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Fe-based amorphous magnetic powder, magnetic powder core with excellent high frequency properties and method of making them

a magnetic powder and high frequency technology, applied in the field of amorphous soft magnetic alloy powder core, can solve the problems of difficult to obtain amorphous alloy powder directly from rapid quenching, low core quality factor, high core loss, etc., and achieve excellent high frequency properties, low oxygen content, and large glass formation ability

Inactive Publication Date: 2009-09-17
LU ZHICHAO +4
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0006]Accordingly, a primary object of the present invention is to provide an amorphous alloy powder with excellent high frequency properties, large glass formation ability, low-cost and low oxygen content, and a method for making it.
[0007]Another object of the present invention is to provide a magnetic powder core with excellent high frequency properties and method for making them thereof.

Problems solved by technology

Though amorphous alloy ribbon can be produced in large scale by single roller rapidly quenched technology, it is still difficult to obtain amorphous alloy powder directly from rapid quenching.
The problem of said magnetic powder core is that the powder obtained by pulverizing ribbons contains much deformed powder and the insulation of the powder is difficult, thus the core generally has low quality factor, high core losses.
The problem of said soft magnetic alloy powder is that, firstly, it contains expensive element of Ga, which is difficult to popularize due to its high price; secondly, it does not contain antioxidation elements such as Ni, Cr, therefore, antioxidation properties are poor and the powder easily oxidates and its properties deteriorate while preparing powder by atomization method.
Said alloy system contains only a small amount of antioxidation element such as Cr and Mo etc, resulting in poor antioxidation ability during the process of atomization.

Method used

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  • Fe-based amorphous magnetic powder, magnetic powder core with excellent high frequency properties and method of making them
  • Fe-based amorphous magnetic powder, magnetic powder core with excellent high frequency properties and method of making them
  • Fe-based amorphous magnetic powder, magnetic powder core with excellent high frequency properties and method of making them

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embodiment 1

[0072]In said embodiment, amorphous Fe72Ni2Al4Sn2P10C2B4Si4 (composition serial number is 1) alloy powder is prepared by water atomization method. The raw materials shall be Fe, Ni, Al, Sn, P—Fe alloy, B—Fe alloy, graphite and Si.

[0073]The morphology of the powder having composition of Fe72Ni2Al4Sn2P10C2B4Si4 is shown in FIG. 1. As shown in this figure, the small particle powder is basically spherical, the big particle powder is elliptical and a small amount of powder is irregular.

[0074]The X-ray diffraction pattern of powder having composition of Fe72Ni2Al4Sn2P10C2B4Si4 is shown in FIG. 2. As shown in this figure, distinct wide atlas exists in X-ray diffraction pattern and there is no notable crystallization peak in it, which indicates that the alloy powder is amorphous. Thereby, Fe72Ni2Al4Sn2P10C2B4Si4 alloy can prepare amorphous alloy powder by water atomization method.

[0075]The DSC thermogram of Fe72Ni2Al4Sn2P10C2B4Si4 powder is shown in FIG. 3. The speed is 10K / minute while per...

embodiment 2

[0081]In said embodiment, amorphous Fe—Ni—Sn—Al—P—C—B—Si series alloy powder is prepared by water atomization method. The raw materials shall select Fe, Ni, Sn, Al, P—Fe alloy, graphite, B—Fe alloy and Si.

[0082]The nominal compositions of said embodiment are listed in Table 1. Glass transition temperature of corresponding alloy, crystallization temperature, melting point, reduced glass transition temperature and width of supercooled liquid region are listed in Table 1 respectively. As seen from this table, except that composition 10 is in a crystallization process, alloy with other composition of said series alloy has high reduced glass transition temperature. The minimum is 0.54 and the maximum is 0.58. The width of supercooled liquid region is over 20K.

TABLE 1Alloy composition in atomicNo.percentageTg / KTx / KTm / KTg / Tm(Tx − Tg) / K1Fe72Ni2Al4Sn2P10C2B4Si464669512090.54492Fe68.5Ni3Al7P11.5C3B565070012090.54503Fe67Ni7Sn2Al4P10B4C2Si465469412080.54404Fe70.5Ni10Sn1Al4P13C2B3Si666569012040....

embodiment 3

[0086]In said embodiment, amorphous Fe—Co—Cr—Sn—Al—P—C—B—Si series alloy powder is prepared by water atomization method. The raw materials are Fe, Co, Cr, Sn, Al, P—Fe alloy, graphite, B—Fe alloy and Si.

[0087]The nominal composition of said embodiment is listed in Table 3. The lists of glass transition temperature of corresponding alloy, crystallization temperature, melting point, approximate glass transition temperature and width of super cooled liquid region are listed in Table 3 respectively. As seen from this table, except that composition 20 cannot be fully formed into amorphous materials, alloy with other compositions all has high reduced glass transition temperature. The minimum is 0.58 and the maximum is 0.60. The width of super cooled liquid region is over 20K.

TABLE 3 3Alloy composition in atomicNo.percentageTg / KTx / KTm / KTg / Tm(Tx − Tg) / K11Fe70Co2Cr2Sn2Al4P10C2B4Si470574412080.583912Fe68.5Co2Cr1Sn2Al7P11.5C3B3Si271574011970.602513Fe68.5Co1Cr5Sn3Al2P11.5C5B2Si271575312230.5838...

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Abstract

The present invention provides an amorphous alloy powder and magnetic powder cores exhibiting excellent high frequency properties and a method for making themof. The composition of said alloy powder by atomic percentage satisfies the following formula: (Fe1-xMx)100-a-b-cPaTbDc, wherein M represents at least one element of Co and Ni; T is over three elements selected from Al, C, B and Si, D is at least one element of Sn, Cr, Mn, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd and Au; the subscripts x, a, b, and c satisfy the relationships 0.01≦x≦0.16, 8≦a≦15, 10≦b≦25 and 0.5≦c≦6. The said amorphous alloy powder is made by atomization method and a magnetic powder core comprises a molded article of mixture of the said alloy powder and an insulating material. A method of making the amorphous alloy powder core includes the steps of screening, insulating, compacting, annealing and spray painting.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional of U.S. patent application Ser. No. 11 / 558,478 filed Nov. 10, 2006, which claims priority to Chinese Patent Application No. 200510114933.4 filed Nov. 16, 2005, both of which are incorporated by reference herein.RELATED TECHNICAL FIELD[0002]The present invention relates to a Fe-based amorphous alloy powder, and more particularly, relates to an amorphous soft magnetic alloy powder core manufactured by said amorphous alloy powder and a method for making themof.ART OF BACKGROUND[0003]Fe-based amorphous and nanocrystalline line soft magnetic alloy, for instance, amorphous Fe—Si—B series alloy disclosed by U.S. Pat. No. 4,217,135 and Fe—Cu—M—Si—B series (wherein M is one of Nb, Mo, Hf, Ta, etc.) nanocrystalline soft magnetic alloy disclosed by U.S. Pat. No. 4,881,989 have been widely used in various electronic parts and components because of their excellent soft magnetic properties. To obtain the said Fe-based a...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B22F1/00B22F3/02
CPCB22F2003/248B22F2998/10C22C33/0257C22C2200/02C22C2202/02H01F1/15308H01F1/15333H01F41/0246H01F1/15366B22F9/082B22F1/0059B22F3/02B22F3/24B22F1/08B22F1/10
Inventor LU, ZHICHAOLU, CAOWEILI, DERENSUN, KOZHOU, SHAOXIONG
Owner LU ZHICHAO
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