EP0092091A2 - Apparat zur Herstellung von magnetischen Pulvern - Google Patents

Apparat zur Herstellung von magnetischen Pulvern Download PDF

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Publication number
EP0092091A2
EP0092091A2 EP83103269A EP83103269A EP0092091A2 EP 0092091 A2 EP0092091 A2 EP 0092091A2 EP 83103269 A EP83103269 A EP 83103269A EP 83103269 A EP83103269 A EP 83103269A EP 0092091 A2 EP0092091 A2 EP 0092091A2
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EP
European Patent Office
Prior art keywords
recited
chill surface
slot
width
powder
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Application number
EP83103269A
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English (en)
French (fr)
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EP0092091A3 (en
EP0092091B2 (de
EP0092091B1 (de
Inventor
Amitava Datta
Davidson M. Nathasingh
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Allied Corp
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Allied Corp
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Publication of EP0092091A3 publication Critical patent/EP0092091A3/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15358—Making agglomerates therefrom, e.g. by pressing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated

Definitions

  • This invention relates to magnetic articles made as cores and pole pieces and to a process for making them from metallic glass powder.
  • Amorphous metal alloys and articles made therefrom are disclosed by Chen and Polk in United States Patent 3,856,513 issued December 24, 1974. That patent teaches certain novel metal alloy compositions which are obtained in the amorphous state and are superior to previously known crystalline alloys based on the same metals. The compositions taught therein are easily quenched to the amorphous state and possess desirable physical properties. The patent discloses further that amorphous metal powders having a particle size ranging from 10 to 250 ⁇ m can be made by grinding or air milling the cast ribbon.
  • the present invention provides amorphous metal alloy powders especially suited for consolidation into bodies having excellent magnetic response.
  • the invention provides a method for manufacture of magnetic articles in which consolidation of glassy metal powder is effected using a thermomechanical process and insulating materials.
  • Articles produced in accordance with the method of this invention have low remanence and permeabilities which remain constant over a wide frequency range.
  • such consolidated magnetic glassy metal alloy bodies have a relative magnetic permeability of at least 15.
  • relative permeability is intended to mean the ratio of the magnetic induction in a medium generated by a certain field to the magnetic induction in vacuum generated by the same field.
  • molded magnetic metal alloy articles are produced in accordance with the invention by a method comprising the step of compacting ferromagnetic glass powder with static pressure at a pressing temperature in the vicinity of the glass transition temperature and below the crystallization temperature of said alloy, and at a pressure of 69 MPa to 690 MPa.
  • a consolidated, glassy metal alloy body is thereby formed, which is especially adapted to be post fabrication annealed at a temperature ranging from 380 to 450°C for a time period of 1 to 4 hours in the presence of a magnetic field of 0 to 800 A/m.
  • the annealed article has improved impedance permeability and is particularly suited for use in signal and high frequency power transformers and the like.
  • the magnetic compact bodies with permeability greater than 15 of the present invention are generally made from glassy metal alloys in powder form.
  • the general process for preparing metallic glass powders from alloys involves a step of rapid quenching and a step of atomization. Alloys are cast directly into ribbon, followed by grinding, ball milling or air milling into powders or flakes of desirable size range. To aid the pulverization process, ribbon samples are subjected to an embrittlement heat treatment below the crystallization temperature of the alloy.
  • powders or flakes defined herein as particles with the major diameter more than an order of magnitude smaller than their thickness, can be cast directly into the final form having a desirable size range using a serrated casting substrate of the type illustrated in Figure 1.
  • the size of the particles or flakes thereby produced will vary, depending on the depth of the serrations and the distance therebetween.
  • the serrations comprise a plurality of regularly spaced peaks and valleys, the distance between adjacent peaks ranging from 0 .01 cm to 0.1 cm and the distance from the top of a peak to the bottom of a valley ranging from 0.005 cm to 0.05 cm.
  • Such configuration of the casting substrate typically yields powder particles or flakes having a size ranging from 0.01 cm to 0.1 cm.
  • the apparatus 10 has a movable chill surface 12, a reservoir 14 for holding molten metal 16 and a nozzle 18 in communication at its top with reservoir 14 and having at its bottom an opening 20 in close proximity to the chill surface 12.
  • the chill surface 12 has a plurality of regularly spaced peaks 22 and valleys 24. Adjacent peaks are separated by a distance, d, of 0.01 cm to 0.1 cm. The distance, y (not shown), from the top of a peak to the bottom of a valley is 0.005 cm to 0.05 cm.
  • Powder is produced directly by deposition of molten alloy on the serrated substrate (chill surface 12) which is a rotatable chill roll, an endless belt (not shown) or the like, adapted for longitudinal movement at a velocity of 100 to 200 meters per minute.
  • the size of the powder particles thereby produced varies directly with the magnitude of distances d and y.
  • the nozzle means has a slot arranged generally perpendicular to the direction of movement of the chill surface.
  • the slot is defined by a pair of parallel lips, a first lip and a second lip numbered in the direction of movement of the chill surface.
  • the slot of nozzle 18 has a width of from 0.2 to 1 millimeter, measured in the direction of movement of the chill surface.
  • the first lip has a width at least equal to the width of the slot, and the second lip has a width of from 1.5 to 3 times the width of the slot.
  • the gap between the lips and the chill surface is from 0.1 to 1 times the width of the slot.
  • Powder adapted for consolidation can comprise fine powder (having particle size under 105 micrometers), coarse powder (having particle size between 105 micrometers and 300 micrometers) and flake (having particle size greater than 300 micrometers). Consolidation can be obtained by pressing glassy metal alloy powder near its glass transition and below the crystallization temperature.
  • a particle diameter of less than 105 micrometers is used.
  • larger particle diameters of 300 micrometers or more are employed.
  • powders can be put in evacuated cans and then be formed to strips or isostatically pressed to discs, rings or any other desirable shape such as transformer and inductor cores, motor stators and rotor parts, and the like. Furthermore, powders can be warm pressed below the crystallization temperature and in the region of glass transition temperature into any desirable shapes of transformer/ inductor cores or motor rotor/stator segments. Consolidation is believed to result from mechanical interlocking and short-range diffusion bonding between the powder or flake particles occurring in the vicinity of the glass transition temperature. At temperatures too far below the glass transition temperature (Tg) the particles are relatively hard and are not readily deformed by shear and compressive forces exerted thereon during consolidation. Temperatures too far above Tg enhance the risk of incipient crystallization of the amorphous particles during consolidation. Generally, it has been found that interpartical bonding is best achieved during consolidation at pressing temperatures within 50°C of Tg.
  • the powders can also be mixed with a suitable organic binder, for instance, paraffin, polysulfone, polyimide, phenolic formaldehyde resins, and then cold pressed to suitable forms.
  • a suitable organic binder for instance, paraffin, polysulfone, polyimide, phenolic formaldehyde resins
  • the amount of binder can be up to 30 weight percent and is preferably less than 10 weight percent and more preferably between 0.5 and 3 weight percent for high permeability cores.
  • Such formed alloy can have a density of at least 60 percent of the theoretical maximum.
  • the pressed object can be cured at a relatively low temperature below the curing temperature of the binder to give more strength and then ground to final dimensions.
  • the preferred product of this process comprises shapes suitable as magnetic components.
  • the curing process can be performed with simultaneous application of a magnetic field.
  • a metallic glass is an alloy product of fusion which has been cooled to a rigid condition without crystallization.
  • Such metallic glasses generally have at least some of the following properties: high hardness and resistance to scratching, great smoothness of a glassy surface, dimensional and shape stability, mechanical stiffness, strength, ductility, high electrical resistance compared with related metals and alloys thereof, and a diffuse X-ray diffraction pattern.
  • alloy is used herein in the conventional sense as denoting a solid mixture of two or more metals (Condensed Chemical Dictionary, Ninth Edition, Van Norstrand Reinhold Co., New York, 1977). These alloys additionally contain admixed at least one non- metallic element.
  • glassy metal alloy metallic glass
  • amorphous metal alloy amorphous metal alloy
  • vitreous metal alloy are all considered equivalent as employed herein.
  • compositions suitable for the processes disclosed in the present invention include the composition
  • Preferred ferromagnetic alloys according to the present invention are based on one member of the group consisting of iron, cobalt and nickel.
  • the iron based alloys have the general composition Fe 40-88 (Co,Ni) 0-40 (Mo,Nb,Ta,V,Cr) 0-10 (B,C,Si) 5-25 ;
  • the cobalt based alloys have the general composition Co 40-88 (Fe,Ni) 0-40 (Mo,Nb,Ta,V,Mn,Cr) 0-10 (B,C,Si) 5-25 and the nickel based alloys have the general composition
  • An especially preferred alloy has the composition 79 atomic percent iron, 16 atomic percent boron and 5 atomic percent silicon.
  • Amorphous metallic powders can be compacted to fabricate parts suitable for a variety of applications such as electromagnetic cores, pole pieces and the like.
  • the glassy metal compacts have either high or low permeability.
  • the resulting cores can be used as transformer cores, motor stators or rotors and in other alternating current applications.
  • Amorphous alloys that are preferred for such applications include Fe 78 B 13 Si 4 , Fe79B16s15 and Fe 81 B 13.5 Si 3.5 C 2 .
  • Amorphous metallic powders having a particle size below 300 ⁇ m and a composition of Fe 79 B 16 Si 5 (subscripts in atom percent) were prepared by air milling ribbon cast directly from the melt according to the procedure detailed in U.S. patent 4,142,571. Cast ribbon was also given an embrittlement treatement in an inert nitrogen atmosphere for 1-2 hours at 400°C prior to ball milling for 16 hours. The above processes resulted in fine amorphous particles ranging from 300-10 ⁇ m. The resulting fine powder particles were sieved into different size ranges, namely "-325 mesh” ( ⁇ 40 ⁇ m), "-150 mesh” ( ⁇ 105 ⁇ m) and "-48 mesh” ( ⁇ 300 ⁇ m).
  • Powders were then coated with either 1-3 wt% SiO 2 by mixing the particles with a slurry containing Si0 2 and methanol or 1 wt% MgO using a slurry containing M O and methanol.
  • the coated powders of -150 and -325 mesh size were then pressed in graphite molds at temperatures, ranging from 410-510°C for 5, 15 and 30 minutes.
  • a post fabrication anneal substantially improves the permeability and the optimum anneal was found to be 1-2 hrs. at 435°C for the specific composition and consolidation process employed in the present example.
  • Amorphous metallic powder particles with size below 105/ ⁇ m of an alloy and a composition of Fe 79 B 16 Si 5 were prepared by air milling as indicated in Example 1.
  • the impedance permeability for the insulated powder cores does not change with frequency; whereas, the permeability for the uninsulated cores rolls off with frequency due to eddy current shielding. This constant permeability is a very important magnetic characteristic desirable for signal and high frequency power transformer applica - tions.
  • Powder and insulation characteristics necessary for optimum low frequency (60-400 Hz) core loss are substantially different fom those necessary for high frequency applications. Since eddy currents are not dominant at lower frequencies, larger particle size (eg. greater than 300 pm) with no insulation is desirable for 60-400 Hz transformer and motor applications. Also, for such lower frequency transformer and motor applications, post fabrication annealing should be conducted at lower temperatures, as in the order of temperatures ranging from 380 to 420°C, to avoid partial crystallization, of the amorphous matrix. For high frequency applications, the particle size is smaller (eg. less than 105 micrometers), the particles are coated with an insulator such as MgO, Si0 2 or the like, and the annealing temperature ranges from 420-450°C.
  • an insulator such as MgO, Si0 2 or the like

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  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Soft Magnetic Materials (AREA)
  • Powder Metallurgy (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
EP83103269A 1982-04-15 1983-04-02 Apparat zur Herstellung von magnetischen Pulvern Expired - Lifetime EP0092091B2 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US36861282A 1982-04-15 1982-04-15
US368612 1982-04-15

Publications (4)

Publication Number Publication Date
EP0092091A2 true EP0092091A2 (de) 1983-10-26
EP0092091A3 EP0092091A3 (en) 1984-03-07
EP0092091B1 EP0092091B1 (de) 1986-06-18
EP0092091B2 EP0092091B2 (de) 1991-01-30

Family

ID=23451974

Family Applications (1)

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EP83103269A Expired - Lifetime EP0092091B2 (de) 1982-04-15 1983-04-02 Apparat zur Herstellung von magnetischen Pulvern

Country Status (4)

Country Link
EP (1) EP0092091B2 (de)
JP (2) JPS5916306A (de)
CA (1) CA1232158A (de)
DE (1) DE3364158D1 (de)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0455113A2 (de) * 1990-04-24 1991-11-06 Alps Electric Co., Ltd. Auf Fe basierende weichmagnetische Legierung, und diese Legierung enthaltendes Magnetmaterial und magnetischer Apparat, der diese Materialien verwendet
US5216844A (en) * 1990-10-05 1993-06-08 Intermac S.R.L. Process for the automatic machining of edges of glass plates and apparatus for carrying out said process
WO2003067615A1 (en) * 2002-02-08 2003-08-14 Honeywell International Inc. Current transformer having an amorphous fe-based core
EP1553814A1 (de) * 2004-01-08 2005-07-13 Ngk Insulators, Ltd. Elektromagnetisches Abschirmgehäuse und Verfahren zur Herstellung
EP3376510A1 (de) * 2017-03-13 2018-09-19 Kabushiki Kaisha Toshiba Vielzahl von flockigen magnetischen metallteilchen, gepresstes pulvermaterial und drehende elektrische maschine

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4594104A (en) * 1985-04-26 1986-06-10 Allied Corporation Consolidated articles produced from heat treated amorphous bulk parts
JPH0733521B2 (ja) * 1988-07-01 1995-04-12 セイコー電子部品株式会社 異方性ボンド磁石用合金粉末の製造方法
JPH11158502A (ja) * 1997-11-26 1999-06-15 Masaaki Yagi 複合粉末および複合粉末の成形方法
JP2008141012A (ja) * 2006-12-01 2008-06-19 Hitachi Powdered Metals Co Ltd リアクトル

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3856513A (en) 1972-12-26 1974-12-24 Allied Chem Novel amorphous metals and amorphous metal articles
DE2628207A1 (de) 1976-06-23 1978-01-05 Draloric Electronic Verfahren zur herstellung von aus magnetwerkstoff und einem bindemittel gepressten weichmagnetischen formkoerpern
US4142571A (en) 1976-10-22 1979-03-06 Allied Chemical Corporation Continuous casting method for metallic strips

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2096092A5 (de) * 1970-06-08 1972-02-11 Fuji Photo Film Co Ltd
US4116728B1 (en) * 1976-09-02 1994-05-03 Gen Electric Treatment of amorphous magnetic alloys to produce a wide range of magnetic properties
AU503857B2 (en) * 1976-10-22 1979-09-20 Allied Chemical Corp. Continuous casting of metal strip
US4215084A (en) * 1978-05-03 1980-07-29 The Battelle Development Corporation Method and apparatus for producing flake particles
JPS55152155A (en) * 1979-05-16 1980-11-27 Sumitomo Special Metals Co Ltd Fine crystalline strip material for high permeability magnetic material, preparation and product thereof
US4321090A (en) * 1980-03-06 1982-03-23 Allied Corporation Magnetic amorphous metal alloys
JPS57187357A (en) * 1981-05-15 1982-11-18 Aisin Seiki Co Ltd Soft magnetic resin composed of amorphous alloy
JPS58163555A (ja) * 1982-03-24 1983-09-28 Nippon Yakin Kogyo Co Ltd 箔片を溶融材料から直接に製造する装置
JPS58163557A (ja) * 1982-03-25 1983-09-28 Nippon Yakin Kogyo Co Ltd 箔片製造装置
JPS58163556A (ja) * 1982-03-25 1983-09-28 Nippon Yakin Kogyo Co Ltd 箔片製造装置
JPS5939224B2 (ja) * 1982-04-08 1984-09-21 日本冶金工業株式会社 箔片製造装置

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3856513A (en) 1972-12-26 1974-12-24 Allied Chem Novel amorphous metals and amorphous metal articles
DE2628207A1 (de) 1976-06-23 1978-01-05 Draloric Electronic Verfahren zur herstellung von aus magnetwerkstoff und einem bindemittel gepressten weichmagnetischen formkoerpern
US4142571A (en) 1976-10-22 1979-03-06 Allied Chemical Corporation Continuous casting method for metallic strips

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
"Condensed Chemical Dictionary", 1977, VAN NORSTRAND REIN- HOLD CO.

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0455113A2 (de) * 1990-04-24 1991-11-06 Alps Electric Co., Ltd. Auf Fe basierende weichmagnetische Legierung, und diese Legierung enthaltendes Magnetmaterial und magnetischer Apparat, der diese Materialien verwendet
EP0455113B1 (de) * 1990-04-24 1997-06-04 Alps Electric Co., Ltd. Auf Fe basierende weichmagnetische Legierung, und diese Legierung enthaltendes Magnetmaterial und magnetischer Apparat, der diese Materialien verwendet
US5216844A (en) * 1990-10-05 1993-06-08 Intermac S.R.L. Process for the automatic machining of edges of glass plates and apparatus for carrying out said process
WO2003067615A1 (en) * 2002-02-08 2003-08-14 Honeywell International Inc. Current transformer having an amorphous fe-based core
US6930581B2 (en) 2002-02-08 2005-08-16 Metglas, Inc. Current transformer having an amorphous fe-based core
EP1553814A1 (de) * 2004-01-08 2005-07-13 Ngk Insulators, Ltd. Elektromagnetisches Abschirmgehäuse und Verfahren zur Herstellung
US7626832B2 (en) 2004-01-08 2009-12-01 Ngk Insulators, Ltd. Electromagnetic wave shield case and a method for manufacturing electromagnetic wave shield case
EP3376510A1 (de) * 2017-03-13 2018-09-19 Kabushiki Kaisha Toshiba Vielzahl von flockigen magnetischen metallteilchen, gepresstes pulvermaterial und drehende elektrische maschine
US10774404B2 (en) 2017-03-13 2020-09-15 Kabushiki Kaisha Toshiba Plurality of flaky magnetic metal particles, pressed powder material, and rotating electric machine
US11459645B2 (en) 2017-03-13 2022-10-04 Kabushiki Kaisha Toshiba Plurality of flaky magnetic metal particles, pressed powder material, and rotating electric machine

Also Published As

Publication number Publication date
JPH0534814B2 (de) 1993-05-25
CA1232158A (en) 1988-02-02
DE3364158D1 (en) 1986-07-24
EP0092091A3 (en) 1984-03-07
EP0092091B2 (de) 1991-01-30
JPS5916306A (ja) 1984-01-27
CA1256667C (de) 1989-07-04
EP0092091B1 (de) 1986-06-18
JPH0277505A (ja) 1990-03-16

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