JP4766045B2 - 鉄基希土類系ナノコンポジット磁石およびその製造方法 - Google Patents
鉄基希土類系ナノコンポジット磁石およびその製造方法 Download PDFInfo
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Description
1a、2a、および8a ガス排気口
1 溶解室
2 急冷室
3 溶解炉
4 貯湯容器
5 出湯ノズル
6 ロート
7 回転冷却ロール
21 溶湯
22 合金薄帯
希土類元素RはLaおよびCeを実質的に含まない希土類金属の1種または2種以上とする。Rの組成比率yが6原子%未満では400kA/mを越えるHcJが得られず、実用的な永久磁石とならない。また、Rの組成比率yが10原子%を越えると、磁石の磁化に寄与するα−Fe相の存在比率が5%以下になり、残留磁束密度Brが0.9T以下になる。このため、Rの組成比率yは6原子%〜10原子%の範囲とする。組成比率yは、7原子%〜10原子%であることが好ましく、8原子%〜9.7原子%であることが更に好ましい。
本発明の好ましい実施形態によれば、合金溶湯を高速で回転する金属製の冷却ロールの表面に接触させることにより、合金溶湯から熱を奪い、急冷凝固させる。適切な量の合金溶湯を冷却ロールの表面に接触させるためには、内径が例えば0.5mm〜数mm程度に絞られたオリフィス(孔)を介して合金溶湯を冷却ロール上に供給することが好ましい。
まず、前述の組成式で表現される原料合金の溶湯21を作製し、図2の溶解室1の貯湯容器4に貯える。次に、この溶湯21は出湯ノズル5から減圧Ar雰囲気中の冷却ロール7上に出湯され、冷却ロール7との接触によって急冷され、凝固する。急冷凝固方法としては、冷却速度を高精度に制御できる方法を用いる必要がある。
好ましい実施形態では、急冷凝固合金に対する熱処理をアルゴン雰囲気中で実行する。好ましい実施形態では、この熱処理工程における昇温速度を0.5℃/秒〜7℃/秒の範囲に調節し、500℃以上800℃以下の温度まで加熱する。その後、500℃以上800℃以下の温度で30秒以上20分以下の時間保持し、やがて室温まで冷却する。
以下の表1に示す各組成を有するように、純度99.5%以上のNd、Pr、B、C、Ti、Co、Zr、VおよびFeの各元素を配合した原料30gを透明石英製ノズル内に投入した。このノズルの底部には、φ0.8mmのオリフィス(孔)が設けられており、オリフィスの真下には、回転する冷却ロールが配置されている。
表1の試料No.9〜No.12の合金組成になるようNd、Pr、B、C、TiおよびFeの各元素を配合した後、実施例と同一の方法で急冷薄帯を作製した。また、得られた合金薄帯に対して実施例と同一の方法で結晶化熱処理を行なった。急冷条件および熱処理条件は、表1に記載するとおりである。
Claims (8)
- Nd2Fe14B相およびα−Fe相を含有する鉄基希土類系ナノコンポジット磁石であって、
組成式T100-x-y-z-n(B1-qCq)xRyTizMn(Tは、Fe、CoおよびNiからなる群から選択された少なくとも1種の元素であって、Feを必ず含む遷移金属元素、RはLaおよびCeを実質的に含まない少なくとも1種の希土類元素、Mは、Al、Si、V、Cr、Mn、Cu、Zn、Ga、Zr、Nb、Mo、Ag、Hf、Ta、W、Pt、Au、およびPbからなる群から選択された1種以上の金属元素)で表現され、
組成比率x、y、z、n、およびqが、それぞれ、
5.5≦x≦9原子%、
6≦y≦10原子%、
0.05≦z≦5原子%、
0≦n≦10原子%、
0.05≦q≦0.5
を満足する組成を有し、
平均結晶粒径1nm〜50nmのα−Fe相の含有率は5体積%以上60体積%以下、
平均結晶粒径5nm〜100nmのNd2Fe14B相の含有率は40体積%以上90体積%以下であり、
少なくともTiおよびC(炭素)を含む非磁性相が前記α−Fe相および前記Nd2Fe14B相の粒界に存在する、鉄基希土類系ナノコンポジット磁石。 - 平均結晶粒径が1nm〜50nmであるα−Fe相の結晶粒径の標準偏差が10nm以下であり、平均結晶粒径が5nm〜100nmであるNd2Fe14B相の結晶粒径の標準偏差が15nm以下である請求項1に記載の鉄基希土類系ナノコンポジット磁石。
- 残留磁束密度Br≧0.9T、最大エネルギー積(BH)max≧120kJ/m3、固有保磁力HcJ≧400kA/mの永久磁石特性を発現する請求項1に記載の鉄基希土類系ナノコンポジット磁石。
- Nd2Fe14B相およびα−Fe相を含有する鉄基希土類系ナノコンポジット磁石の製造方法であって、
組成式T100-x-y-z-n(B1-qCq)xRyTizMn(Tは、Fe、CoおよびNiからなる群から選択された少なくとも1種の元素であって、Feを必ず含む遷移金属元素、RはLaおよびCeを実質的に含まない少なくとも1種の希土類元素、Mは、Al、Si、V、Cr、Mn、Cu、Zn、Ga、Zr、Nb、Mo、Ag、Hf、Ta、W、Pt、Au、およびPbからなる群から選択された1種以上の金属元素)で表現され、
組成比率x、y、z、n、およびqが、それぞれ、
5.5≦x≦9原子%、
6≦y≦10原子%、
0.05≦z≦5原子%、
0≦n≦10原子%、
0.05≦q≦0.5
を満足する組成を有する合金の溶湯を用意する工程と、
前記溶湯を5×103℃/秒以上5×107℃/秒以下の冷却速度にて冷却し、Nd2Fe14B相およびα−Fe相を含む平均結晶粒径100nm以下の結晶質相を10%以上有し、残部が非晶質相からなる急冷凝固合金を作製する溶湯急冷工程と、
を含む鉄基希土類系ナノコンポジット磁石の製造方法。 - 前記溶湯急冷工程の後、前記急冷凝固合金を0.5℃/秒以上7℃/秒以下の速度で500℃以上800℃以下の範囲に昇温する結晶化熱処理を行なう工程を含む、請求項4に記載の鉄基希土類系ナノコンポジット磁石の製造方法。
- 前記溶湯急冷工程の後、前記急冷凝固合金を粉砕する工程を含む、請求項4に記載の鉄基希土類系ナノコンポジット磁石の製造方法。
- 8≦y≦10原子%の関係を満足する請求項4に記載の鉄基希土類系ナノコンポジット磁石の製造方法。
- 請求項6に記載の製造方法によって作製された磁石粉末を用意する工程と、
前記磁石粉末に樹脂バインダーを加え、成形する工程と、
を含む、樹脂結合型永久磁石の製造方法。
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JP6042602B2 (ja) * | 2011-08-17 | 2016-12-14 | ミネベア株式会社 | α−Fe/R2TM14B系ナノコンポジット磁石の製造方法 |
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JP2017011283A (ja) * | 2016-08-10 | 2017-01-12 | ミネベア株式会社 | α−Fe/R2TM14B系ナノコンポジット磁石の製造方法 |
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CN115608996B (zh) * | 2021-07-28 | 2024-05-03 | 中国科学院宁波材料技术与工程研究所 | 一种铁基纳米晶软磁合金粉体及其制备方法 |
CN116959836B (zh) * | 2023-07-10 | 2024-03-22 | 唐山非晶科技有限公司 | 一种感应炉专用非晶磁轭及其制备方法 |
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CN1977061A (zh) | 2007-06-06 |
WO2006101117A1 (ja) | 2006-09-28 |
JPWO2006101117A1 (ja) | 2008-09-04 |
CN100507049C (zh) | 2009-07-01 |
EP1762632A4 (en) | 2008-09-03 |
EP1762632A1 (en) | 2007-03-14 |
KR20070114330A (ko) | 2007-12-03 |
EP1762632B1 (en) | 2011-05-25 |
KR101326930B1 (ko) | 2013-11-11 |
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