CN117464014B - FeSiAl powder processing system - Google Patents

FeSiAl powder processing system Download PDF

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Publication number
CN117464014B
CN117464014B CN202311813431.5A CN202311813431A CN117464014B CN 117464014 B CN117464014 B CN 117464014B CN 202311813431 A CN202311813431 A CN 202311813431A CN 117464014 B CN117464014 B CN 117464014B
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powder
silicon
iron
aluminum
blocks
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CN117464014A (en
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赵凯
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Hunan Special Metal Materials Co ltd
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Hunan Special Metal Materials Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D43/00—Mechanical cleaning, e.g. skimming of molten metals
    • B22D43/001—Retaining slag during pouring molten metal
    • B22D43/004—Retaining slag during pouring molten metal by using filtering means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/06—Metallic powder characterised by the shape of the particles
    • B22F1/065—Spherical particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/14—Treatment of metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/10—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying using centrifugal force
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
    • C21C7/04—Removing impurities by adding a treating agent
    • C21C7/06—Deoxidising, e.g. killing
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/04—Making ferrous alloys by melting
    • C22C33/06—Making ferrous alloys by melting using master alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0824—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid with a specific atomising fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0848—Melting process before atomisation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0888—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid casting construction of the melt process, apparatus, intermediate reservoir, e.g. tundish, devices for temperature control
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Abstract

The invention discloses a processing system of FeSiAl powder, wherein the system comprises a coarse powder pretreatment component, a smelting component and a powder gas atomization preparation device; the coarse powder pretreatment component is used for uniformly mixing the iron-silicon-aluminum coarse powder with the granularity of +200 meshes with water glass and pressing the coarse powder into iron-silicon-aluminum cubes; the smelting assembly is used for firstly smelting iron blocks and silicon blocks with preset mass ratio, and then sequentially adding iron-silicon-aluminum blocks, aluminum blocks and deoxidizer with corresponding mass to obtain alloy melt with lower oxygen content; the powder gas atomization preparation device comprises a tundish, a conical conduit, a circular seam atomization structure and an atomization cylinder which are communicated in a sealing way from top to bottom; the side surface of the conical conduit is also connected with a magnetic induction heating device, and the magnetic induction heating device is used for carrying out preheating treatment on the conical conduit so as to avoid the blockage of the conical conduit by alloy melt; the circular seam atomizing structure is also connected with an inert gas storage tank. The invention aims to realize the high-efficiency recycling of the iron-silicon-aluminum coarse powder with the granularity of +200 meshes.

Description

FeSiAl powder processing system
Technical Field
The invention relates to the technical field of magnetic materials, in particular to a FeSiAl powder processing system.
Background
At present, two methods exist for producing iron-silicon-aluminum powder (9.6% of silicon, 5.4% of aluminum and the balance of iron) for soft magnetic in the industry, namely, iron-silicon-aluminum by a crushing method, namely, mechanically grinding and crushing a smelting cast ingot; and the other is to obtain Fe-Si-Al powder by smelting nitrogen atomization. The qualified products of the two methods are 200 mesh below zero (abbreviated as 200 below), and are based on the fact that the microscopic morphology of the broken sendust is irregular, the microscopic morphology of the atomization sendust is spherical, and then the magnetic performance of the atomization sendust is superior to that of the broken sendust powder. However, the vacuum atomization cost is high, the non-vacuum gas atomization cost is low, and when the Fe-Si-Al alloy is smelted, the aluminum in the alloy melt can undergo a violent reaction with oxygen in the atmosphere due to high temperature to generate a large amount of slag, and the +200 mesh Fe-Si-Al powder prepared by atomization cannot be remelted in a furnace, so that raw material accumulation is wasted. The invention patent with the prior patent publication number of CN115351284A discloses a multistage processing treatment device for iron-silicon-aluminum powder of a metal magnetic powder core, which realizes the processing of iron-silicon-aluminum powder with +200 meshes through the combined arrangement of a rolling crushing assembly, a sorting assembly and a shaping assembly, further improves the recycling of iron-silicon-aluminum powder with +200 meshes, but the whole treatment process is complicated in steps and high in cost, and further a treatment device for recycling the iron-silicon-aluminum coarse powder with +200 meshes with high cost performance is needed to be provided.
Disclosure of Invention
The invention mainly aims to provide a processing system of FeSiAl powder, which aims to solve the technical problem that the conventional iron-silicon-aluminum coarse powder with the granularity of +200 meshes cannot be reused with high efficiency.
In order to achieve the above purpose, the invention provides a processing system of FeSiAl powder, which comprises a coarse powder pretreatment component, a smelting component and a powder gas atomization preparation device;
the coarse powder pretreatment component is used for uniformly mixing the iron-silicon-aluminum coarse powder with the granularity of +200 meshes with water glass and pressing the coarse powder into iron-silicon-aluminum cubes;
the smelting assembly is used for firstly smelting iron blocks and silicon blocks with preset mass ratio, and then sequentially adding iron-silicon-aluminum blocks, aluminum blocks and deoxidizer with corresponding mass to obtain alloy melt with lower oxygen content;
the powder gas atomization preparation device comprises a tundish, a conical conduit, a circular seam atomization structure and an atomization cylinder which are communicated in a sealing way from top to bottom;
the tundish is used for receiving the alloy melt transmitted by the smelting component; the side surface of the conical conduit is also connected with a magnetic induction heating device, and the magnetic induction heating device is used for carrying out preheating treatment on the conical conduit so as to avoid the blockage of the conical conduit by alloy melt;
the circular seam atomizing structure is also connected with an inert gas storage tank.
Optionally, the inert gas storage tank is also in communication with a tundish.
Optionally, the system further comprises a multi-layer filter structure disposed within the tundish, the multi-layer filter structure surfaces each being honeycomb-shaped.
Optionally, the multi-layer filter structure is a first layer filter and a second layer filter which are arranged at intervals up and down.
Optionally, the aperture of the first layer of filter is 2-3 cm, and the aperture of the second layer of filter is 1-2 cm.
Optionally, the tapered conduit includes a plurality of evenly distributed through holes, each through hole being configured to communicate the tundish with the circumferential atomizing structure.
Optionally, the aperture of each through hole is 2-3 mm.
Optionally, a rotary disc is further arranged between the circular seam atomizing structure and the atomizing cylinder.
Optionally, in the coarse powder pretreatment component, the mass ratio of the Fe-Si-Al coarse powder to the water glass is 1 (1-3) mill.
Optionally, in the smelting assembly, the mass ratio of the iron block to the silicon block to the aluminum block is (80-86): (9.5 to 10): (5-10), wherein the mass of the iron-silicon-aluminum square with +200 meshes accounts for 10-30% of the total mass of the iron-silicon-aluminum square, the iron block, the silicon block and the aluminum block.
The beneficial effects are that:
(1) In the system, the +200 meshes of sendust coarse powder is pretreated in advance and is made into a square shape, so that sendust blocks are immersed into the bottom without being in direct contact with air in the smelting process, the blocking caused by excessive oxidized serious slag in coarse powder smelting is prevented, and meanwhile, the utilization rate of +200 meshes of sendust coarse powder raw materials is improved.
(2) The conical guide pipe is arranged, so that alloy melt flows out through the corresponding through hole, the alloy melt is prevented from being concentrated in one pipeline, the contact surface of the alloy melt is further improved, and the atomization efficiency is improved.
(3) The arrangement of the multi-layer filtering structure and the pore diameter between each layer of filtering structure are different, so that the alloy melt is subjected to multiple effective filtering of oxide impurities when passing through the tundish, and the purity of the subsequent alloy powder is improved.
(4) The grain size of the Fe-Si-Al powder prepared by the system is smaller than that of the Fe-Si-Al powder prepared by the conventional gas atomization powder preparation equipment, and the loss of the prepared magnetic powder core is also lower when the Fe-Si-Al powder is subjected to re-melting treatment in a furnace of +200 meshes; in addition, the FeSiAl powder processing system has the advantages of less utilization and arrangement, strong controllability, low cost and convenient popularization and application.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the description of the embodiments or the prior art will be briefly described, it being obvious that the drawings in the description below are only some embodiments of the invention, and that other drawings may be obtained from the structures shown in these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of a powder aerosolization apparatus in an embodiment of a FeSiAl powder processing system according to the present invention;
FIG. 2 is a top view of the filter structure of FIG. 1;
fig. 3 is a schematic cross-sectional view of the tapered catheter shown in fig. 1.
Reference numerals illustrate:
Detailed Description
The following description of the embodiments of the present invention will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are only some, but not all embodiments of the invention. All other embodiments, based on the embodiments of the invention, which are apparent to those of ordinary skill in the art without inventive faculty, are intended to be within the scope of the invention.
It should be noted that all directional indicators (such as upper and lower … …) in the embodiments of the present invention are merely used to explain the relative positional relationship, movement conditions, etc. between the components in a specific posture (as shown in the drawings), and if the specific posture is changed, the directional indicator is changed accordingly.
Furthermore, descriptions such as those referred to as "first," "second," and the like, are provided for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implying an order of magnitude of the indicated technical features in the present disclosure. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature.
Moreover, the technical solutions of the embodiments of the present invention may be combined with each other, but it is necessary to be based on the fact that those skilled in the art can implement the embodiments, and when the technical solutions are contradictory or cannot be implemented, it should be considered that the combination of the technical solutions does not exist, and is not within the scope of protection claimed by the present invention.
The invention provides an embodiment of a FeSiAl powder processing system, which comprises a coarse powder pretreatment component, a smelting component and a powder aerosolization preparation device. The coarse powder pretreatment component is used for uniformly mixing the iron-silicon-aluminum coarse powder with the granularity of +200 meshes with water glass, then pressing the mixture into 8.60-8.60 cm square blocks, and baking the square blocks at the temperature of 80-100 ℃ for 1-2 hours, wherein the mass ratio of the iron-silicon-aluminum coarse powder to the water glass is 1 (1-3) mill.
The smelting assembly is used for firstly smelting iron blocks and silicon blocks in a preset mass ratio, then sequentially adding iron-silicon-aluminum blocks, aluminum blocks and deoxidizer in corresponding mass to obtain alloy melt with lower oxygen content, and preferably, the mass ratio of the iron blocks to the silicon blocks to the aluminum blocks is (80-86): (9.5 to 10): (5-10), wherein the mass of the iron-silicon-aluminum square with +200 meshes accounts for 10-30% of the total mass of the iron-silicon-aluminum square, the iron block, the silicon block and the aluminum block; the smelting assembly comprises a smelting furnace 1, and the specific smelting steps are as follows: weighing Fe and Si blocks according to the proportion, heating and melting the Fe and Si blocks, adding +200 mesh Fe-Si-Al blocks with preset mass, quickly sinking the +200 mesh Fe-Si-Al blocks into the bottom due to the density difference, further avoiding oxidization of the Fe-Si-Al blocks, stirring the alloy melt after the +200 mesh Fe-Si-Al blocks are melted, continuously adding pure aluminum blocks with certain mass, adding deoxidizer into the alloy melt, and quickly expanding the deoxidizer after the deoxidizer contacts the metal melt to form an insulating layer, adsorbing impurities in the alloy melt, carrying out slag skimming treatment, preserving heat for a period of time to ensure that the alloy melt is melted uniformly, and pouring the alloy melt into a tundish 2 for atomization treatment when the heating temperature is 1600-1650 ℃.
The schematic structural diagram of the powder aerosolization preparation device is shown in fig. 1, and the powder aerosolization preparation device comprises a tundish 2, a conical conduit 5, a circular seam aerosolization structure 6 and an aerosolization cylinder 8 which are communicated in a sealing manner from top to bottom.
The tundish 2 is used for receiving the alloy melt conveyed by the smelting component; the side surface of the conical conduit 5 is also connected with a magnetic induction heating device 9, and the magnetic induction heating device 9 is used for preheating the conical conduit 5 so as to prevent alloy melt from blocking the conical conduit 5, wherein the preheating temperature of the conical conduit 5 is 700-800 ℃.
In the system, the +200 meshes of Fe-Si-Al coarse powder is pretreated in advance and is made into a square shape, so that the situation that +200 meshes of Fe-Si-Al powder is directly added is avoided, the powder floats on the surface of alloy melt, is easy to oxidize and agglomerate, forms oxide slag easily, and further reduces the oxygen content in the alloy melt. Although the multilayer filtering structure that powder gas atomization preparation facilities set up can realize filtering oxide slag, be difficult to the package in the middle of blocking up, still there is the oxide of some tiny particle to filter, and then if do not change the powdered structure of +200 mesh sendust coarse powder, will make follow-up production sendust powder oxygen content be greater than 1000ppm, it is higher than the sendust powder oxygen content of conventional gas atomization preparation (conventional oxygen content is generally 800 ppm), the magnetic core loss of preparation is high, also cause +200 mesh sendust powder's material loss volume big, the utilization ratio of raw and other materials is low, can't realize +200 mesh sendust powder's effective utilization.
Further, the tapered conduit 5 includes a plurality of through holes uniformly distributed, each through hole is used for communicating the tundish 2 with the circumferential atomizing structure 6, and the tapered cross section of the tapered conduit 5 is configured as shown in fig. 3. The conical guide pipe is arranged, so that alloy melt flows out through the corresponding through hole, the alloy melt is prevented from being concentrated in one pipeline, the contact surface of the alloy melt is further improved, and the atomization efficiency is improved.
Further, the aperture of each through hole is 2 to 3mm. Preferably, 10-12 holes with uniform size are distributed in the conical conduit 5, and the size of the holes is 2mm.
Further, the annular gap atomizing structure 6 is also connected with an inert gas storage tank 10. Specifically, the inert gas storage tank 10 is used for storing one of helium, nitrogen and argon, preferably argon, in this embodiment, argon, and then the dropped alloy melt is crushed by the annular gap atomizing structure 6 after being output from the inert gas storage tank 10 by argon, and then solidified into metal powder, which falls on the bottom of the atomizing cylinder 8. The circumferential seam atomizing structure 6 comprises a plurality of atomizing nozzles which are distributed in a ring shape, and preferably, the included angle between the gas sprayed by each atomizing nozzle and the horizontal plane is 10-30 degrees.
Further, a rotary disc 7 is further arranged between the circular seam atomizing structure 6 and the atomizing barrel 8. The rotating disc 7 rotates around the center of the rotating disc, and then alloy liquid drops after the action of the atomizing nozzle fall onto the rotating disc 7, and the alloy liquid drops can be secondarily crushed to form fine liquid drops through the centrifugal action, become spherical under the action of surface tension and then solidify into metal powder to fall on the bottom of the atomizing cylinder 8, and finally spherical-200-mesh Fe-Si-Al powder can be obtained.
Further, the inert gas storage tank 10 is also in communication with the tundish 2. Further, in order to avoid oxidation of the alloy melt.
Further, the system comprises a multi-layer filtering structure arranged in the tundish 2, the surfaces of which are all honeycomb-shaped, as shown in fig. 2 in particular. Preferably, the pore size differs between each layer of filter structure, and the pore size of the upper layer of filter structure located in the tundish 2 is larger than the pore size of the lower layer of filter structure. Thereby realizing the effect of multiple times of filtration.
Further, in the embodiment shown in fig. 1, the multi-layer filtering structure is a first layer of filter 3 and a second layer of filter 4 which are arranged up and down at intervals, the aperture of the first layer of filter 3 is 2-3 cm, the aperture of the second layer of filter 4 is 1-2 cm, and further, oxide impurities are effectively filtered out when the alloy melt passes through a tundish, and the principle is that the melting point of metal oxide is higher than that of metal simple substance, so that the purity of the subsequent alloy powder is improved.
Preferably, the materials of the first layer filter 3 and the second layer filter 4 are corundum or zirconia.
Further, in order to better explain the particle size and the corresponding properties of the sendust powder produced in the present system, the following test was conducted.
Example 1
The system of the invention is adopted to prepare the Fe-Si-Al powder, and the specific preparation steps are as follows:
step 1: uniformly mixing iron-silicon-aluminum coarse powder with the granularity of +200 meshes with water glass, pressing into 8.60-8.60 cm square blocks, and baking the blocks at 80-100 ℃ for 1-2 hours, wherein the mass ratio of the iron-silicon-aluminum coarse powder to the water glass is 1:3%;
step 2: weighing 8000g of Fe block and 1000g of Si block, heating and melting iron block and silicon block, adding 2500g of +200 mesh iron-silicon-aluminum block, and quickly sinking the +200 mesh iron-silicon-aluminum block into the bottom due to density difference to avoid oxidation; after the iron-silicon-aluminum blocks with the mesh of +200 are melted, 1000g of pure aluminum blocks with a certain proportion are added into the alloy melt after stirring treatment, then a deoxidizer is added into the alloy melt, and the deoxidizer rapidly expands after contacting with the metal liquid to form an insulating layer, and simultaneously, impurities in the alloy melt are adsorbed, and then slag skimming treatment is carried out; and (3) preserving heat for a period of time to enable the alloy melt to be melted uniformly, and pouring the alloy melt into a tundish for atomization treatment when the heating temperature is 1600-1650 ℃.
Step 3, preheating the conical conduit 5 through the magnetic induction smelting device 9, wherein the aim is to prevent the alloy melt from entering the hole blockage of the conical conduit 5 when the temperature is 700-800 ℃, then pouring the alloy melt into the tundish 2, and simultaneously filling argon into the tundish 2, wherein the argon is provided by an argon tank in order to prevent the alloy melt from being oxidized; two layers of honeycomb filters are placed in the tundish, the upper layer of filters are arranged at the position 1/2 of the tundish, the aperture of the upper layer of filters is 2-3 cm, the aperture of the lower layer of filters is 1-2 cm at the position 3/4 of the tundish, alloy melt enters the guide pipe through the tundish and enters the conical guide pipe 5 through the filters 3 and 4, 10-12 holes with uniform size are distributed in the conical guide pipe 5, and the aperture size is 2mm.
And 4, crushing the alloy melt by adopting argon through a circular seam atomizing structure 6, enabling the liquid drops to fall on a rotating disc 7, performing centrifugal atomization to generate secondary crushing to form fine liquid drops, and solidifying the fine liquid drops into FeSiAl powder 1 after the FeSiAl powder becomes spherical under the action of surface tension, and enabling the FeSiAl powder 1 to fall on the bottom of an atomizing cylinder 8.
Comparative example 1
The iron-silicon-aluminum coarse powder with the granularity of +200 meshes is used as a raw material, and is prepared and treated by adopting a conventional gas atomization device, so that atomization cannot be smoothly performed.
Comparative example 2
By using the apparatus of example 1, only the coarse powder of iron-silicon-aluminum with +200 mesh was used as a raw material to obtain the corresponding fesai powder 2.
Comparative example 3
Iron powder, aluminum powder and silicon powder are used as raw materials, and are prepared and treated by adopting a conventional gas atomization device to obtain corresponding FeSiAl powder 3.
Further, the metal alloy powders 1 to 3 obtained in the above example 1 and comparative examples 2 to 3 were subjected to powder oxygen content and particle size tests, and the results are shown in Table 1.
TABLE 1 oxygen content and particle size of FeSiAl powder produced by different raw materials and apparatus
In the comparative example 3, as shown in Table 1, the conventional gas atomization device is used for preparing the raw materials of iron powder, aluminum powder and silicon powder, the oxygen content of the prepared powder is 800ppm, and the particle size range is-200 meshes; in comparative example 2, the +200 mesh sendust powder is directly smelted by the device of the invention, and the oxygen content of the prepared powder is 1000ppm, because the powder floats on the surface of molten steel when the +200 mesh sendust powder is smelted, is easy to oxidize and agglomerate, and forms slag easily, even if two layers of filters are arranged in the powder aerosolization preparation device, the slag can be filtered, a tundish is not easy to be blocked, but the oxygen content of the generated sendust powder is larger than that of the powder prepared by a conventional aerosolization device, and the particle size of the powder is far larger than that of the powder prepared by the conventional aerosolization device. In example 1 using the preparation apparatus of the present invention, the oxygen content of the powder obtained was 400ppm and the particle size range was-300 mesh, which are smaller than those of comparative examples 2-3, because the iron-silicon-aluminum coarse powder of +200 mesh was pretreated in advance and made into a square shape, so that the iron-silicon-aluminum block was immersed in the bottom without direct contact with air during the melting process, and clogging caused by excessive oxidation of severe slag during the coarse powder melting was prevented. In addition, the setting of filtration effectively filters and contains oxygen impurity to and the setting of toper pipe effectively promotes the atomizing contact surface that improves the alloy melt.
And in comparative example 1, iron-silicon-aluminum coarse powder with +200 meshes is used as a raw material, and is prepared by adopting a conventional gas atomization device, so that oxidation is serious, atomization cannot be smoothly performed, and the utilization rate of the coarse powder is reduced.
Further, the metal alloy powders 1 to 3 prepared in the above example 1 and comparative examples 2 to 3 were collectively made into a magnetic compact and the loss thereof was examined.
Respectively adding 0.8wt% of phosphoric acid into 3 parts of FeSiAl powder with the same weight for passivation, respectively adding 3wt% of organic silicon resin and 3wt% of water glass after the powder is dried, uniformly stirring, drying the powder, finally adding zinc stearate, uniformly mixing, and preparing the corresponding magnetic powder core after pressing, forming and sintering. And loss detection was performed on each magnetic powder core, and the detection results are shown in table 2.
TABLE 2 loss detection of different magnetic powder cores
As can be seen from table 2, the loss of preparing the metal magnetic powder core by using the fesai powder prepared by the system of the invention is lower than the loss of preparing the metal magnetic powder core by using the fesai powder prepared by using the iron-silicon-aluminum coarse powder with +200 meshes as a raw material and directly preparing the metal magnetic powder core by using the iron powder, the silicon powder and the aluminum powder by using a conventional gas atomization device.
The foregoing description of the preferred embodiments of the present invention should not be construed as limiting the scope of the invention, but rather as utilizing equivalent structural changes made in the description of the present invention and the accompanying drawings or directly/indirectly applied to other related technical fields under the inventive concept of the present invention.

Claims (9)

1. A FeSiAl powder processing and treating system is characterized by comprising a coarse powder pretreatment component, a smelting component and a powder gas atomization preparation device;
the coarse powder pretreatment component is used for uniformly mixing the iron-silicon-aluminum coarse powder with the granularity of +200 meshes with water glass and pressing the coarse powder into iron-silicon-aluminum cubes;
the smelting assembly is used for firstly smelting iron blocks and silicon blocks with preset mass ratio, and then sequentially adding iron-silicon-aluminum blocks, aluminum blocks and deoxidizer with corresponding mass to obtain alloy melt with lower oxygen content;
the powder gas atomization preparation device comprises a tundish (2), a conical conduit (5), a circular seam atomization structure (6) and an atomization cylinder (8) which are communicated in a sealing way from top to bottom;
the tundish (2) is used for receiving the alloy melt conveyed by the smelting component; the side surface of the conical conduit (5) is also connected with a magnetic induction heating device (9), and the induction heating device (9) is used for carrying out preheating treatment on the conical conduit (5) so as to avoid the blockage of the conical conduit (5) by alloy melt;
the circular seam atomizing structure (6) is also connected with an inert gas storage tank (10);
the conical conduit (5) comprises a plurality of through holes which are uniformly distributed, and each through hole is used for communicating the tundish (2) with the circular seam atomizing structure (6).
2. The fesai powder processing system according to claim 1, characterized in that the inert gas storage tank (10) is also in communication with a tundish (2).
3. The system for processing fesai powder according to claim 1, further comprising a multi-layer filter structure arranged in the tundish (2), the surfaces of the multi-layer filter structure being honeycomb-shaped.
4. A system for processing fesai powder according to claim 3, characterised in that the multi-layer filter structure is a first layer filter (3) and a second layer filter (4) arranged at intervals up and down.
5. The FeSiAl powder processing system according to claim 4, wherein the pore diameter of the first filter (3) is 2-3 cm, and the pore diameter of the second filter (4) is 1-2 cm.
6. The fesai powder processing system according to claim 1, wherein the pore diameter of each through hole is 2 to 3mm.
7. The fesai powder processing system according to any of claims 1 to 6, characterized in that a rotating disc (7) is also arranged between the circular seam atomizing structure (6) and the atomizing cylinder (8).
8. The FeSiAl powder processing system according to claim 7, wherein the mass ratio of the coarse powder to the water glass in the coarse powder pretreatment component is 1 (1-3) mill.
9. The FeSiAl powder processing system according to claim 7, wherein in the smelting assembly, the mass ratio of iron block, silicon block and aluminum block is (80-86): (9.5 to 10): (5-10), wherein the mass of the iron-silicon-aluminum square with +200 meshes accounts for 10-30% of the total mass of the iron-silicon-aluminum square, the iron block, the silicon block and the aluminum block.
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