CN115156003A - Method for manufacturing magnetic conduction layer by utilizing magnetic conduction material - Google Patents

Method for manufacturing magnetic conduction layer by utilizing magnetic conduction material Download PDF

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Publication number
CN115156003A
CN115156003A CN202210784878.3A CN202210784878A CN115156003A CN 115156003 A CN115156003 A CN 115156003A CN 202210784878 A CN202210784878 A CN 202210784878A CN 115156003 A CN115156003 A CN 115156003A
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China
Prior art keywords
layer
magnetic conductive
magnetic
sublayer
conductive material
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CN202210784878.3A
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Chinese (zh)
Inventor
瞿义生
李超
袁华庭
张明
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Wuhan Supor Cookware Co Ltd
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Wuhan Supor Cookware Co Ltd
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Priority to CN202210784878.3A priority Critical patent/CN115156003A/en
Publication of CN115156003A publication Critical patent/CN115156003A/en
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/36—Successively applying liquids or other fluent materials, e.g. without intermediate treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/52—Two layers
    • B05D7/54—No clear coat specified
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/56—Three layers or more
    • B05D7/58—No clear coat specified
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/23—Magnetisable or magnetic paints or lacquers
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2202/00—Metallic substrate
    • B05D2202/20—Metallic substrate based on light metals
    • B05D2202/25—Metallic substrate based on light metals based on Al

Abstract

There is provided a method of manufacturing a magnetically permeable layer using a magnetically permeable material, the method comprising: providing a base layer with magnetic permeability; and spraying the magnetic conduction material on the base layer to form the magnetic conduction layer. The magnetic conductive material comprises magnetic conductive rare earth alloy and high-entropy ceramic. The magnetic conductive rare earth alloy has magnetostrictive characteristics. The magnetic conduction layer prepared by the method of the invention can reduce or eliminate the noise caused by the induction cooker.

Description

Method for manufacturing magnetic conduction layer by utilizing magnetic conduction material
Technical Field
The present application relates to the field of cooking utensils, and more particularly, to a method for manufacturing a magnetically conductive layer using a magnetically conductive material.
Background
The induction cooker is a household electromagnetic heating device which is widely applied. However, when the cooker is heated by the induction cooker, the cooker vibrates due to the magnetic field acting on the cooker to generate relatively large noise, thereby affecting the user experience.
Therefore, how to provide a cooker capable of reducing the noise generated during electromagnetic heating is a technical problem to be solved.
Disclosure of Invention
The invention aims to provide a method for preparing a magnetic conduction layer by utilizing a magnetic conduction material, and a cooker comprising the magnetic conduction layer prepared by the method can reduce the noise generated during electromagnetic heating.
According to an aspect of the inventive concept, a method of manufacturing a magnetic conductive layer using a magnetic conductive material includes: the method comprises the following steps: providing a base layer with magnetic permeability; and spraying the magnetic conduction material on the base layer to form the magnetic conduction layer, wherein the magnetic conduction material comprises magnetic conduction rare earth alloy and high-entropy ceramic, and the magnetic conduction rare earth alloy has magnetostrictive characteristics.
The rare earth alloy may include terbium dysprosium iron alloy, and the high-entropy ceramic may include at least one of ((Ti/Al) FeCoNi) O and (MgCoNiCuZn) O.
The rare earth alloy can account for 65% -85% of the magnetic conductive material by mol percentage, and the balance can be high-entropy ceramic.
The magnetically permeable material may include a first magnetically permeable material and a second magnetically permeable material.
The magnetically permeable layer may comprise a first sub-layer and a second sub-layer.
The method for spraying the magnetic conduction layer can comprise the following steps: cold spraying a first sublayer on the base layer using a first magnetically permeable material; a second sublayer is thermally sprayed on the first sublayer using a second magnetically permeable material.
The magnetically permeable layer may further comprise a third sublayer and a fourth sublayer.
The method for spraying the magnetic conduction layer can further comprise the following steps: cold spraying a third sublayer on the second sublayer using a first magnetically permeable material; and thermally spraying the fourth sublayer over the third sublayer using a second magnetically permeable material.
The grain size of the first magnetic conductive material can be in the range of 1-50 μm.
The grain size of the second magnetic conductive material can be in the range of 25-48 μm.
The thickness of the first sub-layer and/or the third sub-layer may be in the range of 150 μm to 200 μm.
The thickness of the second sublayer and/or the fourth sublayer may be in the range of 50 μm to 100 μm.
The substrate may be stainless steel.
As briefly described above, the magnetic conductive material according to the present inventive concept, which includes the rare earth alloy, may generate vibration opposite to the base layer having magnetic permeability, to which the magnetic conductive material is attached, by magnetostriction, thereby canceling at least part of noise generated from the base layer having magnetic permeability. Due to the addition of the high-entropy ceramic, on one hand, the porosity of the magnetic conduction layer is increased, and at least part of electromagnetic noise can be absorbed, on the other hand, the natural frequency of the magnetic conduction layer only comprising the magnetostrictive material is changed, the opportunity of resonance with a cooker is avoided, and the sound intensity of the electromagnetic noise is reduced. In addition, the invention adopts the alternative spraying mode of cold spraying and hot spraying, thereby prolonging the service life of the magnetic conduction layer and ensuring that the magnetic conduction layer has excellent noise reduction effect.
Detailed Description
The inventive concept will now be described more fully hereinafter. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
All noise originates from mechanical forces that propagate pressure waves through air, liquid or solid materials, the noise frequency in the human hearing range is typically between about 20Hz to about 20kHz, while the operating frequency of domestic induction cookers is in the range of about 20Hz to about 25kHz, which is well in the critical ultrasonic range, maximizing the stimulation of human hearing.
The noise of the induction cooker is mainly formed by the following reasons: the alternating voltage is converted into direct current through a rectifier, the direct current is converted into high-frequency alternating current exceeding audio frequency through a high-frequency power conversion device, and the high-frequency alternating current is applied to a flat hollow spiral induction heating coil, so that a high-frequency alternating magnetic field is generated. Under the mutual influence of alternating magnetic fields, the magnetic conduction layer and other metal parts generate reciprocating vibration with the same frequency under the action of attractive force and repulsive force of Lorentz force, and extrude air vibration to generate noise.
Noise generated when the induction cooker is used is apt to deteriorate user experience and give an uncomfortable feeling to the user.
Accordingly, the present inventive concept is directed to provide a magnetic conductive material capable of reducing or eliminating noise caused by an induction cooker and a method of manufacturing a magnetic conductive layer through the magnetic conductive material.
Hereinafter, the magnetic conductive material contemplated by the present invention will be described in detail.
For a cookware substrate that is not magnetically permeable (such as aluminum substrate, 304 stainless steel, 316 stainless steel, etc.), when it is used in an induction cooker, a magnetically permeable layer formed of a magnetically permeable material needs to be provided at a portion of the cookware that is in contact with the induction cooker, so that the cookware can be heated under an alternating electric field using the magnetically permeable layer. The magnetic conductive material forming the magnetic conductive layer according to the present inventive concept may include a rare earth alloy and a high-entropy ceramic.
According to an exemplary embodiment, the rare earth alloy may be a terbium dysprosium iron alloy (e.g., with (Tb, dy) Fe 2 An alloy with the compound as a matrix). The Tb-Dy-Fe alloy is magnetostrictive material. Here, magnetostriction means that an object is elongated or shortened in a magnetization direction when magnetized in a magnetic field. Ferromagnetic materials, commonly referred to as ferromagnetic magnetostrictive materials, exhibit a significant change in size when the current through the coil changes or changes the distance from the magnet. The magnetostrictive effect is similar to thermal expansion and contraction, but for some materials, the magnetostriction is oriented, i.e., the material will exhibit significant magnetostriction in only one direction. Magnetic materials with a significant magnetostrictive effect are called magnetostrictive materials.
Therefore, the temperature of the molten metal is controlled,when the magnetic conductive material of the present invention includes the rare earth alloy having the magnetostrictive property, due to the magnetostrictive phenomenon, the magnetic conductive layer made of the magnetic conductive material generates a stretching wave other than the mechanical wave under the magnetic field of the induction cooker, and the phase of the stretching wave is different (for example, opposite) from the phase of the mechanical wave, so that the magnetic conductive layer formed of the magnetic conductive material according to the present invention can at least partially or completely cancel the noise generated by the mechanical vibration of the magnetic conductive base layer, thereby achieving the purpose of reducing or eliminating the electromagnetic noise. According to a preferred embodiment, when Tb-Dy-Fe alloy is Tb 0.3 Dy 0.7 Fe 1.96 And the phase of the magnetic conductive layer is almost opposite to that of the mechanical wave of the magnetic conductive layer, so that the noise generated by the mechanical wave can be better reduced or even eliminated. However, the inventive concept is not so limited and one skilled in the art may use any magnetically permeable rare earth alloy having magnetostrictive properties to implement the inventive concept.
Further, the high-entropy ceramic included in the magnetic conductive material according to the present inventive concept may include at least one of ((Ti/Al) FeCoNi) O and (MgCoNiCuZn) O, and when the high-entropy ceramic includes both ((Ti/Al) FeCoNi) O and (MgCoNiCuZn) O, the ((Ti/Al) FeCoNi) O and (MgCoNiCuZn) O may be used in a mixture with each other at an appropriate ratio. The high-entropy ceramic material can increase the porosity of the magnetic conduction layer so as to absorb a part of electromagnetic noise, and the high-entropy ceramic material has a magnetic conduction effect so as to change the natural frequency of the magnetic conduction layer which is only made of rare earth alloy, avoid the possibility of resonance with a cooker and reduce the sound intensity of the electromagnetic noise.
According to an exemplary embodiment, as described above, the magnetic conductive material includes the rare earth alloy and the high-entropy ceramic, and thus, the amount of the rare earth alloy may be 65% to 85% of the amount of the magnetic conductive material in terms of mole percentage, and the balance may be the high-entropy ceramic. In other words, in the magnetic conductive material, when the mole percentage of the rare earth alloy is 65% (i.e., the ratio of the mole number of the rare earth alloy to the total mole number of the magnetic conductive material), the mole percentage of the high-entropy ceramic may be 35%, and when the mole percentage of the rare earth alloy is 85% (i.e., the ratio of the mole number of the rare earth alloy to the total mole number of the magnetic conductive material), the mole percentage of the high-entropy ceramic may be 15%.
According to an exemplary embodiment, the magnetically permeable material may be present in the form of particles, and at least a portion of the rare earth alloy and at least a portion of the high entropy ceramic included therein may be bonded together to form composite particles. For example, the magnetically permeable material may be coated on at least a portion of the surface of the high entropy ceramic to form coated composite particles. According to an exemplary embodiment, the grain size of the magnetically permeable material may be in the range of 1 μm-50 μm. Here, the term "particle size" refers to the largest dimension of a particle, that is, when the particle is non-spherical in shape, its dimension measured in any direction is not greater than "particle size". When having the above range of particle size, the magnetic conductive layer formed on the base material of the cooker through the magnetic conductive material has a remarkable magnetostrictive property and a moderate porosity, thereby contributing to reduction or elimination of noise generated due to vibration of the cooker.
In the above, the magnetic conductive material according to the exemplary embodiments of the inventive concept is described in detail in connection with the exemplary embodiments.
Hereinafter, a method for preparing a magnetic conductive material according to the inventive concept will be described in detail with reference to exemplary embodiments, but is not limited thereto.
The method for preparing the magnetic conductive material according to the exemplary embodiment of the present inventive concept may include vacuum melting + atomized pulverization, however, the present inventive concept is not limited to the preparation method described herein, that is, a person skilled in the art may obtain the magnetic conductive material of the present inventive concept based on the prior art.
According to an exemplary embodiment, the step of vacuum melting may be implemented using a vacuum arc furnace.
Specifically, the Tb-Dy-Fe alloy raw material and the high-entropy ceramic powder with the particle size ranging from 800 meshes to 2500 meshes can be selected to be mixed and filled into a crucible, then the crucible is placed into a vacuum electric arc furnace, and the vacuum electric arc furnace is pumped by a mechanical pump to be vacuum to 6 x 10 -2 Pa, then pumped to high vacuum of 5X 10 with a diffusion pump -3 Pa. Then, high-purity argon can be flushed into the hearth1.013×10 5 Pa and starting smelting, wherein the arc striking current can be 60-70A. Here, the crucible containing pure titanium may be melted first to remove oxygen in the hearth, and then the alloy raw material may be melted by a welding torch, wherein the melting current may be 200A to 300A. The manipulator can be used for involuting Jin Fanmian every time of smelting, and the smelting is repeated for 5 to 8 times so as to ensure the uniformity of alloy components.
After vacuum melting, an atomized powder process may be performed. Specifically, a high-speed nitrogen gas stream may be introduced through a nozzle to impact and shear the molten alloy-high entropy ceramic mixture, causing it to disperse into fine droplets that are ultimately cooled to form a powder. Here, the nozzle diameter may be in the range of 0.5mm to 1mm, the spray angle may be 30 to 60 degrees, and the nitrogen pressure may be 1.80MPa to 2.0MPa.
Through the steps, the Tb-Dy-Fe alloy coated high-entropy ceramic composite particles can be formed. The composite particles may then be sieved to obtain magnetically permeable materials having different grain size dimensions according to the inventive concept. The cooker with the magnetic conductive layer for the induction cooker according to the present inventive concept can be obtained by forming the magnetic conductive layer on at least a part of the surface (e.g., bottom surface) of the base material of the cooker by selecting a magnetic conductive material of an appropriate size.
In the following, a method of manufacturing a magnetically permeable layer according to the inventive concept will be described in connection with exemplary embodiments
A method of manufacturing a magnetically permeable layer according to an exemplary embodiment of the inventive concept includes: providing a magnetically conductive base layer; and spraying a magnetic conductive material on the substrate using the magnetic conductive material as described above, thereby obtaining the magnetic conductive layer, the magnetic conductive material according to the exemplary embodiment of the inventive concept has been described above in detail, and thus, a description about the magnetic conductive material will be omitted below, and a specific step of forming the magnetic conductive layer using the magnetic conductive material will be described in detail.
According to an exemplary embodiment, the magnetically permeable base layer may be a base material of cookware, in which case the base material of cookware may have magnetic permeability. However, when the cookware is formed of a material that is not magnetically permeable, the magnetically permeable substrate may comprise a material that is magnetically permeable, such as stainless steel magnetically permeable sheets. That is, when the base material of the cooker has magnetic permeability, the base material of the cooker may be used as a base layer that is magnetically permeable, and a magnetic conductive sheet that is additionally provided may be present or omitted. In contrast, when the base material of the cooker does not have magnetic permeability, a magnetic conductive sheet may be additionally provided as a base layer for magnetic conduction, and in this case, the magnetic conductive layer according to the inventive concept may be considered to have a double-layer structure, the first layer including a first magnetic conductive layer of a magnetic conductive material such as stainless steel, and the second layer including a second magnetic conductive layer of a magnetic conductive material according to the inventive concept.
When the base material for a cooker has magnetic permeability, the step of providing the base layer having magnetic permeability may include directly using the base material having magnetic permeability of a cooker as the base layer forming the magnetic conductive layer according to the exemplary embodiment of the inventive concept, in which case the magnetic conductive layer may be directly disposed on the base material, in which case the base layer having magnetic permeability. Or, the substrate may be provided with a magnetic conductive sheet as a base layer of magnetic conductivity, and then the magnetic conductive layer is provided on the magnetic conductive sheet. In addition, when the base material for the cooker does not have magnetic permeability, a base layer (e.g., a magnetic conductive sheet) having magnetic permeability needs to be provided, and thus, the step of providing the base layer having magnetic permeability may include providing the magnetic conductive sheet on the base material of the cooker. Here, the magnetic conductive sheet may be a sheet or plate having a certain thickness and capable of conducting magnetic. According to an exemplary embodiment, the magnetically permeable sheets may be stainless steel magnetically permeable sheets.
According to an exemplary embodiment, when it is required to provide the magnetic conductive sheet, the method of providing the magnetic conductive sheet may include a riveting process. For example, a stainless steel magnetic conductive sheet with a thickness in the range of 0.8mm to 1.2mm may be selected and then cold riveted to a base material of the cookware comprising, for example, aluminum, an aluminum alloy, using a cold riveting process. According to an exemplary embodiment, the cold riveting pressure may be in a range of 20000KN to 30000 KN.
In addition, the step of providing the base layer with magnetic permeability can further comprise the step of carrying out sand blasting treatment on the base layer to enable the surface roughness Ra of the base layer to reach 5-8 μm so as to be beneficial to the attachment of the subsequent magnetic permeability layer. However, the inventive concept is not limited thereto, and the blasting step may be omitted.
After providing the base layer, the step of forming a magnetically permeable layer on the base layer may be performed.
According to an exemplary embodiment, the magnetically permeable layer may comprise a first sublayer and a second sublayer, and further may comprise a third sublayer and a fourth sublayer. The first and third sub-layers may be formed by a cold spray process, and the second and fourth sub-layers may be formed by a thermal spray process. However, only the first sublayer and the second sublayer may be provided, or the third sublayer may be omitted and only the first sublayer, the second sublayer, and the fourth sublayer may be provided. The inventive concept is not so limited.
Since the first and third sub-layers and the second and fourth sub-layers are formed through different spray processes, the first and third sub-layers and the second and fourth sub-layers according to the inventive concept may be formed using magnetic conductive materials having different grain sizes. According to an exemplary embodiment, the first and third sub-layers may be formed of a first magnetically permeable material, and the second and fourth sub-layers may be formed of a second magnetically permeable material, where the first and second magnetically permeable materials each comprise a magnetically permeable rare earth alloy and a high entropy ceramic, which may differ in having a different grain size composition and/or ratio between the magnetically permeable rare earth alloy and the high entropy ceramic between them. However, the present invention is not limited thereto, that is, as will be described below, since the first and third sublayers and the second and fourth sublayers are formed by different processes, the first and second magnetically permeable materials are selected to correspond to the different processes for forming the different sublayers, and thus, one skilled in the art can select magnetically permeable materials of the same grain size or different grain sizes and of the same composition or different compositions as the first, second, or further third and fourth magnetically permeable materials to form the different sublayers according to the inventive concept.
When the first sub-layer and the third sub-layer are formed using a cold spray process, the first sub-layer and the third sub-layer may be formed using a magnetic conductive material having the same composition or different compositions with a grain size ranging from 1 μm to 50 μm through the cold spray process. For example, the cold spray process conditions are as follows: the working gas is high-purity nitrogen, the working temperature (namely the heating temperature of the working gas) is within the range of 650-800 ℃, the spraying pressure is within the range of 1.5-2.5 MPa, the powder feeding speed is within the range of 5-10 Kg/h, and the spraying distance is within the range of 25-50 mm. Under the above parameters, the magnetically permeable material having the above particle size range contemplated by the present invention can be accelerated by the high pressure gas flow formed at the muzzle and then deposited on the material surface to form the first and third sublayers. Here, the thickness of the sub-layer (e.g., first sub-layer, third sub-layer) deposited at each time by cold spraying may be in the range of 150 μm to 200 μm because: if the sublayer is too thick, the cost is increased, and the magnetostriction deformation of the magnetic conductive material is large during working, so that the magnetic conductive layer is easy to fall off, and the service life is shortened; on the contrary, if the sub-layer is too thin, the magnetostrictive deformation amount of the magnetic conductive material is small during operation, and the best effect of reducing noise is not achieved.
In addition, when the second sub-layer and the fourth sub-layer are formed using a thermal spraying process, the second sub-layer and the fourth sub-layer may be formed by the thermal spraying process using a magnetic conductive material having the same composition or different compositions with a grain size in a range of 25 μm to 48 μm. For example, preferably, the second sublayer and the fourth sublayer may be formed by plasma spraying, and the conditions of the spraying process are as follows: the powder feeding speed is within the range of 20g/min to 35g/min, the spraying distance is within the range of 110mm to 140mm, the arc current is within the range of 550A to 650A, the hydrogen pressure is within the range of 0.5MPa to 0.7MPa, the flow rate is within the range of 50L/h to 150L/h, the argon pressure is within the range of 0.8MP to 1.2MPa, and the flow rate is within the range of 1000L/h to 1500L/h. Under the above parameters, the magnetically permeable material can be heated to melt by the high pressure plasma flame stream formed at the muzzle and then deposited on the substrate surface to form the second and fourth sub-layers. Here. The thickness of the thermally sprayed sublayers (e.g., the second sublayer and the fourth sublayer) deposited at a time may be in the range of 50 μm to 100 μm because, if the sublayers are too thick, thermal stress is large and it is easy to peel off; conversely, when the sublayer is too thin, the high entropy ceramic content is insufficient and the coating porosity is insufficient. In addition, the porosity of the second sublayer and the fourth sublayer formed by thermal spraying can be in the range of 15% -30%, because too high porosity can reduce the strength and the electrical conductivity of the coating, and the result that the coating is easy to fall off and cannot have good magnetic conductivity is caused, and too low porosity cannot achieve the beneficial effects of absorbing noise and changing natural frequency.
According to the inventive concept, the processes of cold spraying and thermal spraying may be repeatedly performed to form a magnetically permeable layer including a plurality of sub-layers on the base layer. For example, a first cold spray process may be performed on a base layer to form a first sub-layer having a thickness in a range of 150 μm to 200 μm on the base layer, which is, for example, sand-blasted, a second sub-layer having a thickness in a range of 50 μm to 100 μm may be formed on the first sub-layer using a thermal spray process, a third sub-layer having a thickness in a range of 150 μm to 200 μm may be formed on the second sub-layer using a cold spray process, and a fourth sub-layer having a thickness in a range of 50 μm to 100 μm may be formed on the third sub-layer using a thermal spray process. Therefore, through the cold and hot spraying process which is repeatedly and alternately carried out twice, the magnetic conduction layer with the thickness ranging from 400 micrometers to 600 micrometers can be formed on the base layer. However, the inventive concept is not limited thereto, that is, a person skilled in the art may arrange different numbers of sub-layers based on the magnetic conductive material having the same grain size or different grain sizes, and having the same composition or different compositions of the inventive concept.
By the above method, a magnetically permeable layer having a plurality of sublayers may be formed on the base layer. The invention adopts the mode of repeatedly overlapping and executing cold spraying and hot spraying, because the cold spraying coating is compact, the oxidation degree is low, the magnetic conduction effect is good, but the high-entropy ceramic only has a small amount of impurities due to the fact that the coating is formed by high-speed deformation. The thermal spraying coating is loose, high in oxidation degree and poor in magnetic conduction effect, but high in heat quantity and high in high-entropy ceramic deposition rate. Accordingly, the inventive concept can provide a magnetically conductive layer having a high lifespan and excellent noise reduction or elimination performance. When the magnetic conduction layer is used for a cooker, the user experience can be obviously improved when a user cooks food on the induction cooker by using the cooker.
In the following, advantageous effects of the cooker including the magnetically conductive material of the present inventive concept will be described in conjunction with specific embodiments.
Example 1
The cooker according to embodiment 1 was manufactured by the following method.
Preparing Tb-Dy-Fe alloy Tb 0.3 Dy 0.7 Fe 1.96 And high-entropy ceramic powder ((Ti/Al) FeCoNi) O with the particle size of 1-5 μm.
Vacuum smelting: using a vacuum arc furnace, adding 65% of Tb in terms of mole percentage 0.3 Dy 0.7 Fe 1.96 And 35% (Ti/Al) FeCoNi) O were mixed and charged into a crucible, and evacuated to 6X 10 by a mechanical pump -2 Pa, followed by a high vacuum of 5X 10 with a diffusion pump -3 Pa, then flushing high-purity argon into the hearth to 1.013 multiplied by 10 5 Pa, starting smelting. The arc striking current is 60A, the crucible filled with pure titanium is melted firstly to remove oxygen in a hearth, then the mixture in the crucible is melted by a welding gun, the melting current is 300A, the manipulator is used for closing Jin Fanmian every time the melting is finished, and the melting is repeated for 8 times, so that the uniformity of alloy components is ensured.
Atomizing to prepare powder: introducing high-speed nitrogen gas flow through a nozzle, impacting and shearing the melted alloy liquid, dispersing the alloy liquid into fine metal liquid drops, and finally cooling to form magnetic conductive material particles. Wherein the diameter of the nozzle is 0.5mm, the spraying angle is 60 degrees, and the nitrogen pressure is 1.8MPa.
Selecting an aluminum cooker base material, and cleaning the surface of the aluminum cooker base material. Then selecting a stainless steel magnetic conductive sheet with the thickness of 1.2mm, and carrying out cold riveting on the stainless steel magnetic conductive sheet to the bottom of the base material of the cooker, wherein the cold riveting pressure is 20000KN. Then, the stainless steel magnetic conductive sheet is subjected to sand blasting treatment to ensure that the surface roughness Ra reaches 6 mu m
And performing the following spraying process on the stainless steel magnetic conduction sheet by using the obtained magnetic conduction material particles.
Performing cold spraying on the stainless steel magnetic conduction sheet: selecting a magnetic conductive material with the grain diameter of 1-5 mu m, and loading the magnetic conductive material into a powder feeder, wherein the setting parameters are as follows: the working gas is high-purity nitrogen, the working temperature (namely the heating temperature of the working gas) is 650 ℃, the spraying pressure is 2.5MPa, the powder feeding speed is 5Kg/h, and the spraying distance is 25mm. Accelerating magnetic conductive material particles by using high-pressure airflow formed at a gun nozzle under the parameters so as to spray magnetic conductive material powder on the outer bottom surface of the base material, and finally forming a first sublayer with the thickness of 170 mu m;
performing a plasma spray process on the first sublayer: selecting a magnetic conductive material with the particle size of 25-30 microns, and loading the magnetic conductive material into a powder feeder, wherein the powder feeding speed is 25g/min, the spraying distance is 110mm, the arc current is 550A, the hydrogen pressure is 0.6MPa, the flow rate is 50L/h, the argon pressure is 1.2MPa, and the flow rate is 1500L/h. Under the parameters, the magnetic conductive material is heated to be molten by utilizing high-pressure plasma flame flow formed at the muzzle, and then is deposited on the surface of the base material, and finally a second sublayer with the thickness of 80 mu m is formed;
performing a cold spraying process on the second sublayer, wherein the process is the same as the process for forming the first sublayer, and finally forming a third sublayer with the thickness of 170 mu m;
and performing a plasma spraying process on the third sub-layer, wherein the process is the same as that for forming the second sub-layer, and finally forming a fourth sub-layer with the thickness of 80 mu m.
Through the above steps, the cooker including the magnetically permeable layer of example 1 was completed.
Example 2
Except that Tb-Dy-Fe alloy is Tb 0.5 Dy 0.5 Fe 2 Except that, the embodiment 2 is the same as the method of the embodiment 1 to manufacture the cooker.
Example 3
Except that 85% of Tb by mole percent 0.3 Dy 0.7 Fe 1.96 And 15% of ((Ti/Al) FeCoNi) O were mixed and charged into the crucible, and a cooker according to example 3 was manufactured in the same manner as in example 1.
Example 4
Except that 75% of Tb is calculated by mol percent 0.3 Dy 0.7 Fe 1.96 And 25% of ((Ti/Al) FeCoNi) O were mixed and charged into the crucible, the cooker according to example 4 was manufactured in the same manner as in example 1.
Example 5
The cooker according to example 5 was manufactured in the same manner as in example 1, except that the high-entropy ceramic material was (MgCoNiCuZn) O.
Example 6
The cooker according to example 6 was manufactured in the same manner as in example 1, except that the high-entropy ceramic material was ((Ti/Al) FeCoNi) O and (MgCoNiCuZn) O mixed in a molar ratio of 1:1.
Example 7
The cooker according to embodiment 7 was manufactured in the same method as embodiment 1, except that the cold spray process was performed once. That is, the spraying process of example 7 includes forming the first sublayer of example 1 on the magnetic stainless steel sheet by the cold spraying process, and performing plasma spraying on the first sublayer to form the second sublayer and the fourth sublayer of example 1, respectively.
Example 8
The cooker according to example 8 was manufactured in the same manner as example 1, except that the cold spray process used a magnetic conductive material having a grain size of 45 μm to 50 μm.
Example 9
The cooker according to example 9 was manufactured in the same manner as example 1, except that the cold spray process used a magnetic conductive material having a grain size of 23 μm to 28 μm.
Example 10
The cooker according to example 10 was manufactured in the same manner as example 1, except that the plasma spray process used a magnetic conductive material having a grain size of 43 μm to 48 μm.
Example 11
The cooker according to example 11 was manufactured in the same manner as example 1, except that the plasma spray process used a magnetic conductive material having a grain size of 35 μm to 40 μm.
Comparative example 1
Except for using only Tb 0.3 Dy 0.7 Fe 1.96 The cooker according to comparative example 1 was manufactured in the same manner as in example 1 except for the magnetic conductive material.
Comparative example 2
A stainless steel magnetic conductive sheet of 1.2mm thickness was selected and cold-riveted to the bottom of the base material of the cooker to obtain the cooker of comparative example 2. That is, comparative example 2 is different from example 1 in that comparative example 2 does not include a magnetic conductive layer including a magnetic conductive material.
Comparative example 3
Except that 60% of Tb is calculated by mol percent 0.3 Dy 0.7 Fe 1.96 And 40% (Ti/Al) FeCoNi) O were mixed and charged into the crucible, and the cooker of comparative example 3 was manufactured in the same manner as that of example 1.
Comparative example 4
Except that 90% of Tb by mole percent 0.3 Dy 0.7 Fe 1.96 And ((Ti/Al) FeCoNi) O of 10% were mixed and charged into the crucible, and the cooker of comparative example 4 was manufactured in the same manner as in example 1.
The cookware obtained above was subjected to performance testing and recorded in the following table, the specific performance testing methods are as follows:
the magnetic conduction power test method comprises the following steps: testing by adopting a standard induction cooker according to a domestic induction cooker applicable pot GB _ T32147-2015;
noise sound is: 2100W of water is boiled on a household induction cooker, and the noise is tested by a noise tester at a position 20cm away from a cooker
The performance index test data of the embodiment and the comparative proportion are shown;
serial number Initial power/W Noise decibel/dB
Example 1 1680 27
Example 2 1670 36
Example 3 1700 34
Example 4 1680 32
Example 5 1670 27
Example 6 1680 27
Example 7 1670 28
Example 8 1680 27
Example 9 1680 27
Example 10 1690 27
Example 11 1680 27
Comparative example 1 1800 44
Comparative example 2 1900 60
Comparative example 3 1720 33
Comparative example 4 1750 42
As can be seen from comparison of examples 1 to 11 of the inventive concept with comparative examples 1 to 4, the cooker including the magnetic conductive layer formed of the magnetic conductive material according to the inventive concept has a relatively low initial power within the range conforming to the standard, and a noise significantly lower than that of the conventional electromagnetic heating product.
While one or more embodiments of the present invention have been described, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims.

Claims (10)

1. A method of making a magnetically permeable layer from a magnetically permeable material, the method comprising:
providing a base layer with magnetic permeability;
spraying the magnetic conductive material on the base layer to form the magnetic conductive layer,
the magnetic conductive material comprises magnetic conductive rare earth alloy and high-entropy ceramic, wherein the magnetic conductive rare earth alloy has magnetostrictive characteristics.
2. The method of claim 1,
the rare earth alloy comprises Tb-Dy-Fe alloy, and
the high-entropy ceramic comprises at least one of ((Ti/Al) FeCoNi) O and (MgCoNiCuZn) O.
3. The method of claim 1,
the rare earth alloy accounts for 65-85% of the magnetic conductive material by mol percent, and the balance is high-entropy ceramic.
4. The method of claim 1,
the magnetic conductive material comprises a first magnetic conductive material and a second magnetic conductive material;
the magnetically permeable layer includes a first sub-layer and a second sub-layer, and
the method for spraying the magnetic conduction layer comprises the following steps: cold spraying a first magnetic conductive material on the base layer to form a first sublayer; and thermally spraying a second magnetic conductive material on the first sublayer to form a second sublayer.
5. The method of claim 4, wherein the magnetically permeable layer further comprises a third sublayer and a fourth sublayer, and
the method for spraying the magnetic conduction layer further comprises the following steps:
cold spraying a first magnetic conductive material on the second sublayer to form a third sublayer;
and thermally spraying a second magnetic conductive material on the third sublayer to form a fourth sublayer.
6. The method of claim 4 or 5,
the granularity of the first magnetic conduction material is in the range of 1-50 mu m.
7. The method of claim 4 or 5,
the granularity of the second magnetic conduction material is in the range of 25-48 mu m.
8. The method of claim 4 or 5,
the thickness of the first sub-layer and/or the third sub-layer is in the range of 150-200 μm.
9. The method of claim 4 or 5,
the thickness of the second sublayer and/or the fourth sublayer is in the range of 50 μm to 100 μm.
10. The method of claim 1, wherein the base layer comprises aluminum and/or an aluminum alloy.
CN202210784878.3A 2022-06-29 2022-06-29 Method for manufacturing magnetic conduction layer by utilizing magnetic conduction material Pending CN115156003A (en)

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