Soft magnetic material and method for producing the same

Patent metadata

Field	Value
Publication number	US-11078561-B2
Application number	US-201916417786-A
Country	US
Kind code	B2
Filing date	May 21, 2019
Priority date	May 30, 2018
Publication date	Aug 3, 2021
Grant date	Aug 3, 2021

Abstract

There are provided a soft magnetic material having a high saturation magnetization and a low coercive force and excellent in thermal endurance, and a method for producing the same. The present disclosure relates to a soft magnetic material represented by the following composition formula: Fe 100-x-y B x Ni y , wherein x satisfies 10≤x≤16 in at %, and y satisfies 0<y≤4 in at %, having a coercive force of 20 A/m or less, and having a coercive force characteristic decrease rate after a thermal endurance test {[(coercive force after thermal endurance test−coercive force before thermal endurance test)/coercive force before thermal endurance test]×100 (%)} of 20% or less, wherein the thermal endurance test is carried out by allowing the soft magnetic material to stand in a constant temperature oven at 170° C. in the air for 100 h, and a method for producing the same.

First claim

What is claimed is:

1. A soft magnetic material represented by the following composition formula:
Fe 100-x-y B x Ni y

wherein x satisfies 10≤x≤16 in at %, y satisfies 0<y≤4 in at %, part of B may be replaced by at least one element selected from the group consisting of Si, P, and C, the replaced B is 3 at % or less based on an entire composition, part of Fe and part of Ni may be replaced by at least one element selected from Nb, Co, Zr, Hf, Cu, Ag, Au, Zn, Sn, As, Sb, Bi, Y, and rare earth elements, and the replaced Fe and Ni is 3 at % or less based on the entire composition,
having a coercive force of 20 A/m or less, and
having a coercive force characteristic decrease rate after a thermal endurance test {[(coercive force after thermal endurance test−coercive force before thermal endurance test)/coercive force before thermal endurance test]×100 (%)} of 20% or less, wherein the thermal endurance test is carried out by allowing the soft magnetic material to stand in a constant temperature oven at 170° C. in the air for 100 h.

2. The soft magnetic material according to claim 1 , wherein 12≤x≤14 in at %.

3. The soft magnetic material according to claim 1 , wherein 1≤y≤4 in at %.

4. A method for producing a soft magnetic material, comprising:
providing an alloy having a composition represented by the following composition formula:
Fe 100-x-y B x Ni y

wherein x satisfies 10≤x≤16 in at %, y satisfies 0<y≤4 in at %, part of B may be replaced by at least one element selected from the group consisting of Si, P, and C, the replaced B is 3 at % or less based on an entire composition, part of Fe and part of Ni may be replaced by at least one element selected from Nb, Co, Zr, Hf, Cu, Ag, Au, Zn, Sn, As, Sb, Bi, Y, and rare earth elements, and the replaced Fe and Ni is 3 at % or less based on the entire composition,
and having an amorphous phase; and
heat-treating the alloy under conditions in which the alloy is heated at a heating rate of 10° C./s or more to a temperature region of {T 1 +0.88(T 2 −T 1 )} or more to less than T 2 , wherein T 1 is an α-Fe crystal formation start temperature, and T 2 is a Fe—B compound formation start temperature, and held in the temperature region for a holding time of 0 to 80 s.

5. The method according to claim 4 , wherein a molten metal is quenched to provide the alloy.

6. The method according to claim 4 , wherein the heating rate is 125° C./s or more.

7. The method according to claim 5 , wherein the heating rate is 125° C./s or more.

8. The method according to claim 4 , wherein the heating rate is 325° C./s or more.

9. The method according to claim 5 , wherein the heating rate is 325° C./s or more.

10. The method according to claim 4 , wherein the holding time is 3 s to 10 s.

11. The method according to claim 5 , wherein the holding time is 3 s to 10 s.

12. The method according to claim 6 , wherein the holding time is 3 s to 10 s.

13. The method according to claim 8 , wherein the holding time is 3 s to 10 s.

14. The method according to claim 4 , wherein the heat treatment is carried out by sandwiching the alloy between heated blocks.

15. The method according to claim 5 , wherein the heat treatment is carried out by sandwiching the alloy between heated blocks.

16. The method according to claim 6 , wherein the heat treatment is carried out by sandwiching the alloy between heated blocks.

17. The method according to claim 8 , wherein the heat treatment is carried out by sandwiching the alloy between heated blocks.

18. The method according to claim 10 , wherein the heat treatment is carried out by sandwiching the alloy between heated blocks.

19. The method according to claim 4 , wherein 12≤x≤14 in at %.

20. The method according to claim 4 , wherein 1≤y≤4 in at %.

Assignees

• Toyota Motor Co Ltd

Inventors

• Onodera Kiyotaka
• Kishimoto Hidefumi

Classifications

• C22C45/04 Primary

  with nickel or cobalt as the major constituent · CPC title

• C21D1/26

  Methods of annealing · CPC title

• C22C38/16

  containing copper · CPC title

• C22C2202/02

  Magnetic · CPC title

• H01F1/15333

  containing nanocrystallites, e.g. obtained by annealing · CPC title