Manufacturing method for sintered compact

Patent metadata

Field	Value
Publication number	US-10058919-B2
Application number	US-201514793091-A
Country	US
Kind code	B2
Filing date	Jul 7, 2015
Priority date	Jul 8, 2014
Publication date	Aug 28, 2018
Grant date	Aug 28, 2018

Abstract

A manufacturing method for a sintered compact includes a first step in which magnetic powder is fabricated by rapid solidification, a second step in which a mass of the magnetic powder is housed in a forming mold, and preliminary heating is performed by placing the mass of the magnetic powder in a preliminary heating part of the forming mold at first temperature that is lower than coarse crystal particle generation temperature, and a third step in which main heating is performed by placing the preliminarily heated mass of the magnetic powder at second temperature that is lower than the coarse crystal particle generation temperature and higher than the first temperature, and press forming is performed while keeping temperature of the magnetic powder at densification temperature or higher.

First claim

What is claimed is:

1. A manufacturing method for a sintered compact serving as a precursor of a rare earth magnet, comprising:
a first step of fabricating magnetic powder having a microscopic crystal particle by rapid solidification;
a second step of housing a mass of the magnetic powder in a forming mold having a preliminary heating part and a main heating part, and preliminary heating the mass of the magnetic powder by placing the mass of magnetic powder in the preliminary heating part at a first temperature that is lower than a coarse crystal particle generation temperature; and
a third step of main heating the preliminarily heated mass of the magnetic powder by placing the preliminarily heated mass of the magnetic powder in the main heating part at a second temperature that is lower than the coarse crystal particle generation temperature and higher than the first temperature, and performing press forming while keeping a temperature of the magnetic powder at a densification temperature or higher, wherein
the forming mold includes a lower die, a side die that is located above the lower die and forms a cavity with the lower die, and an upper die that is located above the side die and is able to enter and exit from the cavity,
the preliminary heating part, which structures the forming mold, performs high frequency heating above the side die and on an outer periphery of the upper die,
the main heating part, which structures the forming mold, is included in the side die, and,
after the preliminary heating of the mass of the magnetic powder is performed in the preliminary heating part, the preliminarily heated mass of the magnetic powder is housed in the cavity and press-formed while main heating is performed in the main heating part.

2. A manufacturing method for a sintered compact serving as a precursor of a rare earth magnet, comprising:
a first step of fabricating magnetic powder having a microscopic crystal particle by rapid solidification;
a second step of housing a mass of the magnetic powder in a forming mold having a preliminary heating part and a main heating part, and preliminary heating the mass of the magnetic powder by placing the mass of magnetic powder in the preliminary heating part at a first temperature that is lower than a coarse crystal particle generation temperature; and
a third step of main heating the preliminarily heated mass of the magnetic powder by placing the preliminarily heated mass of the magnetic powder in the main heating part at a second temperature that is lower than the coarse crystal particle generation temperature and higher than the first temperature, and performing press forming while keeping a temperature of the magnetic powder at a densification temperature or higher, wherein
the forming mold includes a lower die, a side die that is located above the lower die and forms a cavity with the lower die, and an upper die that is located above the side die and is able to enter and exit from the cavity, and
one of a lower region and an upper region of the side die is the preliminary heating part, the other one is the main heating part, and, after the mass of the magnetic powder is housed and preliminarily heated in a preliminary heating cavity space corresponding to the preliminary heating part in the cavity, the preliminarily heated mass of the magnetic powder is moved to a main heating cavity space corresponding to the main heating part and press-formed while performing main heating in the main heating part.

Assignees

• Toyota Motor Co Ltd

Inventors

• Inuzuka Tomonori
• Kano Akira

Classifications

• H01F41/0266

  Moulding; Pressing (H01F41/0273 takes precedence; hard magnetic particles H01F1/06, H01F1/11) · CPC title

• B22F9/04

  starting from solid material, e.g. by crushing, grinding or milling ({C22C1/1084 takes precedence}; crushing, grinding or milling, in general, see the relevant subclasses, e.g. B02C) · CPC title

• B22F3/14

  simultaneously · CPC title

• H01F1/0577

  sintered · CPC title

• B22F2009/048

  by pulverising a quenched ribbon · CPC title