Method of manufacturing magnetic material

Patent metadata

Field	Value
Publication number	US-11056254-B2
Application number	US-201615767427-A
Country	US
Kind code	B2
Filing date	Oct 18, 2016
Priority date	Oct 19, 2015
Publication date	Jul 6, 2021
Grant date	Jul 6, 2021

Abstract

A method of manufacturing a magnetic material, includes a surface oxides decreasing step of decreasing surface oxides of an iron powder; a powder-molded body forming step of mixing the iron powder whose surface oxides are already decreased obtained by the surface oxides decreasing step, and a compound powder “A” constituted by a La element and a Si element, and compressing and molding the obtained mixture powder; and a sintered body forming step of preparing a sintered body from the powder-molded body obtained by the powder-molded body forming step, by a solid phase reaction under vacuum atmosphere.

First claim

What is claimed is:

1. A method of manufacturing a magnetic material, comprising:
a surface oxides decreasing step of decreasing surface oxides of an iron powder;
a powder-molded body forming step of mixing the iron powder whose surface oxides are already decreased obtained by the surface oxides decreasing step, and a compound powder “A” constituted by a La element and a Si element, and compressing and molding the obtained mixture powder; and
a sintered body forming step of preparing a sintered body from the powder-molded body obtained by the powder-molded body forming step, by a solid phase reaction under vacuum atmosphere,
wherein the surface oxides decreasing step includes
an iron powder placing step of placing the iron powder in a heating chamber of an electric furnace,
an evacuation step of evacuating the heating chamber to be vacuum, after the iron powder placing step, and
after the evacuation step, a surface reduction treatment step of performing a surface reduction treatment of the iron powder by heating the heating chamber to process temperature greater than or equal to 600° C. and less than or equal to 650° C., and also exposing the iron powder to hydrogen gas to obtain the iron powder whose surface oxides are already decreased.

2. The method of manufacturing a magnetic material according to claim 1 , wherein in the powder-molded body forming step, the iron powder whose surface oxides are already decreased and the compound powder “A” are mixed such that, in the mixture powder, the ratio of the La element is greater than or equal to 7.1 at % and less than or equal to 9.3 at %, the ratio of the Fe element is greater than or equal to 76.1 at % and less than or equal to 84.5 at %, and the ratio of the Si element is greater than or equal to 8.4 at % and less than or equal to 16.7 at %.

3. A method of manufacturing a magnetic material comprising:
an iron ingot forming step of forming an iron ingot by melting and degassing electrolytic iron;
a grinding step of grinding the iron ingot obtained by the iron ingot forming step to obtain an iron powder whose surface oxides are decreased;
a powder-molded body forming step of mixing the iron powder whose surface oxides are decreased, and a compound powder “A” constituted by a La element and a Si element, and compressing and molding the obtained mixture powder; and
a sintered body forming step of preparing a sintered body from the powder-molded body obtained by the powder-molded body forming step, by a solid phase reaction under vacuum atmosphere.

Assignees

• Fujita Asaya
• Ozaki Kimihiro
• Aist

Inventors

• Fujita Asaya
• Ozaki Kimihiro

Classifications

• B22F1/145

  Chemical treatment, e.g. passivation or decarburisation · CPC title

• B22F1/12

  Metallic powder containing non-metallic particles (containing lubricating or binding agents or organic material B22F1/10) · CPC title

• C22C38/02 Primary

  containing silicon · CPC title

• H01F1/015

  Metals or alloys · CPC title

• C22C38/005

  containing rare earths, i.e. Sc, Y, Lanthanides · CPC title