Al.
  • the built-in material reaction barrel of the diffusion device of the present invention adopts a detachable installation method, so it can be used alternately, thereby facilitating continuous operation of loading and unloading, to greatly improve production efficiency; simultaneously, the diffusion source and the base material are always in the diffusion process. There is contact and relative movement, so the bonding between substrates and the bonding between diffusion sources and substrates can be avoided, and effective diffusion can be achieved to improve the performance of sintered NdFeB magnets.
  • the present invention adopts a three-stage heating and cooling diffusion heat treatment method, wherein the purpose of the first heat preservation stage is to eliminate the residual moisture and organic matter on the surface and interior of the diffusion source, the substrate; and when the temperature is lower than 300°C, the heat preservation time is longer.
  • the second The purpose of the heat preservation stage is to make the diffusion source fully react with the substrate, so that the heavy rare earth elements in the diffusion source can be effectively concentrated in a narrow range near the grain boundary, so as to reduce the remanence loss while increasing the Hcj of the magnet; when the temperature When the temperature is lower than 750°C, the diffusion rate of heavy rare earths decreases, which is not conducive to improving the Hcj performance of the magnet, and the utilization rate of heavy rare earths is also low; when the temperature is higher than 980°C, heavy rare earths will continue to enter the grain boundary phase Diffuse into the main phase Nd 2 Fe 14 B, thereby destroying the crystal structure, resulting in the reduction of both Br and Hcj of the magnet.
  • the present invention controls the secondary heat treatment temperature within the range of 750-980°C to produce high-performance sintered NdFeB magnets; the temperature setting in the third cooling stage is slightly lower than that in the second stage by 20-50°C. A slight temperature drop is generated, allowing the diffusion source to flow more fully to improve the diffusion effect.
  • Powder making finally obtain a powder with an average particle size of 3.0 ⁇ m through hydrogen explosion + jet mill;
  • step (4) Process the substrates obtained in step (4) to obtain products with a size of 40-20-5mm (that is, a thickness of 5mm), and then carry out surface chemical pretreatment by degreasing, cleaning, and pickling, so that the substrates Oxide-free skin on the surface to prevent the diffusion of inhibited diffusion sources;
  • Diffusion treatment evenly spread the R 1 m Fe n B p M 2 w substrate after surface pretreatment in step (5) and the R H x M 1 y B z diffusion source alloy prepared in step (6)
  • the built-in reaction barrel mass ratio of base material: diffusion source alloy is 1:2.3
  • install the diffusion furnace pump it below 100Pa and start heating.
  • °C*20h heat preservation the third stage is 880°C*10h heat preservation; the heating rate of each stage is 6°C/min; the cooling rate is 10°C/min;
  • Comparative Example 1 The difference between Comparative Example 1 and Example 1 is that the content of each element in the R H x M 1 y B z diffusion source is composed as follows: 85% Tb, no B, and the rest of Ti+Al (mass ratio is 2:1) composition .
  • Comparative Example 2 The difference between Comparative Example 2 and Example 1 is that the content of each element in the R H x M 1 y B z diffusion source is as follows: 85% Tb, 1% B, and the rest of Ti+Al (mass ratio is 2:1) composition.
  • Example 1 and comparative example 1, comparative example 2 obtained magnet appearance and magnetic performance comparison
  • Powder making finally obtain a powder with an average particle size of 3.0 ⁇ m through hydrogen explosion + jet mill;
  • step (4) Process the substrates obtained in step (4) to obtain products with a size of 40-20-10mm (that is, a thickness of 10mm), and then carry out surface chemical pretreatment by degreasing, cleaning, and pickling, so that the substrates Oxide-free skin on the surface to prevent the diffusion of inhibited diffusion sources;
  • Diffusion treatment evenly spread the R 1 m Fe n B p M 2 w substrate after surface pretreatment in step (5) and the R H x M 1 y B z diffusion source alloy prepared in step (6)
  • substrate diffusion material is loaded into the diffusion furnace according to the mass ratio of 1:2
  • the pumping is below 100Pa and heating is started.
  • the temperature of the first stage of diffusion is 400°C*4h for heat preservation, and the second stage is 930°C* 30h heat preservation; the third stage is 880°C*10h heat preservation; the heating rate of each stage is 6°C/min; the cooling rate is 10°C/min; the aging is 500°C*6h.
  • each element content in the R H x M 1 y B z diffusion source is as follows: 70% Tb, 0.3% B, the Ti+Zr of balance (mass ratio is 1.5:1 )composition.
  • Comparative Example 4 The difference between Comparative Example 4 and Example 2 is that the diffusion of step (7) adopts two-stage treatment, that is, the temperature of the first stage of diffusion is 400°C*4h for heat preservation, and the second stage is 930°C*30h for heat preservation; the temperature rise of each stage The rate is 6°C/min; the cooling rate is 10°C/min; the aging is 500°C*6h.
  • the second stage of diffusion is 930°C*40h heat preservation.
  • Comparative Example 3 reduces the proportion of Tb content, and the Hcj of the magnet obtained after its diffusion is reduced; Comparative Example 4 adjusts the diffusion process, and the diffusion method of heating and cooling in three stages The Hcj of the magnet thus obtained is reduced by adjusting the diffusion mode of two-stage heating and cooling.
  • the results of Example 3 show that when the thickness of the R 1 m Fe n B p M 2 w substrate is increased, the Hcj performance of the diffused magnet can also be improved by adjusting the time of the three-stage heating and cooling diffusion treatment.

Abstract

本发明公开一种高性能烧结钕铁硼磁体及其制备方法，所述磁体以R 1 mFe nB pM 2 w为基材，R H xM 1 yB z合金为扩散源，通过扩散热处理制得。本发明通过以R H xM 1 yB z合金为扩散源，并采用可拆卸的物料反应桶进行扩散的方式，高效生产出高性价比的稀土永磁体，从而解决了扩散工艺中扩散源与基材间的熔接、粘着问题，并提高了烧结钕铁硼磁体的Hcj，并解决了扩散过程提效问题；且本发明的扩散源能够重复利用以降低烧结钕铁硼磁体的生产成本，且能适用于尺寸较大的磁体，尤其能保证取向方向厚度在8-30mm的高性价比烧结钕铁硼产品的量产。

Description

一种高性能烧结钕铁硼磁体及其制备方法
本申请要求享有2021年7月20日向中国国家知识产权局提交的，专利申请号为202110819841.5，发明名称为“一种高性能烧结钕铁硼磁体及其制备方法”的在先申请的优先权权益。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
本发明属于稀土永磁材料领域，具体涉及一种高性能烧结钕铁硼磁体及其制备方法。
背景技术
钕铁硼磁体作为现代性能相对优异的永磁体，其性能也有差异，其中性能最为优异的是高性能烧结钕铁硼。高性能烧结钕铁硼是通过速凝甩带法、氢破碎、气流磨、压型及烧结等工序，采用无氧工艺等以制得Hcj(内禀矫顽力，KOe)及(BH)max(最大磁能积，MGOe)之和大于60的烧结钕铁硼永磁材料。近几年来，如何开发Br降幅很小、成本增幅不大，且Hcj提高显著的钕铁硼磁体生产工艺，成为了各钕铁硼磁体生产厂商的重要目标。起初通过成分优化，例如采用价格昂贵的重稀土代替轻稀土等，然后通过晶粒细化来提高钕铁硼磁体的磁能积和矫顽力；同时也在开展晶界强化工艺，例如双合金、双主相工艺等等，但上述工艺均需要投入高比例的重稀土，从而导致Br有较大幅度的降低，且主要使用的重稀土Dy和Tb的储量有限，且成本较高，因此限制了此工艺的发展。近几年，行业内发展较快的一种提升钕铁硼磁体Hcj性能的新工艺为烧结钕铁硼晶界扩散稀土及稀土合金，此工艺性价比高，在推动稀土永磁资源节约、产品升级换代、节能减排、可持续发展等方面发挥了重要作用。
如公开号为CN101707107A的专利申请，公开了一种高剩磁高矫顽力稀土永 磁材料的制造方法，它包括母合金制备、粉碎、成型、烧结制成烧结磁体、时效处理、机械加工、表面处理工艺步骤，其特点是在烧结制成烧结磁体R1-T-B-M1工艺步骤之后，将烧结磁体埋入重稀土HR2M2合金粉与R3氧化物、R4氟化物、R5氟化物的一种或几种粉末构成的预先混好的混合粉中。其中，HR2为Dy、Ho和Tb中的至少一种，M2为Al、Cu、Co、Ni、Mn、Ga、In、Sn、Pb、Bi、Zn和Ag中的至少一种，R3、R4、R5为包含Y和Sc的稀土元素中的一种或多种。上述方法在扩散处理时，磁体间需要分开留有一定的间隙，否则磁体接触面存在粘接的风险，从而影响其外观。故需要作业人员间隔摆放磁体，这样就降低了作业效率，且因间隔摆放影响了装炉量，故生产效率也降低。
公开号为CN106298219A的专利申请，公开了一种制备R-T-B稀土永磁体的方法，包括以下步骤，a)制备用做扩散源的R L uR H vFe 100-u-v-w-zB wM z稀土合金，所述的R L表示Pr、Nd中的至少一种元素，R H表示Dy、Tb、Ho中的至少一种元素，M表示Co、Nb、Cu、Al、Ga、Zr、Ti中的至少一种元素，此稀土合金含有R-Fe-B四方晶的主相结构，u、v、w、z为各物质的重量百分数，u、v、w、z满足以下关系，0≤u≤10，35≤v≤70，0.5≤w≤5，0≤z≤5；b)粉碎R L uR H vFe 100-u-v-w-zB wM z稀土合金，形成合金粉；c)所述的合金粉与R-T-B磁体一起装入扩散装置进行热扩散，温度区间为750-950℃，时间区间为4-72h；d)进行时效处理。该发明采用的扩散源合金为R-Fe-B合金，但当R-Fe-B合金作为扩散源，且扩散源中含B量过高时，其熔点会相对较高，从而导致扩散速率低。即在相同时间内进入到基材的有效成分少，而一旦提高扩散温度，又会破坏主相晶粒，从而减弱扩散效果。因此扩散效率差，达不到理想性能。
公开号为CN107731437A的专利申请，公开了一种降低烧结钕铁硼薄片磁体不可逆损失的方法，通过将轻稀土金属Nd、Pr或者PrNd合金速凝片，和不合格烧结钕铁硼薄片磁体按一定比例混合，之后放入扩散炉中在一定的转速、温度条件下进行热处理；最后将扩散后的磁体在460℃-520℃下进行3-5h的退火处理。此发明采用轻稀土金属Nd、Pr或者PrNd合金速凝片作为扩散源，使Nd或Pr元素 扩散到块体烧结钕铁硼薄片磁体表面层区域内，进而修补烧结钕铁硼薄片磁体表面区域损坏的显微组织，以提高烧结钕铁硼破薄片磁体的矫顽力。但因该工艺采用的扩散源为轻稀土，轻稀土的扩散效果有限，故只针对薄片产品相对有效，其Hcj性能提高有限(仅增加了1-3KOe)，而针对厚度稍大的产品其改善Hcj性能作用不明显。
公开号为CN105321702A的专利申请，公开了一种提高烧结NdFeB磁体矫顽力的方法，通过采用不含重稀土元素的晶界扩散合金材料通过晶界扩散法提高烧结NdFeB磁体矫顽力；扩散合金的成分为Re 100-x-yAl xM y，Re为Ce、Pr、Nd中的一种或几种，M为Mg、Cu中的一种或几种，2≤X≤33，0≤y≤5。该工艺的具体步骤为：真空冶炼扩散合金，将扩散合金制备成粉末或快淬成薄带，将扩散合金包覆在烧结钕铁硼磁体表面，随后在真空炉中，于600-1000℃扩散1-10小时，500℃回火1-5小时。该方法除含有上述分析的专利文献CN107731437A分析的弊端外，其扩散过程是将扩散源包覆于磁体表面进行扩散，易导致磁体表面粘着扩散源粉末或碎片，且下表面因磁体本身重力原因会出现不同程度的凹坑缺陷，因此会影响产品尺寸和/或外观。
公开号为CN103003899A的专利申请，公开了一种处理装置，其具备扩散处理部、分离部、热处理部，其中扩散处理部，用于一边加热Re-Fe-B类烧结磁体和包含重稀土元素的金属RH的金属或合金的扩散源，一边进行旋转；分离部，从由扩散处理部接收的烧结磁体和RH扩散源中选择性分离RH扩散源；热处理部，对于扩散有重稀土元素的Re-Fe-B烧结磁体，在去除RH扩散源的状态下进行热处理。该装置中不同腔体的链接部位易产生温度低点，炉内均温区不易保证；另一方面因扩散区和热处理区所需的节拍相对较长，而分离部相对用时稍短，故该连续处理炉不能更好地起到提效作用，比如扩散区有物料时，分离部和热处理部处于无料等待状态，因而与扩散部、分离部、热处理部分别单独设备无明显优势。
因此，如何解决烧结钕铁硼磁体扩散工艺中扩散源与基材间的熔接、粘着 问题，Hcj提升不足、扩散难以提效、扩散源无法重复利用而导致成本较高，且无法适用于尺寸较大磁体的钕铁硼产品成为亟待解决的技术难题。
发明内容
为了改善上述技术问题，本发明提供一种R H xM 1 yB z合金，所述的R H选自Dy、Tb中的一种或两种元素，M 1选自Ti、Zr、Al元素中的一种、两种或三种元素，B为硼元素，x、y、z代表元素的重量百分数，x、y、z满足以下关系：75％≤x≤90％，0.1％≤z≤0.5％，y＝1-x-z。
根据本发明的实施方案，所述R H xM 1 yB z合金中，80％≤x≤85％，0.15％≤z≤0.3％，y＝1-x-z；示例性地，x＝80％、81％、82％、83％、84％、85％；z＝0.1％、0.15％、0.2％、0.25％、0.3％。
根据本发明示例性的实施方案，所述R H xM 1 yB z合金中，M 1优选为Ti、Zr、Al元素中的任意两种，两种元素的质量比为1:1～2:1，示例性为1:1、1.5:1、1:2、2:1。
根据本发明示例性的实施方案，所述R H xM 1 yB z合金中，R H为Dy，M 1为Ti、Al中的两种，x＝85％，z＝0.4％，y＝14.6％。例如，所述R H xM 1 yB z合金为Dy 85％Ti 9.73％Al 4.87％B 0.4％。
根据本发明示例性的实施方案，所述R H xM 1 yB z合金中，R H为Tb，M 1为Ti、Zr中的两种，x＝80％，z＝0.3％，y＝19.7％。例如，所述R H xM 1 yB z合金为Tb 80％Ti 11.82％Zr 7.88％B 0.3％。
根据本发明的实施方案，所述R H xM 1 yB z合金可以为片状形态，例如其平均厚度≤10mm；优选地，平均厚度≤5mm；示例性为1mm、1.8mm、2mm、3mm、4mm、5mm。
本发明还提供上述R H xM 1 yB z合金的制备方法，所述制备方法包括：将包括R H元素、M 1元素和B元素的原料经过熔炼、速凝，制备得到所述R H xM 1 yB z合金。
根据本发明的实施方案，所述R H元素、M 1元素和B元素具有如上文所述的 含义。
根据本发明的实施方案，所述R H元素、M 1元素和B元素的用量按照R H:M 1:B重量比＝x:y:z称量；其中，x、y和z具有如上文所述的含义。
根据本发明的实施方案，所述熔炼在惰性气氛中进行，例如所述惰性气氛可以由氩气和/或氦气提供，优选由氩气提供。
根据本发明的实施方案，所述熔炼的温度为1350℃～1550℃，示例性为1350℃、1450℃、1480℃、1500℃；进一步地，所述熔炼的保温时间为0～30min，示例性为5min、10min、20min、30min。
根据本发明的实施方案，所述熔炼为至原料熔融形成合金液，合金液熔清为止。
根据本发明的实施方案，所述制备方法还包括待熔炼得到的合金液熔清后，进行冷却至浇注温度。
优选地，所述冷却的速率为3～9℃/min，示例性为3℃/min、4℃/min、6℃/min、8℃/min、9℃/min。
优选地，所述浇注的温度为1330～1530℃，示例性为1340℃、1400℃、1430℃、1450℃。
根据本发明的实施方案，所述制备方法包括：将冷却至浇注温度的合金液通过甩带法进行浇注，得到R H xM 1 yB z速凝合金片。
根据本发明的实施方案，所述R H xM 1 yB z速凝合金片的平均厚度≤10mm；优选地，平均厚度≤5mm；示例性为1mm、2mm、3mm、4mm、5mm。
根据本发明示例性的实施方案，所述制备方法包括在惰性气氛中，对包括R H元素、M 1元素和B元素的原料熔炼成合金液，待合金液熔清后，冷却至浇注温度，采用甩带法进行浇注，得到平均厚度为≤10mm的R H xM 1 yB z速凝合金片。
本发明还提供上述R H xM 1 yB z合金在制备烧结钕铁硼材料中的应用，优选在制备高性能烧结钕铁硼材料中的应用。其中，所述高性能烧结钕铁硼材料意指Hcj(内禀矫顽力，KOe)及(BH)max(最大磁能积，MGOe)之和大于60的烧结 钕铁硼永磁材料。优选地，上述R H xM 1 yB z合金在制备烧结钕铁硼材料中作为扩散源。
本发明还提供一种烧结钕铁硼磁体，其以R 1 mFe nB pM 2 w为基材，R H xM 1 yB z合金为扩散源，通过扩散热处理制得。
根据本发明的实施方案，所述R H xM 1 yB z合金具有如上文所述的含义。
根据本发明的实施方案，所述R 1 mFe nB pM 2 w基材中，所述的R 1选自Pr、Nd、Dy、Tb、Ho、Gd、Ce、La和Y元素组中的一种、两种或更多种，Fe为铁元素，B为硼元素，M 2选自Ti、Zr、Co、V、Nb、Ni、Cu、Zr、Al和Ga元素组中的一种、两种或更多种元素。
优选地，所述R 1选自Nd和Dy，所述M 2选自Ti、Cu、Ga和Co。
根据本发明的实施方案，所述R 1 mFe nB pM 2 w基材中，m代表R 1的重量百分含量，35％≥m≥27％；示例性地，m＝29％、29.5％、30％、31％、32％。
根据本发明的实施方案，所述R 1 mFe nB pM 2 w基材中，n代表Fe的重量百分含量，70％≥n≥60％，示例性地，n＝62％、64％、66.5％、67.5％、68.5％。
根据本发明的实施方案，所述R 1 mFe nB pM 2 w基材中，p代表B的重量百分含量，所述B元素的含量为0.8％≤p≤1.5％，示例性地，p＝0.8％、1.0％、1.1％。
根据本发明的实施方案，所述R 1 mFe nB pM 2 w基体材料的制备方法，包括熔炼、制粉、压型、烧结时效制成磁体，还可以进一步包含机械加工、表面处理步骤。
根据本发明的实施方案，所述基材的取向方向厚度不超过30mm，例如为1-30mm，可划分为1-8mm，8-15mm，15-20mm，20-30mm。
根据本发明的实施方案，所述烧结钕铁硼磁体的Hcj(内禀矫顽力)不低于20kOe，优选为21-29kOe，示例性为23.61kOe、24.45kOe、25.63kOe、26.40kOe、27.50kOe、28.89kOe。
根据本发明的实施方案，所述烧结钕铁硼磁体的Br为13.8-14.6kGs，示例性为13.85kGs、13.94kGs、14.1kGs、14.2kGs、14.3kGs、14.55kGs。
根据本发明的实施方案，所述烧结钕铁硼磁体的密度为7.50～7.60g/cm 3，示 例性为7.50g/cm 3、7.56g/cm 3、7.60g/cm 3，优选为7.56g/cm 3。
本发明还提供上述烧结钕铁硼磁体的制备方法，所述制备方法包括如下步骤：
将扩散源R H xM 1 yB z合金和基体材料R 1 mFe nB pM 2 w均匀混合，通过扩散热处理，得到所述烧结钕铁硼磁体。
根据本发明的实施方案，扩散源R H xM 1 yB z合金与基材R 1 mFe nB pM 2 w的质量比为(1～5):1，示例性为1:1、1.5:1、2:1、2.3:1、3:1、5:1。
根据本发明的实施方案，所述扩散热处理采用阶段升降温的方式。优选地，采用三级阶梯升降温方式。
根据本发明的实施方案，三级阶梯升降温方式的第一阶段升温至300-650℃，示例性为400℃、480℃、550℃、650℃；第一阶段保温1-8h，示例性为2h、4h、6h、8h；
第二阶段升温至750-980℃，示例性为800℃、850℃、930℃、980℃；第二阶段保温7-50h，示例性为10h、20h、30h、40h、50h；
第三阶段降温至700～930℃，示例性为750℃、800℃、880℃、930℃；第三阶段保温3-20h，示例性为5h、10h、15h、20h。
例如，各阶段的升温速率为3-15℃/min，示例性为6℃/min、10℃/min；降温速率为5-30℃/min，示例性为6℃/min、10℃/min、20℃/min。
根据本发明的实施方案，所述扩散热处理还包括时效处理。优选地，时效处理温度为400-680℃，示例性为400℃、500℃、520℃、600℃、680℃；时效处理的保温时间为2-10h，示例性为2h、4h、6h、8h、10h。
根据本发明的实施方案，所述扩散热处理在可拆卸安装的扩散装置中进行。可拆卸安装的物料反应桶能够方便替换，当处理完一桶物料后，可连续下一炉处理，便于烧结钕铁硼磁体的连续化生产。
本发明的有益效果:
(1)本发明通过以R H xM 1 yB z合金为扩散源，并采用可拆卸的反应桶进行扩散的方式，高效生产出高性价比的稀土永磁体，从而解决了扩散工艺中扩散源与基材间的熔接、粘着问题，提高了烧结钕铁硼磁体的Hcj，并解决了扩散过程中提效问题；且本发明的扩散源能够重复利用以降低高性能烧结钕铁硼磁体的生产成本，且能适用于尺寸较大的磁体，尤其能保证取向方向厚度在8-30mm的高性价比烧结钕铁硼产品的量产。
(2)本发明中扩散源R H xM 1 yB z合金中R H采用Dy、Tb中的一种或组合来进行扩散，并控制B元素含量为0.1％≤z≤0.5％时，可适当提高R H xM 1 yB z合金的熔点，同时保证在扩散过程中Dy，Tb能够高效的扩散进入磁体内部，并可避免Dy，Tb等因温度过高升华而导致浪费；M 1是选自Ti、Zr、Al元素组中的一种或多种元素，通过合理优化上述成分的配比能在保证重稀土扩散效果的同时，有效改善扩散源的温度稳定性，从而显著提高烧结钕铁硼磁体的Hcj和磁能积，以制得高性能的烧结钕铁硼材料磁体。
(3)本发明扩散装置的内置物料反应桶采用可拆卸安装方式，因此可交替使用，从而利于上料、下料连续作业，以大大提高生产效率；同时扩散源与基材在扩散过程中一直存在接触和相对运动，因此可避免基材间粘接及扩散源与基材间的粘接，并能有效扩散，以提高烧结钕铁硼材料磁体的性能。
(4)本发明通过采用三级升降温扩散热处理方式，其中第一保温阶段目的是排除扩散源、基材表面及内部的残留水分及有机物；且当温度低于300℃时，需保温时间较长，耗能大；而当温度高于650℃时，磁体表面晶界趋于熔融态，个别部位会优先扩散，导致再升温过程中，其扩散量会不均匀，性能波动较大；第二保温阶段目的是为使扩散源充分与基材反应，使得扩散源中重稀土元素能够有效的集中在晶界附近很窄的范围内，以在提高磁体Hcj的同时，降低剩磁损失；当温度低于750℃时，重稀土扩散速率降低，不利于提升磁体的Hcj性能，且对重稀土的利用率也较低；而当温度高于980℃时，重稀土进入晶界相后仍会继续扩散进入主相Nd 2Fe 14B，从而破坏掉晶体结构，导致磁体的Br和Hcj都降低。 因此本发明将二级热处理温度控制在750-980℃范围内，以制得高性能的烧结钕铁硼材料磁体；第三降温阶段温度设定比第二阶段稍低20-50℃，目的是产生一个轻度温降，使得扩散源更充分的流动，以提升扩散效果。
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1
(1)通过熔炼法制备R 1 mFe nB pM 2 w基材：在氩气气氛中熔炼各原料，该合金配方由29.5％Nd，0.5％Dy，1.0％B，0.2％Ti，0.2％Cu，0.1％Ga，1％Co，余量为Fe组成；按配方比例准备各原材料加入到熔炼炉中，待合金熔融后升至1480℃进行保温5min，而后冷却至1400℃进行浇铸，通过甩带工艺得到平均厚度为0.28mm的速凝片；
(2)制粉：通过氢爆+气流磨最终得到平均粒度为3.0μm的粉末；
(3)压型：通过在磁场下压制成压坯，并经过等静压形成约4.6g/cm 3的压坯；
(4)烧结成型：先通过350℃保温3h，然后升温至850℃保温1h进行脱气，再于1060℃高温保温120min进行烧结，最后于520℃时效保温300min后，从而形成烧结钕铁硼基材；
(5)对步骤(4)制得的基材进行加工分别得到40-20-5mm尺寸的产品(即厚度为5mm)，再通过除油、清洗、酸洗进行表面化学预处理，使得基材表面无氧化物表皮，防止抑制扩散源的扩散；
(6)扩散源R H xM 1 yB z合金-在氩气气氛中熔炼各原料，该合金由85％Tb，0.4％B，余量的Ti+Al(质量比为2:1)组成；待合金熔清后，升温至1500℃保温10min，冷却至1430℃进行浇铸，通过甩带工艺得到平均厚度为1.8mm的速凝厚片；
(7)扩散处理：将经过步骤(5)表面预处理后的R 1 mFe nB pM 2 w基材及步骤(6)制得的R H xM 1 yB z扩散源合金均匀散布在内置反应桶(基材：扩散源合金按质量比为1:2.3)中，装入扩散炉，抽至100Pa以下开始加热，扩散第一阶段温度为400℃*4h保温，第二阶段为930℃*20h保温；第三阶段为880℃*10h保温；各阶段的升温速率均为6℃/min；降温速率为10℃/min；时效为520℃*4h，得到烧结钕铁硼磁体。
对比例1
对比例1与实施例1的区别在于：R H xM 1 yB z扩散源中各元素含量组成如下：85％Tb，无B，余量的Ti+Al(质量比为2:1)组成。
对比例2
对比例2与实施例1的区别在于：R H xM 1 yB z扩散源中各元素含量组成如下：85％Tb，1％B，余量的Ti+Al(质量比为2:1)组成。
通过对比例1和对比例2调整扩散材中B含量，来考察扩散材中B含量对扩散后磁体的外观及磁性能的影响(外观检验方式为：一定数量物料出炉后，100％检料外观，如果该炉物料扩散结束后磁体两片或多片间无粘连，则视为外观粘着比例为0％，当两片或多片间粘连不能分开的，则视为粘连片，则粘着比例＝(粘连片数/总出炉片数)*100％)，结果如下表1所示。
表1实施例1与对比例1、对比例2得到的磁体外观及磁性能对比
Figure PCTCN2022106752-appb-000001
Figure PCTCN2022106752-appb-000002
从表1中结果可知：适量B的加入能够适当提高R H xM 1 yB z合金的熔点，从而避免R H xM 1 yB z扩散源合金因表面熔融引发的粘连，进而降低磁体之间的外观粘着比例，以改善磁体的出炉外观，并有效提升磁体的Hcj；但当B含量过高时，则影响了扩散通道，反而会影响扩散后磁体的Hcj提升幅度。
实施例2
(1)通过熔炼法制备R 1 mFe nB pM 2 w基材：在氩气气氛中熔炼各原料，该合金由29.5％Nd，0.5％Dy，1.0％B，0.2％Ti，0.2％Cu，0.1％Ga，1％Co，余量为Fe组成；待合金熔融后升至1480℃进行保温5min，而后冷却至1400℃进行浇铸，通过甩带工艺得到平均厚度为0.28mm的速凝片；
(2)制粉：通过氢爆+气流磨最终得到平均粒度为3.0μm的粉末；
(3)压型：通过在磁场下压制成压坯，并经过等静压形成约4.6g/cm 3的压坯；
(4)烧结成型：先通过350℃保温3h，然后升温至850℃保温1h进行脱气，再于1060℃高温保温120min进行烧结，最后于520℃时效保温300min后，从而形成烧结钕铁硼基材；
(5)对步骤(4)制得的基材进行加工分别得到40-20-10mm尺寸的产品(即厚度为10mm)，再通过除油、清洗、酸洗进行表面化学预处理，使得基材表面无氧化物表皮，防止抑制扩散源的扩散；
(6)扩散源R H xM 1 yB z合金-在氩气气氛中熔炼各原料，该合金由80％Tb， 0.3％B，余量的Ti+Zr(质量比为1.5:1)组成；待合金熔清后，升温至1500℃保温10min，冷却至1430℃进行浇铸，通过甩带工艺得到平均厚度为2.0mm的速凝厚片；
(7)扩散处理：将经过步骤(5)表面预处理后的R 1 mFe nB pM 2 w基材及步骤(6)制得的R H xM 1 yB z扩散源合金均匀散布在内置反应桶(基材：扩散材按质量比为1:2装入扩散炉)中，抽至100Pa以下开始加热，扩散第一阶段温度为400℃*4h保温，第二阶段为930℃*30h保温；第三阶段为880℃*10h保温；各阶段的升温速率均为6℃/min；降温速率为10℃/min；时效为500℃*6h。
对比例3
对比例3与实施例2的区别仅在于：R H xM 1 yB z扩散源中各元素含量组成如下：70％Tb，0.3％B，余量的Ti+Zr(质量比为1.5:1)组成。
对比例4
对比例4与实施例2的区别在于：步骤(7)的扩散采用二级处理，即：扩散第一阶段温度为400℃*4h保温，第二阶段为930℃*30h保温；各阶段的升温速率均为6℃/min；降温速率为10℃/min；时效为500℃*6h。
实施例3
本实施例与实施例2的区别在于：
①将R 1 mFe nB pM 2 w基材加工得到40-20-15mm尺寸的产品(即厚度为15mm)；
②扩散第二阶段为930℃*40h保温。
对实施例2-3及对比例3-4制得的磁体的外观及磁性能进行测试，结果如下表2所示。
表2实施例2-3与对比例3-4得到的磁体外观及磁性能对比
Figure PCTCN2022106752-appb-000003
由上表2可知，与实施例2对比，对比例3降低了Tb含量的比例，其扩散后制得的磁体的Hcj降低；对比例4调整了扩散工艺，由三级阶段升降温的扩散方式调整为两级升降温的扩散方式，由此制得的磁体的Hcj降低。实施例3结果表明：当增加R 1 mFe nB pM 2 w基材的厚度时，通过调整三级阶段升降温扩散处理的时间，亦能提升扩散后磁体的Hcj性能。
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R H xM 1 yB z合金，其特征在于，所述的R H选自Dy、Tb中的一种或两种元素，M 1选自Ti、Zr、Al元素中的一种、两种或三种元素，B为硼元素，x、y、z代表元素的重量百分数，x、y、z满足以下关系：75％≤x≤90％，0.1％≤z≤0.5％，y＝1-x-z。
  2. 如权利要求1所述的R H xM 1 yB z合金，其特征在于，所述R H xM 1 yB z合金中，80％≤x≤85％，0.15％≤z≤0.3％，y＝1-x-z。
    优选地，所述R H xM 1 yB z合金中，M 1为Ti、Zr、Al元素中的任意两种，两种元素的质量比为1:1～2:1。
    优选地，所述R H xM 1 yB z合金可以为片状形态，例如其平均厚度≤10mm；优选地，平均厚度≤5mm。
  3. 如权利要求1或2所述R H xM 1 yB z合金的制备方法，其特征在于，所述制备方法包括：将包括R H元素、M 1元素和B元素的原料经过熔炼、速凝，制备得到所述R H xM 1 yB z合金。
    优选地，所述R H元素、M 1元素和B元素具有如权利要求1所述的含义。
    优选地，所述R H元素、M 1元素和B元素的用量按照R H:M 1:B重量比＝x:y:z称量；其中，x、y和z具有如权利要求1所述的含义。
  4. 如权利要求3所述的制备方法，其特征在于，所述熔炼在惰性气氛中进行，优选所述惰性气氛由氩气提供。
    优选地，所述熔炼的温度为1350℃～1550℃，所述熔炼的保温时间为0～30min。
    优选地，所述熔炼为至原料熔融形成合金液，合金液熔清为止。
    优选地，所述制备方法还包括待熔炼得到的合金液熔清后，进行冷却至浇 注温度。
    优选地，所述冷却的速率为3～9℃/min。
    优选地，所述浇注的温度为1330～1530℃。
  5. 如权利要求3或4所述的制备方法，其特征在于，所述制备方法包括：将冷却至浇注温度的合金液通过甩带方法进行浇注，得到R H xM 1 yB z速凝合金片。
    优选地，所述R H xM 1 yB z速凝合金片的平均厚度≤10mm；优选地，平均厚度≤5mm。
    优选地，所述制备方法包括在惰性气氛中，对包括R H元素、M 1元素和B元素的原料熔炼成合金液，待合金液熔清后，冷却至浇注温度，采用甩带方法进行浇注，得到平均厚度为≤10mm的R H xM 1 yB z速凝合金片。
  6. 权利要求1或2所述R H xM 1 yB z合金和/或权利要求3-5任一项所述的制备方法制得的R H xM 1 yB z合金在制备烧结钕铁硼材料中的应用，优选在制备高性能烧结钕铁硼材料中的应用。
    优选地，权利要求1或2所述R H xM 1 yB z合金和/或权利要求3-5任一项所述的制备方法制得的R H xM 1 yB z合金在制备烧结钕铁硼材料中作为扩散源。
  7. 一种烧结钕铁硼磁体，其特征在于，所述磁体以R 1 mFe nB pM 2 w为基材，R H xM 1 yB z合金为扩散源，通过扩散热处理制得。
    优选地，所述R H xM 1 yB z合金具有如权利要求1或2所述的含义。
  8. 如权利要求7所述的磁体，其特征在于，所述R 1 mFe nB pM 2 w基材中，所述的R 1选自Pr、Nd、Dy、Tb、Ho、Gd、Ce、La和Y元素组中的一种、两种或更多种，Fe为铁元素，B为硼元素，M 2选自Ti、Zr、Co、V、Nb、Ni、Cu、Zr、Al和Ga元素组中的一种、两种或更多种元素。
    优选地，所述R 1选自Nd和Dy，所述M 2选自Ti、Cu、Ga和Co。
    优选地，所述R 1 mFe nB pM 2 w基材中，m代表R 1的重量百分含量，35％≥m≥27％。
    优选地，所述R 1 mFe nB pM 2 w基材中，n代表Fe的重量百分含量，70％≥n≥60％。
    优选地，所述R 1 mFe nB pM 2 w基材中，p代表B的重量百分含量，所述B元素的含量为0.8％≤p≤1.5％。
    优选地，所述R 1 mFe nB pM 2 w基体材料的制备方法，包括熔炼、制粉、压型、烧结时效制成磁体，还可以进一步包含机械加工、表面处理步骤。
    优选地，所述基材的取向方向厚度不超过30mm，例如为1-30mm。
  9. 如权利要求7或8所述的磁体，其特征在于，所述烧结钕铁硼磁体的Hcj(内禀矫顽力)不低于20kOe，优选为21-29kOe。
    优选地，所述烧结钕铁硼磁体的Br为13.8-14.6kGs。
    优选地，所述烧结钕铁硼磁体的密度为7.50～7.60g/cm 3。
  10. 权利要求7-9任一项所述的磁体的制备方法，特征在于，所述制备方法包括如下步骤：
    将扩散源R H xM 1 yB z合金和基体材料R 1 mFe nB pM 2 w均匀混合，通过扩散热处理，得到所述烧结钕铁硼磁体。
    优选地，扩散源R H xM 1 yB z合金与基材R 1 mFe nB pM 2 w的质量比为(1～5):1。
    优选地，所述扩散热处理采用阶段升降温的方式。优选地，采用三级阶梯升降温方式。
    优选地，三级阶梯升降温方式的第一阶段升温至300-650℃，第一阶段保温1-8h；
    第二阶段升温至750-980℃，第二阶段保温7-50h；
    第三阶段降温至700～930℃，第三阶段保温3-20h。
    优选地，各阶段的升温速率为3-15℃/min，降温速率为5-30℃/min。
    优选地，所述扩散热处理还包括时效处理。
    优选地，时效处理的温度为400-680℃，时效处理的保温时间为2-10h。
PCT/CN2022/106752 2021-07-20 2022-07-20 一种高性能烧结钕铁硼磁体及其制备方法 WO2023001189A1 (zh)

Priority Applications (2)

Application Number Priority Date Filing Date Title
KR1020247002013A KR20240022643A (ko) 2021-07-20 2022-07-20 고성능 소결 NdFeB 자석 및 이의 제조 방법
EP22845354.4A EP4358103A1 (en) 2021-07-20 2022-07-20 High-performance sintered neodymium-iron-boron magnet and preparation method therefor

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CN202110819841.5 2021-07-20
CN202110819841.5A CN113593800B (zh) 2021-07-20 2021-07-20 一种高性能烧结钕铁硼磁体及其制备方法

Publications (1)

Publication Number Publication Date
WO2023001189A1 true WO2023001189A1 (zh) 2023-01-26

Family

ID=78248455

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CN2022/106752 WO2023001189A1 (zh) 2021-07-20 2022-07-20 一种高性能烧结钕铁硼磁体及其制备方法

Country Status (4)

Country Link
EP (1) EP4358103A1 (zh)
KR (1) KR20240022643A (zh)
CN (1) CN113593800B (zh)
WO (1) WO2023001189A1 (zh)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113593800B (zh) * 2021-07-20 2023-01-10 烟台正海磁性材料股份有限公司 一种高性能烧结钕铁硼磁体及其制备方法
CN114974776A (zh) 2022-05-31 2022-08-30 烟台东星磁性材料股份有限公司 钕铁硼稀土磁体及其制备方法

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101707107A (zh) 2009-11-23 2010-05-12 烟台首钢磁性材料股份有限公司 一种高剩磁高矫顽力稀土永磁材料的制造方法
CN103003899A (zh) 2010-07-13 2013-03-27 日立金属株式会社 处理装置
CN105321702A (zh) 2015-11-19 2016-02-10 北京科技大学 一种提高烧结NdFeB磁体矫顽力的方法
CN106298219A (zh) 2016-08-17 2017-01-04 宁波永久磁业有限公司 一种制备r‑t‑b稀土永磁体的方法及装置
CN107689279A (zh) * 2017-09-13 2018-02-13 内蒙古科技大学 一种提高烧结钕铁硼复合磁体矫顽力的方法
CN107731437A (zh) 2017-10-30 2018-02-23 北京工业大学 一种降低烧结钕铁硼薄片磁体不可逆损失的方法
JP2018101680A (ja) * 2016-12-20 2018-06-28 パレス化学株式会社 Ｒ−ｔ−ｂ系焼結磁石の製造方法
CN110808158A (zh) * 2019-09-12 2020-02-18 浙江东阳东磁稀土有限公司 一种提高烧结钕铁硼磁体矫顽力的方法及烧结钕铁硼磁体
CN111636035A (zh) * 2020-06-11 2020-09-08 福建省长汀金龙稀土有限公司 重稀土合金、钕铁硼永磁材料、原料和制备方法
CN113593800A (zh) * 2021-07-20 2021-11-02 烟台正海磁性材料股份有限公司 一种高性能烧结钕铁硼磁体及其制备方法

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5874951B2 (ja) * 2011-05-02 2016-03-02 日立金属株式会社 Ｒ−ｔ−ｂ系焼結磁石の製造方法

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101707107A (zh) 2009-11-23 2010-05-12 烟台首钢磁性材料股份有限公司 一种高剩磁高矫顽力稀土永磁材料的制造方法
CN103003899A (zh) 2010-07-13 2013-03-27 日立金属株式会社 处理装置
CN105321702A (zh) 2015-11-19 2016-02-10 北京科技大学 一种提高烧结NdFeB磁体矫顽力的方法
CN106298219A (zh) 2016-08-17 2017-01-04 宁波永久磁业有限公司 一种制备r‑t‑b稀土永磁体的方法及装置
JP2018101680A (ja) * 2016-12-20 2018-06-28 パレス化学株式会社 Ｒ−ｔ−ｂ系焼結磁石の製造方法
CN107689279A (zh) * 2017-09-13 2018-02-13 内蒙古科技大学 一种提高烧结钕铁硼复合磁体矫顽力的方法
CN107731437A (zh) 2017-10-30 2018-02-23 北京工业大学 一种降低烧结钕铁硼薄片磁体不可逆损失的方法
CN110808158A (zh) * 2019-09-12 2020-02-18 浙江东阳东磁稀土有限公司 一种提高烧结钕铁硼磁体矫顽力的方法及烧结钕铁硼磁体
CN111636035A (zh) * 2020-06-11 2020-09-08 福建省长汀金龙稀土有限公司 重稀土合金、钕铁硼永磁材料、原料和制备方法
CN113593800A (zh) * 2021-07-20 2021-11-02 烟台正海磁性材料股份有限公司 一种高性能烧结钕铁硼磁体及其制备方法

Also Published As

Publication number Publication date
CN113593800A (zh) 2021-11-02
CN113593800B (zh) 2023-01-10
KR20240022643A (ko) 2024-02-20
EP4358103A1 (en) 2024-04-24

Similar Documents

Publication Publication Date Title
WO2023001189A1 (zh) 一种高性能烧结钕铁硼磁体及其制备方法
WO2021238867A1 (zh) 一种钕铁硼磁体及其制备方法和应用
WO2021169886A1 (zh) 一种钕铁硼磁体材料、原料组合物及制备方法和应用
TWI755152B (zh) 釹鐵硼磁體材料、原料組合物及製備方法和應用
WO2021249159A1 (zh) 重稀土合金、钕铁硼永磁材料、原料和制备方法
WO2021169891A1 (zh) 钕铁硼磁体材料、原料组合物、制备方法、应用
CN102436889A (zh) 钛锆镓复合添加的低失重钕铁硼磁性材料及其制备方法
WO2021169887A1 (zh) 一种钕铁硼磁体材料、原料组合物及制备方法和应用
WO2019223431A1 (zh) 一种低成本扩散源合金和晶界扩散磁体及其制备方法
CN106920617A (zh) 高性能钕铁硼稀土永磁材料及其制备方法
WO2021169888A1 (zh) 钕铁硼磁体材料、原料组合物及制备方法和应用
CN108154986B (zh) 一种含y高丰度稀土永磁体及其制备方法
CN109585113A (zh) 一种烧结钕铁硼磁体的制备方法
CN111312461B (zh) 一种钕铁硼磁体材料、原料组合物及制备方法和应用
CN108389711A (zh) 一种具有高矫顽力的烧结钕铁硼磁体的制备方法
WO2021169890A1 (zh) 钕铁硼磁体材料、原料组合物、制备方法、应用
CN104575901A (zh) 一种添加铽粉的钕铁硼磁体及其制备方法
WO2021169889A1 (zh) 钕铁硼磁体材料、原料组合物、制备方法、应用
WO2023083100A1 (zh) 一种烧结钕铁硼磁体材料及其制备方法和应用
WO2022258070A1 (zh) 一种低成本高矫顽力富LaCe钕铁硼永磁体及其制备方法和应用
WO2021169892A1 (zh) 钕铁硼磁体材料、原料组合物、制备方法、应用
WO2023124688A1 (zh) 钕铁硼磁体及其制备方法和应用
CN114927302A (zh) 稀土磁体及其制备方法
WO2022143780A1 (zh) 一种稀土永磁体及其制备方法
CN113539600A (zh) 一种高磁能积和高矫顽力的含Dy稀土永磁体及制备方法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 22845354

Country of ref document: EP

Kind code of ref document: A1

WWE Wipo information: entry into national phase

Ref document number: 2022845354

Country of ref document: EP

ENP Entry into the national phase

Ref document number: 20247002013

Country of ref document: KR

Kind code of ref document: A

WWE Wipo information: entry into national phase

Ref document number: 1020247002013

Country of ref document: KR

ENP Entry into the national phase

Ref document number: 2022845354

Country of ref document: EP

Effective date: 20240117

NENP Non-entry into the national phase

Ref country code: DE