EP3572165A1 - Method and system for the manufacture of a material for the production of rare earth magnets - Google Patents
Method and system for the manufacture of a material for the production of rare earth magnets Download PDFInfo
- Publication number
- EP3572165A1 EP3572165A1 EP19170743.9A EP19170743A EP3572165A1 EP 3572165 A1 EP3572165 A1 EP 3572165A1 EP 19170743 A EP19170743 A EP 19170743A EP 3572165 A1 EP3572165 A1 EP 3572165A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- powder particles
- rare earth
- powdery
- intermediate product
- earth magnets
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 229910052761 rare earth metal Inorganic materials 0.000 title claims abstract description 88
- 150000002910 rare earth metals Chemical class 0.000 title claims abstract description 88
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 43
- 238000000034 method Methods 0.000 title claims abstract description 40
- 239000000463 material Substances 0.000 title claims abstract description 12
- 239000000843 powder Substances 0.000 claims abstract description 80
- 239000002245 particle Substances 0.000 claims abstract description 69
- 230000005291 magnetic effect Effects 0.000 claims abstract description 44
- 239000002994 raw material Substances 0.000 claims abstract description 25
- 238000000227 grinding Methods 0.000 claims description 51
- 239000007858 starting material Substances 0.000 claims description 30
- 239000013067 intermediate product Substances 0.000 claims description 25
- 239000007789 gas Substances 0.000 claims description 16
- 239000000047 product Substances 0.000 claims description 12
- 230000008569 process Effects 0.000 claims description 10
- 239000011261 inert gas Substances 0.000 claims description 6
- 230000001681 protective effect Effects 0.000 claims description 5
- 238000002360 preparation method Methods 0.000 claims description 2
- 239000006247 magnetic powder Substances 0.000 description 26
- 239000000543 intermediate Substances 0.000 description 10
- 229910001172 neodymium magnet Inorganic materials 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 8
- 229910045601 alloy Inorganic materials 0.000 description 7
- 239000000956 alloy Substances 0.000 description 7
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 6
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000001878 scanning electron micrograph Methods 0.000 description 4
- QJVKUMXDEUEQLH-UHFFFAOYSA-N [B].[Fe].[Nd] Chemical compound [B].[Fe].[Nd] QJVKUMXDEUEQLH-UHFFFAOYSA-N 0.000 description 3
- 229910017052 cobalt Inorganic materials 0.000 description 3
- 239000010941 cobalt Substances 0.000 description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 229910052759 nickel Inorganic materials 0.000 description 3
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 238000004064 recycling Methods 0.000 description 2
- 229910000521 B alloy Inorganic materials 0.000 description 1
- 229910000952 Be alloy Inorganic materials 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 229910052692 Dysprosium Inorganic materials 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- 229910052688 Gadolinium Inorganic materials 0.000 description 1
- 229910000583 Nd alloy Inorganic materials 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910052777 Praseodymium Inorganic materials 0.000 description 1
- 229910052772 Samarium Inorganic materials 0.000 description 1
- 229910052771 Terbium Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- KBQHZAAAGSGFKK-UHFFFAOYSA-N dysprosium atom Chemical compound [Dy] KBQHZAAAGSGFKK-UHFFFAOYSA-N 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 230000005294 ferromagnetic effect Effects 0.000 description 1
- 239000003302 ferromagnetic material Substances 0.000 description 1
- -1 ferrous metals Chemical class 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 230000005415 magnetization Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
- KZUNJOHGWZRPMI-UHFFFAOYSA-N samarium atom Chemical compound [Sm] KZUNJOHGWZRPMI-UHFFFAOYSA-N 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- GZCRRIHWUXGPOV-UHFFFAOYSA-N terbium atom Chemical compound [Tb] GZCRRIHWUXGPOV-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
- H01F41/0293—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets diffusion of rare earth elements, e.g. Tb, Dy or Ho, into permanent magnets
-
- 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
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
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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
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
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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
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
- H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
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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
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
- H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
- H01F1/0575—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together
- H01F1/0576—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together pressed, e.g. hot working
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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
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
- H01F1/06—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys in the form of particles, e.g. powder
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- 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
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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
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C2202/00—Physical properties
- C22C2202/02—Magnetic
Definitions
- the present invention relates to a process for producing a raw material for the production of a rare earth magnet and to a plant for producing a raw material for the production of rare earth magnets according to the features of the independent claims.
- a permanent magnet or permanent magnet consists of a magnetizable material, for example iron, cobalt or nickel, which retains a static magnetic field, without requiring an electric current flow in contrast to electromagnets.
- a permanent magnet can be generated by the action of a magnetic field on ferromagnetic material.
- rare earth magnet is a group of permanent magnets consisting essentially of ferrous metals (iron, cobalt, rare nickel) and rare earth metals (especially neodymium, samarium, praseodymium, dysprosium, terbium, gadolinium). Rare earth magnets are characterized by the fact that they have a high magnetic remanence flux density and thus a high magnetic energy density.
- Permanent magnets are made of crystalline powder.
- the magnetic powder is pressed into a mold in the presence of a strong magnetic field.
- the crystals align with their preferred magnetization axis in the direction of the magnetic field.
- the pellets are then sintered.
- the pulverized constituents of the powder are joined or compacted by heating, but no or at least not all starting materials are melted.
- the compacts often under elevated pressure - heated so that the temperatures remain below the melting temperature of the main components, so that the shape of the workpiece is maintained.
- rare earth metal-rich alloys for the production of a material for the production of rare earth magnets also old magnets gain increasing importance, which for the production of a material for the production of rare earth magnets.
- Magnets are reused and / or recycled.
- the old magnets are, for example, magnets which were used in motors or in old electrical appliances or the like and are no longer needed or which do not and / or no longer completely fulfill their desired properties and / or desired performance. In this respect one speaks of the use of old magnets also of a recycled material.
- the invention has for its object to provide a method for producing a starting material for the production of rare earth magnets available through which the present in a powdery intermediate sharp corners and edges of the powder particles at least largely reduced in a simple manner and / or be reduced, thereby providing an optimized starting material for the production of improved rare earth magnets.
- the process for producing a powdery starting material for the production of rare earth magnets itself is to be optimized.
- a plant for producing a raw material for the production of rare earth magnets is provided, by means of which the method for producing a starting material for the production of a rare earth magnet can be carried out in a simple manner and by the optimized starting material for the production of a Rare earth magnets can be provided.
- At least one magnetic or magnetizable raw material is provided.
- This may be, for example, an alloy comprising a rare earth metal.
- magnetic recycling material can be used, for example old magnets which have been used in engines and / or in old electrical appliances and no longer have any use there for further use.
- the at least one magnetic or magnetizable raw material or the recycling material is Nd-Fe-B (neodymium-iron-boron) -containing alloys or Nd-Fe-B (neodymium-iron-boron) magnets.
- the provided magnetic or magnetizable raw material is comminuted, wherein a powdery intermediate product is formed from the at least one magnetic or magnetizable raw material.
- a powdery intermediate product is formed from the at least one magnetic or magnetizable raw material.
- the comminution of the magnetic or magnetizable raw material is carried out in such a way that the powder particles formed thereby of the powdery intermediate product have a particle size between about 2 microns to 10 microns, preferably between 3 microns to 5 microns.
- the comminution takes place in particular by means of a comminution device, for example by means of conventionally known comminution techniques.
- a first coarse crushing for the production of coarse powder having a particle size of about 100 microns to 300 microns can be done for example by the use of mechanical crushing plants and / or by the use of hydrogen technology.
- grinding systems for fine grinding such as fluidized bed jet mills or similar grinding plants are used, which are operated in particular under inert gas.
- the protective gas used is usually nitrogen or argon.
- the powder particles of the powdery intermediate product are rounded, ie in the further step, the corners and edges of the powder particles are rounded off and / or reduced and / or largely ground off.
- the resulting rounded powder particles preferably have substantially the same size as the angular powder particles of the powdery intermediate product, namely a particle size between about 2 ⁇ m to 10 ⁇ m, preferably between 3 ⁇ m to 5 ⁇ m.
- the system comprises a grinding device which is designed for rounding the angular, sharp-edged powder particles of the powdery intermediate product.
- the grinding device comprises a receiving space, in which the powdery intermediate product is filled. This is now swirled around within the receiving space, so that the powder particles rub against each other, whereby the corners and edges are reduced and, in particular, ground off.
- filling into and treating the powdery intermediate within the grinding apparatus is accomplished using a shielding gas.
- the powdery intermediate product is processed for a defined time, for example between 30 minutes and two hours, preferably for about one hour in the grinding device.
- the receiving space of the grinding device is preferably filled for the grinding process to 50% to 99% with powdery intermediate, in particular, the powdery intermediate product should fill at least 80% of the receiving space.
- the remaining space within the receiving space of the grinding device is filled by the protective gas used.
- a conventional grinding device can be modified such that the powdery intermediate product is swirled around on the one hand vigorously within the modified grinding device, so that the powder particles rub against each other.
- no further grinding of the powdery intermediate takes place, which would lead to fresh, sharp break edges.
- This gentle grinding process is achieved, for example, by operating the grinding device / modified grinding device with a low gas pressure, in particular with a gas pressure between 0.25 bar and 1.00 bar.
- the gas pressure must be adjusted in particular such that the powder particles of the powdery intermediate product are largely freely movable in the grinding device / modified grinding device, but the energy of the powder particles is not sufficient for further grinding.
- the movement of the powder particles in the grinder / modified grinder causes frictional effects between the individual powder particles. These frictional effects cause the sharp corners and edges of the powdery intermediate product to become distinct be rounded off, creating an optimized powdered product with rounded powder particles.
- This optimized powdered product can already be used as the first starting material for the production of first rare earth magnets.
- the first rare earth magnets produced using the first starting material have significantly better magnet values and higher magnetic energy densities, respectively, than magnets made from the powdery intermediate described above.
- the optimized pulverulent product is subjected to a classification process in a further method step in order to remove the fine-dust fractions occurring during the friction of the powder particles within the grinding device from the optimized pulverulent product.
- a fraction is formed, which contains only rounded powder particles of a size between about 2 microns to 10 microns, preferably between 3 microns to 5 microns. If this fraction is used as a second starting material for the production of second rare-earth magnets, then products with further improved magnet values or higher magnetic energy densities can be produced.
- a separator for classifying the optimized powdery product into a fine fraction comprising the ultrafine abrasive particles and a coarse fraction comprising the desired rounded powder particles prepared from the magnetic or magnetizable raw material for example, a dynamic sifter or a fast rotating sifter can be used.
- Experimental data shows that the first rare earth magnets made using rounded powder particles, and especially the second rare earth magnets made using classified rounded powder particles, have better magnetic properties and, in particular, exhibit magnetic or magnetic energy densities , which come closer to the theoretically calculated values.
- FIG. 1 shows a scanning electron micrograph of a conventionally produced rare earth magnet powder and FIG. 2 shows by way of example schematically illustrated individual particles 2 of such a conventionally produced rare-earth magnetic powder 1.
- the production of the rare-earth magnetic powder for example, by grinding a corresponding raw material.
- the magnetic or magnetizable raw material may be alloys comprising ferromagnetic metals, for example iron, nickel, cobalt, in particular an alloy of neodymium, iron and boron (NdFeB), or old magnets or mixtures of rare earth alloys and old magnets.
- the magnetic or magnetizable raw material is ground, for example, in fluid bed jet mills or similar grinding plants such that a fine rare earth magnetic powder 1 is formed in which the average particle size (d50 value) of the powder particles 2 between 2 .mu.m to 10 .mu.m, preferably between 3 .mu.m is up to 5 microns.
- FIG. 3 shows a scanning electron micrograph of a second optimized starting material AM2 for the production of rare earth magnets 20 - see also the figure description of FIG. 5 - and FIG. 4 shows exemplary schematically illustrated individual particles 12, 12a, 12b of the second optimized starting material AM 2.
- the second optimized starting material AM2 is produced in particular by a process as described in connection with FIG. 5 will be described in detail below.
- the second optimized starting material AM2 contains, in particular, powder particles 12 which, compared to the powder particles 2 of the rare earth magnetic powder 1, have only a significantly reduced number of rounded corners 13 and rounded edges 14, in particular rounded and / or rounded powder particles 12a or rounded powder particles 12b ,
- FIG. 5 shows individual process steps for producing an optimized starting material AM1, AM2, in particular an optimized rare-earth magnetic powder 10 or a rare earth magnet powder further optimized by additional classification, for the production of rare-earth magnets 19, 20 based on at least one magnetic or magnetizable raw material M.
- FIG. 6 schematically shows a system 25 for producing a powdery and intended for the production of rare earth magnets 20 starting material AM2.
- At least one magnetic or magnetizable raw material M is provided.
- the at least one magnetic or magnetizable raw material M is preferably rare-earth alloys and / or old magnets, in particular Nd-Fe-B alloys and / or Nd-Fe-B aged magnets.
- the provided at least one magnetic or magnetizable raw material M is comminuted, wherein from the at least one magnetic or magnetizable raw material M a powdery intermediate ZP, in particular a rare earth magnetic powder 1 with powder 2 with 3 corners and edges 4 according to Figures 1 and 2 arises.
- the comminution takes place by means of a comminution device 30, for example by means of conventionally known comminution techniques.
- a first coarse crushing for the production of coarse powder having a particle size of about 100 microns to 300 microns for example, by the use of mechanical crushing plants, such as mills 31 and / or by using hydrogen technology.
- grinding systems for fine grinding such as fluidized bed jet mills 32 or similar grinding systems are used, which are operated in particular under inert gas S.
- the protective gas used is usually nitrogen or argon.
- Such produced rare earth magnetic powder 1 is used, for example, for producing conventional rare earth magnets 5.
- this rare-earth magnetic powder 1 is now filled under inert gas S into a grinding device 40 and then moved in this grinding device 40 under inert gas S for a defined period of time. At this time, the powder particles 2 of the rare earth magnetic powder 1 are swirled inside the grinding device 40.
- the defined period of time for this process step is between 0.5 hours and 3 hours, in particular about one hour.
- the receiving space of the grinding device 40 is not completely filled with rare earth magnet powder 1.
- the receiving space is filled such that the rare earth magnetic powder 1 fills between 50% and 99% of the grinding chamber.
- the receiving space is filled in such a way that the rare-earth magnetic powder 1 fills at least 80% of the receiving space.
- the remaining 20% of the grinding chamber are filled by inert gas S.
- the rare earth magnetic powder 1 is whirled around vigorously, whereby the corners 3 and edges 4 of the powder particles 2 are mutually abraded by mutual friction of the powder particles 2 with each other.
- no further grinding of the rare-earth magnetic powder 1 takes place in the grinding device 40, so that no fresh sharp corners 3 and broken edges 4 can arise.
- the grinding device 40 is preferably operated with a low gas pressure, for example with a gas pressure between 0.25 bar and 1.00 bar.
- the gas pressure must be adjusted in each case so that the intermediate ZP or rare earth magnet powder 1 can indeed be swirled around in the grinding device 40, so that the powder particles 2 rub against each other, whereby the corners 3 and edges 4 rubbed off and rounded powder particles 12 according to FIGS. 3 and 4 be formed.
- the energy of the powder particles 2 and 12 must not be sufficient for further grinding.
- the conventionally produced rare-earth magnetic powder 1 is treated in the grinding device 40 until largely only rounded powder particles 12 b are obtained FIG. 4 available.
- the rounding produces an optimized rare-earth magnetic powder 10, which can already be used as the first starting material AM1 for the production of first optimized rare-earth magnet 19.
- the optimized rare earth magnet powder 10 contains, in addition to the rounded powder particles 12 - see also FIGS. 3 and 4 - But still Feinstabriebanmaschine F, in particular, the abrasion of the corners 3 and edges 4 of the powder 2 of the rare earth magnetic powder 1 represent.
- these ultrafine abrasive fractions F are removed to produce a further optimized second starting material AM2 for the production of second further optimized rare earth magnets 20.
- the ultrafine abrasive fractions F are removed by subsequently classifying the first optimized rare-earth magnetic powder 10 in a separator 50, for example a fast-rotating dynamic classifier 51, such that the second starting material AM2 is for the production of second further optimized rare-earth magnets 20 contains only rounded powder particles 12.
- first optimized rare earth magnets 19 and in particular second further optimized rare earth magnets 20 have magnet values or magnetic energy densities which are higher than the magnet values or magnetic energy densities of rare earth magnets 5 which are made from a conventionally produced magnet Rare earth magnetic powder 1 are manufactured.
- the second rare earth magnets 20 are made of a second one Optimized starting material AM2 on a magnetic value or a value of the magnetic energy density, which approaches significantly to a theoretically calculated optimum value.
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Abstract
Die Erfindung betrifft ein Verfahren und eine Anlage zur Herstellung eines pulverförmigen und zur Fertigung von Seltenerd-Magneten vorgesehenen Materials. Zuerst wird mindestens ein magnetisches bzw. magnetisierbares Rohmaterial bereitgestellt und mittels herkömmlicher Zerkleinerungsmethoden in ein pulverförmiges Zwischenprodukt zerkleinert, welches Pulverteilchen mit Ecken und Kanten umfasst. Anschließend werden die scharfkantigen Pulverteilchen verrundet. Das, die verrundeten Pulverteilchen umfassende, optimierte pulverförmige Produkt wird zur Fertigung von Seltenerd-Magneten verwendet.The invention relates to a method and a plant for producing a powdery material intended for the production of rare earth magnets. First, at least one magnetic or magnetizable raw material is provided and comminuted by conventional crushing techniques into a powdery intermediate comprising powdered particles with corners and edges. Subsequently, the sharp-edged powder particles are rounded. The optimized powdered product, comprising the rounded powder particles, is used to make rare earth magnets.
Description
Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung eines Ausgangsmaterials für die Herstellung eines Seltenerd-Magneten sowie eine Anlage zur Herstellung eines Ausgangsmaterials für die Herstellung von Seltenerd-Magneten gemäß den Merkmalen der unabhängigen Ansprüche.The present invention relates to a process for producing a raw material for the production of a rare earth magnet and to a plant for producing a raw material for the production of rare earth magnets according to the features of the independent claims.
Ein Dauermagnet bzw. Permanentmagnet besteht aus einem magnetisierbaren Material, zum Beispiel Eisen, Kobalt oder Nickel, welches ein statisches Magnetfeld behält, ohne dass im Gegensatz zu Elektromagneten ein elektrischer Stromfluss benötigt wird. Ein Dauermagnet kann durch die Einwirkung eines Magnetfeldes auf ferromagnetisches Material erzeugt werden.A permanent magnet or permanent magnet consists of a magnetizable material, for example iron, cobalt or nickel, which retains a static magnetic field, without requiring an electric current flow in contrast to electromagnets. A permanent magnet can be generated by the action of a magnetic field on ferromagnetic material.
Unter dem Namen Seltenerd-Magnet wird eine Gruppe von Permanentmagneten zusammengefasst, die im Wesentlichen aus Eisenmetallen (Eisen, Cobalt, seltener Nickel) und Seltenerd-Metallen (insbesondere Neodym, Samarium, Praseodym, Dysprosium, Terbium, Gadolinium) bestehen. Seltenerd-Magneten zeichnen sich dadurch aus, dass sie eine hohe magnetische Remanenzflussdichte und damit eine hohe magnetische Energiedichte aufweisen.The term rare earth magnet is a group of permanent magnets consisting essentially of ferrous metals (iron, cobalt, rare nickel) and rare earth metals (especially neodymium, samarium, praseodymium, dysprosium, terbium, gadolinium). Rare earth magnets are characterized by the fact that they have a high magnetic remanence flux density and thus a high magnetic energy density.
Permanentmagnete werden aus kristallinem Pulver hergestellt. Das Magnetpulver wird in Gegenwart eines starken Magnetfelds in eine Form gepresst. Dabei richten sich die Kristalle mit ihrer bevorzugten Magnetisierungsachse in Richtung des Magnetfelds aus. Die Presslinge werden anschließend gesintert. Beim Sintern werden die pulverisierten Bestandteile des Pulvers durch Erwärmung miteinander verbunden oder verdichtet, wobei jedoch keine oder zumindest nicht alle Ausgangsstoffe aufgeschmolzen werden. Dabei werden die Presslinge - oft unter erhöhtem Druck - derart erhitzt, dass die Temperaturen unterhalb der Schmelztemperatur der Hauptkomponenten bleiben, so dass die Gestalt (Form) des Werkstückes erhalten bleibt.Permanent magnets are made of crystalline powder. The magnetic powder is pressed into a mold in the presence of a strong magnetic field. The crystals align with their preferred magnetization axis in the direction of the magnetic field. The pellets are then sintered. During sintering, the pulverized constituents of the powder are joined or compacted by heating, but no or at least not all starting materials are melted. Here are the compacts - often under elevated pressure - heated so that the temperatures remain below the melting temperature of the main components, so that the shape of the workpiece is maintained.
Zur Herstellung eines Materials, welches zur Fertigung von Permanentmagneten, insbesondere von Nd-Fe-B (Neodym-Eisen-Bor) Magneten, benötigt wird, ist im Stand der Technik bekannt, Seltenerdmetall umfassende Legierungen zu einem pulverförmigen Zwischenprodukt, beispielsweise in Form von Grobpulver oder Feinpulver, zu vermahlen. Zur Herstellung von pulverförmigen Zwischenprodukten eignen sich in der Regel die herkömmlichen Zerkleinerungstechniken, beispielsweise Dampfstrahlmühlen oder ähnliches.For producing a material which is required for the production of permanent magnets, in particular of Nd-Fe-B (neodymium-iron-boron) magnets, it is known in the prior art to include alloys comprising rare earth metal to give a powdery intermediate product, for example in the form of coarse powder or fine powder, to grind. For the preparation of powdery intermediates are usually the conventional crushing techniques, such as steam jet mills or the like.
Da die Vorkommen von Seltenerdmetallen begrenzt sind und insbesondere die Gewinnung derselben sehr teuer ist, gewinnen neben Seltenerdmetall umfassenden Legierungen zur Herstellung eines Materials für die Fertigung von Seltenerd-Magneten auch Altmagnete zunehmend an Bedeutung, welche für die Herstellung eines Materials für die Fertigung von Seltenerd-Magneten wiederverwendet und/oder recycelt werden. Bei den Altmagneten handelt es sich beispielsweise um Magnete, welche in Motoren oder in Elektroaltgeräten oder dergleichen eingesetzt wurden und nicht mehr benötigt werden bzw. welche ihre gewünschten Eigenschaften und/oder ihre gewünschte Leistungsstärke nicht und/oder nicht mehr vollständig erfüllen. Insofern spricht man bei der Verwendung von Altmagneten auch von einem Recycling-Material.Since the occurrence of rare earth metals are limited and in particular the extraction of the same is very expensive, in addition to rare earth metal-rich alloys for the production of a material for the production of rare earth magnets also old magnets gain increasing importance, which for the production of a material for the production of rare earth magnets. Magnets are reused and / or recycled. The old magnets are, for example, magnets which were used in motors or in old electrical appliances or the like and are no longer needed or which do not and / or no longer completely fulfill their desired properties and / or desired performance. In this respect one speaks of the use of old magnets also of a recycled material.
Problematisch ist jedoch, dass bei der Feinmahlung von solchen Seltenerd-Magnetpulvern mit herkömmlichen Verfahren, beispielsweise in Fließbettstrahlmühlen oder ähnlichen Mahlanlagen, Pulverteilchen entstehen, die scharfe Ecken und Kanten aufweisen. Diese scharfen Ecken und Kanten sind aus verschiedensten Gründen in höchstem Maße unerwünscht, insbesondere deshalb, weil Magnete, die unter Verwendung eines solchen scharfkantigen Pulvers hergestellt wurden, schlechtere Magnetwerte bzw. geringere magnetische Energiedichten zeigen, als theoretisch zu erwarten wäre, wenn man bei den Berechnungen die Existenz von gerundeten Pulverpartikeln, d.h. ohne scharfe Ecken und Kanten, voraussetzt.The problem, however, is that in the fine grinding of such rare earth magnetic powders by conventional methods, for example in fluidized bed jet mills or similar grinding plants, powder particles are formed which have sharp corners and edges. These sharp corners and edges are highly undesirable for a variety of reasons, particularly because magnets made using such a sharp powder exhibit inferior magnet values, or lower magnetic energy densities, than would be theoretically expected by the calculations presupposes the existence of rounded powder particles, ie without sharp corners and edges.
Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zur Herstellung eines Ausgangsmaterials für die Fertigung von Seltenerd-Magneten zur Verfügung zu stellen, durch welches die in einem pulverförmigen Zwischenprodukt vorhandenen scharfen Ecken und Kanten der Pulverteilchen zumindest weitgehend auf einfache Art und Weise verringert und/oder reduziert werden, wodurch ein optimiertes Ausgangsmaterial zur Herstellung von verbesserten Seltenerd-Magneten bereitgestellt wird. Gleichzeitig soll das Verfahren zur Herstellung eines pulverförmigen Ausgangsmaterials zur Herstellung von Seltenerd-Magneten selbst optimiert werden. Weiter ist eine Anlage zur Herstellung eines Ausgangsmaterials für die Fertigung von Seltenerd-Magneten vorgesehen, mittels welcher das Verfahren zur Herstellung eines Ausgangsmaterials für die Herstellung eines Seltenerd-Magneten auf einfache Art und Weise durchgeführt werden kann und durch die ein optimiertes Ausgangsmaterial für die Herstellung eines Seltenerd-Magneten bereitgestellt werden kann.The invention has for its object to provide a method for producing a starting material for the production of rare earth magnets available through which the present in a powdery intermediate sharp corners and edges of the powder particles at least largely reduced in a simple manner and / or be reduced, thereby providing an optimized starting material for the production of improved rare earth magnets. At the same time, the process for producing a powdery starting material for the production of rare earth magnets itself is to be optimized. Further, a plant for producing a raw material for the production of rare earth magnets is provided, by means of which the method for producing a starting material for the production of a rare earth magnet can be carried out in a simple manner and by the optimized starting material for the production of a Rare earth magnets can be provided.
Die obige Aufgabe wird durch ein Verfahren zur Herstellung eines pulverförmigen und zur Fertigung von Seltenerd-Magneten vorgesehenen Ausgangsmaterials und eine Anlage zur Herstellung eines pulverförmigen und zur Fertigung von Seltenerd-Magneten vorgesehenen Ausgangsmaterials gelöst, die die Merkmale in den unabhängigen Patentansprüchen umfassen. Weitere vorteilhafte Ausgestaltungen werden durch die Unteransprüche beschrieben.The above object is achieved by a method for producing a powdery raw material intended for producing rare-earth magnets and a plant for producing a powdery starting material intended for the production of rare-earth magnets, which comprise the features in the independent patent claims. Further advantageous embodiments are described by the subclaims.
In einem ersten Schritt wird mindestens ein magnetisches bzw. magnetisierbares Rohmaterial bereitgestellt. Dabei kann es sich beispielsweise um eine Seltenerdmetall umfassende Legierung handeln. Alternativ oder zusätzlich kann magnetisches Recyclingmaterial verwendet werden, beispielsweise Altmagneten, welche in Motoren und/oder in Elektroaltgeräte eingesetzt wurden und dort jeweils für eine weitere Verwendung keinen Nutzen mehr haben. Vorzugsweise handelt es sich bei dem mindestens einen magnetischen bzw. magnetisierbaren Rohmaterial bzw. dem Recyclingmaterial um Nd-Fe-B (Neodym-Eisen-Bor) haltige Legierungen oder Nd-Fe-B (Neodym-Eisen-Bor) Magneten.In a first step, at least one magnetic or magnetizable raw material is provided. This may be, for example, an alloy comprising a rare earth metal. Alternatively or additionally, magnetic recycling material can be used, for example old magnets which have been used in engines and / or in old electrical appliances and no longer have any use there for further use. Preferably, the at least one magnetic or magnetizable raw material or the recycling material is Nd-Fe-B (neodymium-iron-boron) -containing alloys or Nd-Fe-B (neodymium-iron-boron) magnets.
In einem nächsten Schritt erfolgt ein Zerkleinern des bereitgestellten magnetischen bzw. magnetisierbaren Rohmaterials, wobei aus dem mindestens einen magnetischen bzw. magnetisierbaren Rohmaterial ein pulverförmiges Zwischenprodukt gebildet wird. Dieses umfasst Pulverteilchen, die Ecken und Kanten aufweisen. Diese Ecken und Kanten bewirken, dass Magnete, die aus dem pulverförmigen Zwischenmaterial hergestellt werden, einen gemessenen Magnetwert bzw. einen gemessenen Wert magnetischer Energiedichte aufweisen, der deutlich unterhalb eines berechneten, theoretisch zu erwartenden Magnetwertes liegt.In a next step, the provided magnetic or magnetizable raw material is comminuted, wherein a powdery intermediate product is formed from the at least one magnetic or magnetizable raw material. This includes powder particles that have corners and edges. These corners and edges cause magnets, which are made of the powdery intermediate material, having a measured magnetic value or a measured value of magnetic energy density, which is significantly below a calculated, theoretically expected magnetic value.
Die Zerkleinerung des magnetischen bzw. magnetisierbaren Rohmaterials erfolgt dabei in einer Art und Weise, dass die dabei gebildeten Pulverteilchen des pulverförmigen Zwischenproduktes eine Partikelgröße zwischen etwa 2 µm bis 10 µm, vorzugsweise zwischen 3 µm bis 5 µm, aufweisen.The comminution of the magnetic or magnetizable raw material is carried out in such a way that the powder particles formed thereby of the powdery intermediate product have a particle size between about 2 microns to 10 microns, preferably between 3 microns to 5 microns.
Die Zerkleinerung erfolgt insbesondere vermittels einer Zerkleinerungseinrichtung, beispielsweise vermittels herkömmlich bekannter Zerkleinerungstechniken. Eine erste Grobzerkleinerung zur Herstellung von Grobpulver mit einer Partikelgröße von circa 100 µm bis 300 µm kann beispielsweise durch den Einsatz von mechanischen Zerkleinerungsanlagen und/oder durch die Verwendung von Wasserstofftechnologie erfolgen. Für die Feinmahlung bzw. zur Herstellung von Feinpulver mit einer Partikelgröße von circa 0,1 µm bis 20 µm werden Mahlanlagen zur Feinmahlung, wie beispielsweise Fließbettstrahlmühlen oder ähnliche Mahlanlagen eingesetzt, die insbesondere unter Schutzgas betrieben werden. Bei dem verwendeten Schutzgas handelt es sich für gewöhnlich um Stickstoff oder Argon.The comminution takes place in particular by means of a comminution device, for example by means of conventionally known comminution techniques. A first coarse crushing for the production of coarse powder having a particle size of about 100 microns to 300 microns can be done for example by the use of mechanical crushing plants and / or by the use of hydrogen technology. For the fine grinding or for the production of fine powder having a particle size of about 0.1 .mu.m to 20 .mu.m, grinding systems for fine grinding, such as fluidized bed jet mills or similar grinding plants are used, which are operated in particular under inert gas. The protective gas used is usually nitrogen or argon.
In einem weiteren Schritt des erfindungsgemäßen Verfahrens werden die Pulverteilchen des pulverförmigen Zwischenproduktes verrundet, d.h. in dem weiteren Schritt werden die Ecken und Kanten der Pulverteilchen abgerundet und/oder reduziert und/oder weitgehend abgeschliffen. Die dabei entstehenden verrundeten Pulverteilchen weisen dabei vorzugsweise im Wesentlichen dieselbe Größe auf wie die kantigen Pulverteilchen des pulverförmigen Zwischenproduktes, nämlich eine Partikelgröße zwischen etwa 2 µm bis 10 µm, vorzugsweise zwischen 3 µm bis 5 µm.In a further step of the method according to the invention, the powder particles of the powdery intermediate product are rounded, ie in the further step, the corners and edges of the powder particles are rounded off and / or reduced and / or largely ground off. The resulting rounded powder particles preferably have substantially the same size as the angular powder particles of the powdery intermediate product, namely a particle size between about 2 μm to 10 μm, preferably between 3 μm to 5 μm.
Hierfür umfasst die Anlage eine Schleifvorrichtung, die zum Verrunden der eckigen, scharfkantigen Pulverteilchen des pulverförmigen Zwischenproduktes ausgebildet ist. Die Schleifvorrichtung umfasst einen Aufnahmeraum, in den das pulverförmige Zwischenprodukt eingefüllt wird. Dieses wird nunmehr innerhalb des Aufnahmeraums herumgewirbelt, so dass die Pulverteilchen aneinander reiben, wodurch die Ecken und Kanten reduziert und insbesondere abgeschliffen werden. Vorzugsweise erfolgt das Einfüllen in die und das Behandeln des pulverförmigen Zwischenproduktes innerhalb der Schleifvorrichtung unter Verwendung eines Schutzgases. Das pulverförmige Zwischenprodukt wird insbesondere für eine definierte Zeit, beispielsweise zwischen 30 Minuten und zwei Stunden, vorzugsweise für etwa eine Stunde in der Schleifvorrichtung bearbeitet. Der Aufnahmeraum der Schleifvorrichtung wird vorzugsweise für den Schleifprozess zu 50% bis 99% mit pulverförmigem Zwischenprodukt befüllt, insbesondere sollte das pulverförmige Zwischenprodukt mindestens 80% des Aufnahmeraums ausfüllen. Vorzugsweise wird der restliche Raum innerhalb des Aufnahmeraums der Schleifvorrichtung durch das verwendete Schutzgas ausgefüllt.For this purpose, the system comprises a grinding device which is designed for rounding the angular, sharp-edged powder particles of the powdery intermediate product. The grinding device comprises a receiving space, in which the powdery intermediate product is filled. This is now swirled around within the receiving space, so that the powder particles rub against each other, whereby the corners and edges are reduced and, in particular, ground off. Preferably, filling into and treating the powdery intermediate within the grinding apparatus is accomplished using a shielding gas. In particular, the powdery intermediate product is processed for a defined time, for example between 30 minutes and two hours, preferably for about one hour in the grinding device. The receiving space of the grinding device is preferably filled for the grinding process to 50% to 99% with powdery intermediate, in particular, the powdery intermediate product should fill at least 80% of the receiving space. Preferably, the remaining space within the receiving space of the grinding device is filled by the protective gas used.
Als Schleifvorrichtung kann beispielsweise eine herkömmliche Mahlvorrichtung derart modifiziert werden, dass das pulverförmige Zwischenprodukt einerseits kräftig innerhalb der modifizierten Mahlvorrichtung herumgewirbelt wird, so dass die Pulverteilchen aneinander reiben. Andererseits darf bei dem Schleifprozess keine weitere Vermahlung des pulverförmigen Zwischenproduktes stattfinden, das zu frischen scharfen Bruchkanten führen würde. Dieser schonende Schleifprozess wird beispielsweise dadurch erreicht, dass die Schleifvorrichtung / modifizierte Mahlvorrichtung mit einem niedrigen Gasdruck, insbesondere mit einem Gasdruck zwischen 0,25 bar und 1,00 bar betrieben wird. Der Gasdruck muss dabei insbesondere derart angepasst werden, dass die Pulverteilchen des pulverförmigen Zwischenproduktes zwar in der Schleifvorrichtung / modifizierten Mahlvorrichtung weitgehend frei beweglich sind, wobei jedoch die Energie der Pulverteilchen für eine weitere Vermahlung nicht ausreicht. Bei der Bewegung der Pulverteilchen in der Schleifvorrichtung / modifizierten Mahlvorrichtung kommt es zu Reibungseffekten zwischen den einzelnen Pulverteilchen. Diese Reibungseffekte bewirken, dass die scharfen Ecken und Kanten des pulverförmigen Zwischenproduktes deutlich abgerundet werden, wodurch ein optimiertes pulverförmiges Produkt mit verrundeten Pulverteilchen entsteht.As a grinding device, for example, a conventional grinding device can be modified such that the powdery intermediate product is swirled around on the one hand vigorously within the modified grinding device, so that the powder particles rub against each other. On the other hand, in the grinding process, no further grinding of the powdery intermediate takes place, which would lead to fresh, sharp break edges. This gentle grinding process is achieved, for example, by operating the grinding device / modified grinding device with a low gas pressure, in particular with a gas pressure between 0.25 bar and 1.00 bar. The gas pressure must be adjusted in particular such that the powder particles of the powdery intermediate product are largely freely movable in the grinding device / modified grinding device, but the energy of the powder particles is not sufficient for further grinding. The movement of the powder particles in the grinder / modified grinder causes frictional effects between the individual powder particles. These frictional effects cause the sharp corners and edges of the powdery intermediate product to become distinct be rounded off, creating an optimized powdered product with rounded powder particles.
Dieses optimierte pulverförmige Produkt kann bereits als erstes Ausgangsmaterial zur Fertigung erster Seltenerd-Magnete verwendet werden. Die unter Verwendung des ersten Ausgangsmaterials hergestellten ersten Seltenerd-Magnete weisen deutlich bessere Magnetwerte bzw. höhere magnetische Energiedichten auf als Magnete, die aus dem oben beschriebenen pulverförmigen Zwischenprodukt gefertigt werden.This optimized powdered product can already be used as the first starting material for the production of first rare earth magnets. The first rare earth magnets produced using the first starting material have significantly better magnet values and higher magnetic energy densities, respectively, than magnets made from the powdery intermediate described above.
Alternativ ist vorgesehen, dass das optimierte pulverförmige Produkt in einem weiteren Verfahrensschritt einem Klassierungsprozess unterzogen wird, um die bei der Reibung der Pulverteilchen innerhalb der Schleifvorrichtung anfallenden Feinstabriebanteile aus dem optimierten pulverförmigen Produkt zu entfernen. Dabei wird eine Fraktion gebildet, die nur noch verrundete Pulverteilchen einer Größe zwischen etwa 2 µm bis 10 µm, vorzugsweise zwischen 3 µm bis 5 µm, enthält. Wird diese Fraktion als zweites Ausgangsmaterial zur Fertigung von zweiten Seltenerd-Magneten verwendet, dann können Produkte mit weiter verbesserten Magnetwerten bzw. höheren magnetischen Energiedichten hergestellt werden.Alternatively, it is provided that the optimized pulverulent product is subjected to a classification process in a further method step in order to remove the fine-dust fractions occurring during the friction of the powder particles within the grinding device from the optimized pulverulent product. In this case, a fraction is formed, which contains only rounded powder particles of a size between about 2 microns to 10 microns, preferably between 3 microns to 5 microns. If this fraction is used as a second starting material for the production of second rare-earth magnets, then products with further improved magnet values or higher magnetic energy densities can be produced.
Als Trenneinrichtung zur Klassierung des optimierten pulverförmigen Produktes in eine Feinfraktion, umfassend die Feinstabriebanteile, und eine Grobfraktion, umfassend die aus dem magnetischen bzw. magnetisierbaren Rohmaterial hergestellten gewünschten verrundeten Pulverteilchen, kann beispielsweise ein dynamischer Sichter oder ein schnell rotierender Sichter eingesetzt werden.As a separator for classifying the optimized powdery product into a fine fraction comprising the ultrafine abrasive particles and a coarse fraction comprising the desired rounded powder particles prepared from the magnetic or magnetizable raw material, for example, a dynamic sifter or a fast rotating sifter can be used.
Experimentelle Daten zeigen, dass die ersten Seltenerd- Magnete, die unter Verwendung von verrundeten Pulverteilchen hergestellt wurden, und insbesondere die zweiten Seltenerd- Magnete, die unter Verwendung von klassierten verrundeten Pulverteilchen hergestellt wurden, bessere magnetische Eigenschaften aufweisen und insbesondere Magnetwerte bzw. magnetische Energiedichten zeigen, die näher an die theoretisch berechneten Werte herankommen.Experimental data shows that the first rare earth magnets made using rounded powder particles, and especially the second rare earth magnets made using classified rounded powder particles, have better magnetic properties and, in particular, exhibit magnetic or magnetic energy densities , which come closer to the theoretically calculated values.
Es sei an dieser Stelle ausdrücklich erwähnt, dass alle Aspekte und Ausführungsvarianten, die im Zusammenhang mit der erfindungsgemäßen Vorrichtung erläutert wurden, gleichermaßen Teilaspekte des erfindungsgemäßen Verfahrens betreffen oder sein können. Wenn daher an einer Stelle bei der Beschreibung oder auch bei den Anspruchsdefinitionen zur erfindungsgemäßen Vorrichtung von bestimmten Aspekten und/oder Zusammenhängen und/oder Wirkungen die Rede ist, so gilt dies gleichermaßen für das erfindungsgemäße Verfahren. In umgekehrter Weise gilt dasselbe, so dass auch alle Aspekte und Ausführungsvarianten, die im Zusammenhang mit dem erfindungsgemäßen Verfahren erläutert wurden, gleichermaßen Teilaspekte der erfindungsgemäßen Vorrichtung betreffen oder sein können. Wenn daher an einer Stelle bei der Beschreibung oder auch bei den Anspruchsdefinitionen zum erfindungsgemäßen Verfahren von bestimmten Aspekten und/oder Zusammenhängen und/oder Wirkungen die Rede ist, so gilt dies gleichermaßen für die erfindungsgemäße Vorrichtung.It should be expressly mentioned at this point that all aspects and variants which have been explained in connection with the device according to the invention, may equally relate to partial aspects of the method according to the invention or may be. Therefore, if at some point in the description or in the claim definitions for the device according to the invention of certain aspects and / or relationships and / or effects is mentioned, this is equally true for the inventive method. Conversely, the same applies, so that all aspects and variants which have been explained in connection with the method according to the invention can equally relate to or may be partial aspects of the device according to the invention. Therefore, if at some point in the description or in the claim definitions for the method according to the invention of certain aspects and / or relationships and / or effects is mentioned, this applies equally to the inventive device.
Im Folgenden sollen Ausführungsbeispiele die Erfindung und ihre Vorteile anhand der beigefügten Figuren näher erläutern. Die Größenverhältnisse der einzelnen Elemente zueinander in den Figuren entsprechen nicht immer den realen Größenverhältnissen, da einige Formen vereinfacht und andere Formen zur besseren Veranschaulichung vergrößert im Verhältnis zu anderen Elementen dargestellt sind.
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zeigt eine rasterelektronenmikroskopische Aufnahme eines herkömmlich hergestellten Seltenerd-Magnetpulvers.Figur 1 -
zeigt beispielhaft schematisch dargestellte Einzelpartikel eines herkömmlich hergestellten Seltenerd-Magnetpulvers.Figur 2 -
zeigt eine rasterelektronenmikroskopische Aufnahme eines optimierten Ausgangsmaterials zur Herstellung von Seltenerd-Magneten.Figur 3 -
zeigt beispielhaft schematisch dargestellte Einzelpartikel des optimierten Ausgangsmaterials.Figur 4 -
Figur 5 zeigt einzelne Verfahrensschritte zur Herstellung eines optimierten Seltenerd-Magnetpulvers zur Fertigung von Seltenerd-Magneten, basierend auf mindestens einem magnetischen bzw. magnetisierbaren Rohmaterial. -
Figur 6 zeigt schematisch eine Anlage zur Herstellung eines pulverförmigen und zur Fertigung von Seltenerd-Magneten vorgesehenen Ausgangsmaterials.
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FIG. 1 shows a scanning electron micrograph of a conventionally produced rare earth magnet powder. -
FIG. 2 shows by way of example schematically illustrated individual particles of a conventionally produced rare-earth magnetic powder. -
FIG. 3 shows a scanning electron micrograph of an optimized starting material for the production of rare earth magnets. -
FIG. 4 shows exemplary exemplified individual particles of the optimized starting material. -
FIG. 5 shows individual process steps for producing an optimized rare earth magnetic powder for the production of rare earth magnets, based on at least one magnetic or magnetizable raw material. -
FIG. 6 shows schematically a plant for the production of a powdered and intended for the production of rare earth magnets starting material.
Für gleiche oder gleich wirkende Elemente der Erfindung werden identische Bezugszeichen verwendet. Ferner werden der Übersicht halber nur Bezugszeichen in den einzelnen Figuren dargestellt, die für die Beschreibung der jeweiligen Figur erforderlich sind. Die dargestellten Ausführungsformen stellen lediglich Beispiele dar, wie die erfindungsgemäße Vorrichtung oder das erfindungsgemäße Verfahren ausgestaltet sein können und stellen keine abschließende Begrenzung dar.For identical or equivalent elements of the invention, identical reference numerals are used. Furthermore, for the sake of clarity, only reference symbols are shown in the individual figures, which are required for the description of the respective figure. The illustrated embodiments are merely examples of how the device or method of the invention may be configured and are not an exhaustive limitation.
Wie in den
Das zweite optimierte Ausgangsmaterial AM2 wird insbesondere durch ein Verfahren hergestellt, wie es im Zusammenhang mit
In einem ersten Verfahrensschritt wird mindestens ein magnetisches bzw. magnetisierbares Rohmaterial M bereitgestellt. Bei dem mindestens einen magnetischen bzw. magnetisierbaren Rohmaterial M handelt es sich vorzugsweise um Seltenerd-Legierungen und/oder um Altmagnete, insbesondere um Nd-Fe-B-Legierungen und/oder Nd-Fe-B-Altmagnete.In a first method step, at least one magnetic or magnetizable raw material M is provided. The at least one magnetic or magnetizable raw material M is preferably rare-earth alloys and / or old magnets, in particular Nd-Fe-B alloys and / or Nd-Fe-B aged magnets.
In einem nächsten Verfahrensschritt wird das bereitgestellte mindestens eine magnetische bzw. magnetisierbare Rohmaterial M zerkleinert, wobei aus dem mindestens einen magnetischen bzw. magnetisierbaren Rohmaterial M ein pulverförmiges Zwischenprodukt ZP, insbesondere ein Seltenerd-Magnetpulver 1 mit Pulverteilchen 2 mit Ecken 3 und Kanten 4 gemäß den
Die Zerkleinerung erfolgt vermittels einer Zerkleinerungseinrichtung 30, beispielsweise vermittels herkömmlich bekannter Zerkleinerungstechniken. Eine erste Grobzerkleinerung zur Herstellung von Grobpulver mit einer Partikelgröße von circa 100 µm bis 300 µm kann beispielsweise durch den Einsatz von mechanischen Zerkleinerungsanlagen, wie Mühlen 31 und/oder durch die Verwendung von Wasserstofftechnologie erfolgen. Für die Feinmahlung bzw. zur Herstellung von Feinpulver mit einer Partikelgröße von circa 0,1 µm bis 20 µm werden Mahlanlagen zur Feinmahlung, wie beispielsweise Fließbettstrahlmühlen 32 oder ähnliche Mahlanlagen eingesetzt, die insbesondere unter Schutzgas S betrieben werden. Bei dem verwendeten Schutzgas handelt es sich für gewöhnlich um Stickstoff oder Argon. Ein derartig hergestelltes Seltenerd-Magnetpulver 1 wird beispielsweise zur Herstellung herkömmlicher Seltenerd- Magnete 5 verwendet. In einem weiteren Verfahrensschritt wird nunmehr dieses Seltenerd-Magnetpulver 1 unter Schutzgas S in eine Schleifvorrichtung 40 eingefüllt und dann in dieser Schleifvorrichtung 40 unter Schutzgas S eine definierte Zeitspanne bewegt. Dabei werden die Pulverteilchen 2 des Seltenerd-Magnetpulvers 1 innerhalb der Schleifvorrichtung 40 herumgewirbelt. Vorzugsweise liegt die definierte Zeitspanne für diesen Verfahrensschritt zwischen 0,5 Stunden und 3 Stunden, insbesondere bei circa einer Stunde.The comminution takes place by means of a comminution device 30, for example by means of conventionally known comminution techniques. A first coarse crushing for the production of coarse powder having a particle size of about 100 microns to 300 microns, for example, by the use of mechanical crushing plants, such as mills 31 and / or by using hydrogen technology. For the fine grinding or for the production of fine powder having a particle size of about 0.1 .mu.m to 20 .mu.m, grinding systems for fine grinding, such as fluidized bed jet mills 32 or similar grinding systems are used, which are operated in particular under inert gas S. The protective gas used is usually nitrogen or argon. Such produced rare earth
Der Aufnahmeraum der Schleifvorrichtung 40 wird dabei nicht vollständig mit Seltenerd-Magnetpulver 1 befüllt. Vorzugsweise wird der Aufnahmeraum derart befüllt, dass das Seltenerd-Magnetpulver 1 zwischen 50% und 99% des Mahlraums ausfüllt. Insbesondere wird der Aufnahmeraum derart befüllt, dass das Seltenerd-Magnetpulver 1 mindestens 80% des Aufnahmeraums ausfüllt. Die restlichen 20% des Mahlraums werden durch Schutzgas S ausgefüllt.The receiving space of the grinding
In der Schleifvorrichtung 40 wird das Seltenerd-Magnetpulver 1 kräftig herumgewirbelt, wodurch die Ecken 3 und Kanten 4 der Pulverteilchen 2 durch gegenseitige Reibung der Pulverteilchen 2 untereinander aneinander abgeschliffen werden. Dadurch entsteht ein optimiertes Seltenerd-Magnetpulver 10 mit verrundeten Pulverteilchen 12 gemäß
Die Schleifvorrichtung 40 wird vorzugsweise mit einem geringen Gasdruck betrieben, beispielsweise mit einem Gasdruck zwischen 0,25 bar und 1,00 bar. Der Gasdruck muss dabei jeweils so angepasst werden, dass das Zwischenprodukt ZP beziehungsweise Seltenerd-Magnetpulver 1 zwar in der Schleifvorrichtung 40 herumgewirbelt werden kann, so dass die Pulverteilchen 2 aneinander reiben, wodurch die Ecken 3 und Kanten 4 abgerieben und verrundete Pulverteilchen 12 gemäß
Durch das Verrunden entsteht ein optimiertes Seltenerd-Magnetpulver 10, das nunmehr bereits als erstes Ausgangsmaterial AM1 für die Herstellung von ersten optimierten Seltenerd-Magneten 19 verwendet werden kann. Das optimierte Seltenerd-Magnetpulver 10 enthält neben den verrundeten Pulverteilchen 12 - vergleiche auch
Es konnte experimentell nachgewiesen werden, dass erste optimierte Seltenerd- Magnete 19 und insbesondere zweite weiter optimierte Seltenerd- Magnete 20 Magnetwerte bzw. magnetische Energiedichten aufweisen, die höher sind als die Magnetwerte bzw. magnetische Energiedichten von Seltenerd-Magneten 5, die aus einem herkömmlich hergestellten Seltenerd- Magnetpulver 1 gefertigt werden. Insbesondere weisen die zweiten Seltenerd-Magnete 20 aus einem zweiten optimierten Ausgangsmaterial AM2 einen Magnetwert bzw. einen Wert der magnetischen Energiedichte auf, der sich deutlich an einen theoretisch berechneten optimalen Wert annähert.It has been experimentally proven that first optimized rare earth magnets 19 and in particular second further optimized
Die Ausführungsformen, Beispiele und Varianten der vorhergehenden Absätze, die Ansprüche und die Figuren, einschließlich ihrer verschiedenen Ansichten oder jeweiligen individuellen Merkmale, können unabhängig voneinander oder in beliebiger Kombination verwendet werden. Merkmale, die in Verbindung mit einer Ausführungsform beschrieben werden, sind für alle Ausführungsformen anwendbar, sofern die Merkmale nicht unvereinbar sind.The embodiments, examples and variants of the preceding paragraphs, the claims and the figures, including their various views or respective individual features, may be used independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments as long as the features are not inconsistent.
Wenn auch im Zusammenhang der Figuren generell von "schematischen" Darstellungen und Ansichten die Rede ist, so ist damit keineswegs gemeint, dass die Figurendarstellungen und deren Beschreibung hinsichtlich der Offenbarung der Erfindung von untergeordneter Bedeutung sein sollen. Der Fachmann ist durchaus in der Lage, aus den schematisch und abstrakt gezeichneten Darstellungen genug an Informationen zu entnehmen, die ihm das Verständnis der Erfindung erleichtern, ohne dass er etwa aus den gezeichneten und möglicherweise nicht exakt maßstabsgerechten Größenverhältnissen der Pulverteilchen oder anderer gezeichneter Elemente in irgendeiner Weise in seinem Verständnis beeinträchtigt wäre. Die Figuren ermöglichen es dem Fachmann als Leser somit, anhand der konkreter erläuterten Umsetzungen des erfindungsgemäßen Verfahrens und der konkreter erläuterten Funktionsweise der erfindungsgemäßen Vorrichtung ein besseres Verständnis für den in den Ansprüchen sowie im allgemeinen Teil der Beschreibung allgemeiner und/oder abstrakter formulierten Erfindungsgedanken abzuleiten.Although in the context of the figures in general of "schematic" representations and views is mentioned, this does not mean that the figure representations and their description with respect to the disclosure of the invention should be of minor importance. The person skilled in the art is quite capable of taking enough information from the schematic and abstract representations to facilitate his understanding of the invention, without having to approximate, for example, the drawn and possibly not exactly to scale proportions of the powder particles or other drawn elements Way in his understanding would be impaired. The figures thus make it possible for a person skilled in the art as a reader to derive a better understanding of the concept of the invention as formulated in the claims and in the general part of the description more generally and / or more abstractly on the basis of the specifically explained conversions of the method according to the invention and the more specifically explained mode of operation of the device according to the invention.
Die Erfindung wurde unter Bezugnahme auf eine bevorzugte Ausführungsform beschrieben. Es ist jedoch für einen Fachmann vorstellbar, dass Abwandlungen oder Änderungen der Erfindung gemacht werden können, ohne dabei den Schutzbereich der nachstehenden Ansprüche zu verlassen.The invention has been described with reference to a preferred embodiment. However, it will be apparent to those skilled in the art that modifications or changes may be made to the invention without departing from the scope of the following claims.
- 11
- Seltenerd-MagnetpulverRare earth magnetic powder
- 22
- Pulverteilchenpowder
- 33
- Eckecorner
- 44
- Kante / BruchkanteEdge / break edge
- 55
- herkömmlicher Seltenerd-Magnetconventional rare earth magnet
- 1010
- optimiertes Seltenerd-Magnetpulveroptimized rare earth magnet powder
- 1212
- Pulverteilchenpowder
- 12a12a
- angerundete und/oder abgerundete PulverteilchenRounded and / or rounded powder particles
- 12b12b
- gerundete Pulverteilchenrounded powder particles
- 1313
- abgerundete Eckerounded corner
- 1414
- abgerundete Kanterounded edge
- 1919
- optimierter Seltenerd- Magnetoptimized rare earth magnet
- 2020
- weiter optimierter Seltenerd- Magnetfurther optimized rare earth magnet
- 2525
- Anlageinvestment
- 3030
- Zerkleinerungseinrichtungcomminution device
- 3131
- MühleMill
- 3232
- FließbettstrahlmühleFluidized Bed Jet Mill
- 4040
- Schleifvorrichtunggrinder
- 5050
- Trenneinrichtungseparator
- 5151
- Sichtersifter
- AM1, AM2AM1, AM2
- Ausgangsmaterialstarting material
- FF
- FeinstabriebanteileOf fine debris shares
- MM
- magnetisches bzw. magnetisierbares Rohmaterialmagnetic or magnetizable raw material
- SS
- Schutzgasprotective gas
- ZPZP
- Zwischenproduktintermediate
Claims (12)
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EP3827916A1 (en) * | 2019-11-28 | 2021-06-02 | Yantai Shougang Magnetic Materials Inc. | A manufacturing method of sintered nd-fe-b permanent magnet |
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