Soft magnetic material and method for producing the same

Patent metadata

Field	Value
Publication number	US-2025118470-A1
Application number	US-202418891038-A
Country	US
Kind code	A1
Filing date	Sep 20, 2024
Priority date	Oct 10, 2023
Publication date	Apr 10, 2025
Grant date	—

Abstract

A soft magnetic material and a method for producing the same. The soft magnetic material is: Fe 100-x-y-z-w B x Ni y Si z M w (In the formula, M is one or more inevitable elements selected from Nb, Mo, Ta, W, Co, and Sn, and x, y, z, and w are in atomic percent satisfying 12≤x≤17, 1≤y≤3, 0<z≤1, 0<w≤0.1). Soft magnetic material includes α-Fe phase which contains crystals whose average particle size is 30 nm or less. The average particle size of crystals is average value of projected area circular equivalent diameters of crystals in a transmission electron microscope image of soft magnetic material thinned by focused ion beam. The ratio of peak area of crystalline plane to overall peak area as measured by XRD of α-Fe phase on surface of soft magnetic material is equal to or greater than 0.10.

First claim

What is claimed is:

1 . A soft magnetic material represented by a following compositional formula:
Fe 100-x-y-z-w B x Ni y Si z M w (In the formula, M is one or more inevitable elements selected from Nb, Mo, Ta, W, Co, and Sn, and x, y, z, and w are in atomic percent satisfying 12≤x≤17, 1≤y≤3, 0<z≤1, 0<w≤0.1), and wherein the soft magnetic material includes an α-Fe phase, wherein the α-Fe phase contains crystals whose average particle size is 30 nm or less, wherein the average particle size of the crystals is an average value of projected area circular equivalent diameters of the crystals in a transmission electron microscope (TEM) image of the soft magnetic material thinned by a focused ion beam (FIB), wherein a ratio of a peak area of the crystalline (211) plane to an overall peak area as measured by XRD of the α-Fe phase on the surface of the soft magnetic material is equal to or greater than 0.10.

2 . The soft magnetic material according to claim 1 ,
wherein z satisfies 0.2≤z≤0.9.

3 . A method for producing a soft magnetic material, comprising
preparing an alloy having a composition represented by a following compositional formula: Fe 100-x-y-z-w B x Ni y Si z M w (In the formula, M is one or more inevitable elements selected from Nb, Mo, Ta, W, Co, and Sn, and x, y, z, and w are in atomic percent satisfying 12≤x≤17, 1≤y≤3, 0<z≤1, 0<w≤0.1), and an amorphous phase; and performing rapid heat treatment on the alloy such that an attained temperature of the alloy is in a temperature range from a crystal formation start temperature of an α-Fe phase to below a Fe—B compound formation start temperature.

4 . The method for producing a soft magnetic material according to claim 3 ,
wherein in the rapid heat treatment, the attained temperature of the alloy is from 485° C. to 500° C.

5 . The method for producing a soft magnetic material according to claim 4 ,
wherein in the rapid heat treatment, a temperature increase rate of the alloy is 100° C./sec to 415° C./sec.

6 . The method for producing a soft magnetic material according to claim 5 ,
wherein in the rapid heat treatment, a holding time of the alloy is from 0 to 80 seconds.

7 . The method for producing a soft magnetic material according to claim 3 ,
wherein the rapid heat treatment is performed by clamping the alloy between heated blocks.

Assignees

• Toyota Motor Co Ltd

Inventors

• Ito Masaaki
• Hiraoka Motoki
• Komori Kensuke
• Onitsuka Yusuke
• Nomura Takuya

Classifications

• C22C38/08

  containing nickel {(C22C38/105 takes precedence)} · CPC title

• C22C38/002 Primary

  containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60 · CPC title

• H01F1/15341

  Preparation processes therefor · CPC title

• H01F1/15333

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

• H01F1/15308 Primary

  based on Fe/Ni (H01F1/15325 takes precedence) · CPC title