JP6828027B2 - PrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法 - Google Patents
PrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法 Download PDFInfo
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- 229910052761 rare earth metal Inorganic materials 0.000 title claims description 55
- 150000002910 rare earth metals Chemical class 0.000 title claims description 43
- 229910052721 tungsten Inorganic materials 0.000 title claims description 28
- 229910052777 Praseodymium Inorganic materials 0.000 title claims description 25
- 238000004519 manufacturing process Methods 0.000 title claims description 20
- 239000002131 composite material Substances 0.000 title claims description 11
- 239000000843 powder Substances 0.000 claims description 42
- 230000005291 magnetic effect Effects 0.000 claims description 40
- 229910045601 alloy Inorganic materials 0.000 claims description 39
- 239000000956 alloy Substances 0.000 claims description 39
- 239000002994 raw material Substances 0.000 claims description 38
- 238000000465 moulding Methods 0.000 claims description 36
- 238000000034 method Methods 0.000 claims description 35
- 238000010298 pulverizing process Methods 0.000 claims description 35
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 28
- 229910052739 hydrogen Inorganic materials 0.000 claims description 28
- 239000001257 hydrogen Substances 0.000 claims description 28
- 238000010791 quenching Methods 0.000 claims description 27
- 230000000171 quenching effect Effects 0.000 claims description 27
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 24
- 229910052760 oxygen Inorganic materials 0.000 claims description 24
- 239000001301 oxygen Substances 0.000 claims description 24
- 238000005245 sintering Methods 0.000 claims description 19
- 238000005266 casting Methods 0.000 claims description 13
- 230000008569 process Effects 0.000 claims description 13
- 229910052750 molybdenum Inorganic materials 0.000 claims description 8
- 229910052779 Neodymium Inorganic materials 0.000 claims description 7
- 229910052804 chromium Inorganic materials 0.000 claims description 7
- 229910052733 gallium Inorganic materials 0.000 claims description 7
- 229910052787 antimony Inorganic materials 0.000 claims description 6
- 229910052796 boron Inorganic materials 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 6
- 229910052735 hafnium Inorganic materials 0.000 claims description 6
- 229910052758 niobium Inorganic materials 0.000 claims description 6
- 229910052710 silicon Inorganic materials 0.000 claims description 6
- 229910052717 sulfur Inorganic materials 0.000 claims description 6
- 229910052718 tin Inorganic materials 0.000 claims description 6
- 229910052719 titanium Inorganic materials 0.000 claims description 6
- 229910052720 vanadium Inorganic materials 0.000 claims description 6
- 229910052725 zinc Inorganic materials 0.000 claims description 6
- 229910052726 zirconium Inorganic materials 0.000 claims description 6
- 239000000654 additive Substances 0.000 claims description 5
- 230000000996 additive effect Effects 0.000 claims description 5
- 229910052698 phosphorus Inorganic materials 0.000 claims description 5
- 239000000155 melt Substances 0.000 claims description 3
- 239000007789 gas Substances 0.000 description 20
- 238000002844 melting Methods 0.000 description 19
- 230000008018 melting Effects 0.000 description 19
- 239000013078 crystal Substances 0.000 description 18
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 18
- 239000010949 copper Substances 0.000 description 17
- 230000000052 comparative effect Effects 0.000 description 16
- 230000000694 effects Effects 0.000 description 16
- 239000012071 phase Substances 0.000 description 16
- 239000002245 particle Substances 0.000 description 15
- YRHYCMZPEVDGFQ-UHFFFAOYSA-N methyl decanoate Chemical compound CCCCCCCCCC(=O)OC YRHYCMZPEVDGFQ-UHFFFAOYSA-N 0.000 description 14
- 238000005259 measurement Methods 0.000 description 12
- 229910052751 metal Inorganic materials 0.000 description 12
- 239000002184 metal Substances 0.000 description 12
- 239000000203 mixture Substances 0.000 description 11
- 230000005347 demagnetization Effects 0.000 description 10
- 229910000722 Didymium Inorganic materials 0.000 description 9
- 241000224487 Didymium Species 0.000 description 9
- 229910052802 copper Inorganic materials 0.000 description 9
- 238000009826 distribution Methods 0.000 description 9
- 230000003647 oxidation Effects 0.000 description 9
- 238000007254 oxidation reaction Methods 0.000 description 9
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 7
- 239000012535 impurity Substances 0.000 description 7
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 7
- 238000011156 evaluation Methods 0.000 description 6
- 229910052782 aluminium Inorganic materials 0.000 description 5
- 229910052799 carbon Inorganic materials 0.000 description 5
- 230000004907 flux Effects 0.000 description 5
- 229910052742 iron Inorganic materials 0.000 description 5
- 238000002156 mixing Methods 0.000 description 5
- 238000010587 phase diagram Methods 0.000 description 5
- 239000000523 sample Substances 0.000 description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 238000013329 compounding Methods 0.000 description 4
- 230000002706 hydrostatic effect Effects 0.000 description 4
- 230000006698 induction Effects 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 230000002159 abnormal effect Effects 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 239000007791 liquid phase Substances 0.000 description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 2
- 229910000583 Nd alloy Inorganic materials 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 150000004678 hydrides Chemical class 0.000 description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
- 230000005415 magnetization Effects 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- JGHZJRVDZXSNKQ-UHFFFAOYSA-N methyl octanoate Chemical compound CCCCCCCC(=O)OC JGHZJRVDZXSNKQ-UHFFFAOYSA-N 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000011733 molybdenum Substances 0.000 description 2
- 229910001172 neodymium magnet Inorganic materials 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 238000000746 purification Methods 0.000 description 2
- 239000000700 radioactive tracer Substances 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 2
- 239000010937 tungsten Substances 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000011362 coarse particle Substances 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 230000005292 diamagnetic effect Effects 0.000 description 1
- 238000004453 electron probe microanalysis Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 150000002222 fluorine compounds Chemical class 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 238000002595 magnetic resonance imaging Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 230000001376 precipitating effect Effects 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
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- H—ELECTRICITY
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
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- 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
- H01F1/0577—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 sintered
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- C22C38/00—Ferrous alloys, e.g. steel alloys
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- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/12—Ferrous alloys, e.g. steel alloys containing tungsten, tantalum, molybdenum, vanadium, or niobium
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- C22C38/16—Ferrous alloys, e.g. steel alloys containing copper
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- H—ELECTRICITY
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
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- 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
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- B22F9/00—Making metallic powder or suspensions thereof
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Description
Prの融点が低いので、鋳造組織に変化が起きる。また、PrはNdと比べて蒸気圧が低い為、溶解する時、溶解冷却する時の揮発物が少ないので、銅ロールとの熱接触が良くなると考えられる。
NdはPrと比べ、水素化物の組成比や水素化物相の数が違う。結果として、Pr−Fe−B−W系急冷合金は割れやすい。
1、2の結果で、粉砕性時に亀裂が入る結晶面や、不純物相の分布に変化が生じる。これは、PrはNdよりも活性なため、優先的に酸素、炭素源と反応すると考えられる。その結果、粒界にPrの酸化物、Prの炭化物を多く含む粉末が出来る。
1、2、3の結果で、微粉末が異なる事と、NdとPrの融点が異なる為に、焼結時の液相発生温度、液相の主相結晶表面の濡れ性等に微妙な変化を与え、焼結の性能が異なる。且つ、粒界相の成分も異なる。よって、最終的に出来た磁石の粒界相組織が異なる。その結果、ニュークリエション型の保磁力発生機構を持つR2Fe14B型焼結磁石の保磁力、角形、耐熱性は大きな影響を受ける。
原料配合工程:純度99.5%のNd、純度99.9%のPr、工業用Fe−B、工業用純Fe、純度99.5%のCo、純度99.5%のCuと純度99.99%のWを準備した。質量百分比wt%で計算する。
原料配合工程:純度99.5%のNd、純度99.9%のFe−B、純度99.9のFe、純度99.9%のPr、純度99.5%のCu、Alと純度99.999%のWを準備した。質量百分比wt%で計算する。
原料配合工程:純度99.5%のNd、純度99.9%のFe−B、純度99.9のFe、純度99.9%のPr、純度99.5%のCu、Gaと純度99.999%のWを準備した。質量百分比wt%で計算する。
原料配合工程:純度99.8%のNd、工業用Fe−B、工業用純Fe、純度99.9%のCoと純度99.5%のAl、Crを準備した。質量百分比wt%で計算する。
Claims (10)
- PrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法であり、前記希土類焼結磁石はR2Fe14B型主相を含み、Rは少なくともPrを含む希土類元素であり、
原料成分は7wt%以上のPrと0.0005wt%〜0.03wt%のWと0.1〜0.8wt%のCuを含み、
前記希土類焼結磁石は、
前記原料成分の溶融液を急冷して急冷合金を製造する工程と、前記急冷合金を微粉に粉砕する工程と、前記微粉を磁場成形法で成形して成形体を製造する工程と、前記成形体を焼結する工程と、
を用いて製造されることを特徴とするPrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法。 - Prの含有量は前記原料成分の7wt%〜32wt%を占めることを特徴とする請求項1に記載のPrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法。
- 前記Rは少なくともNdとPrを含む希土類元素であることを特徴とする請求項1に記載のPrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法。
- 前記希土類焼結磁石の酸素含有量は2000ppm以下であることを特徴とする請求項1に記載のPrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法。
- 前記希土類焼結磁石の酸素含有量は1000ppm以下であることを特徴とする請求項1に記載のPrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法。
- 前記原料成分はさらに2.0wt%以下のCo、Zr、V、Mo、Zn、Ga、Nb、Sn、Sb、Hf、Bi、Ni、Ti、Cr、Si、S或はPから選んだ少なくとも一種の添加元素、0.8wt%以下のAl、及び残量にFeを含むことを特徴とする請求項1に記載のPrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法。
- 前記急冷合金は前記原料成分の溶融液をストリップキャスト法で、102℃/秒以上、104℃/秒以下の冷却速度で作られたものであり、前記微粉に粉砕する工程が粗粉砕と微粉砕を含み、前記粗粉砕は前記急冷合金を水素吸収して粗粉末を得る工程であり、前記微粉砕は前記粗粉末を気流粉砕する工程であることを特徴とする請求項1に記載のPrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法。
- 前記原料成分は0.1〜0.8wt%のAlを含むことを特徴とする請求項6に記載のPrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法。
- 前記原料成分は0.3wt%〜2.0wt%のCo、Zr、V、Mo、Zn、Ga、Nb、Sn、Sb、Hf、Bi、Ni、Ti、Cr、Si、S或はPから選んだ少なくとも一種の添加元素を含むことを特徴とする請求項6に記載のPrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法。
- 前記原料成分はさらに2.0wt%以下のCo、Zr、V、Mo、Zn、Ga、Nb、Sn、Sb、Hf、Bi、Ni、Ti、Cr、Si、S或はPから選んだ少なくとも一種の添加元素、0.8wt%以下のAl、0.8wt%〜0.92wt%のB、及び残量にFeを含むことを特徴とする請求項1に記載のPrとWを複合含有するR−Fe−B系希土類焼結磁石の製造方法。
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