Patent Application
20090232693
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.
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 amorphous alloy, a high cooling rate of approximately 10−5K/s is necessary. 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.
Fe-based amorphous and nanocrystalline alloy powder can be obtained by pulverizing ribbons, wherein the magnetic powder core can be obtained by several procedures such as sticking, pressing annealing and so forth. 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.
Bulk amorphous Fe—Al—Ga—P—C—B—Si systems disclosed by U.S. Pat. No. 5,876,519 have large glass formation ability, wherein the supercooled liquid region is over 50K, bulk amorphous alloy of 1.5 mm in thickness can be obtained by mold casting and the said alloy has excellent soft magnetic properties. By using the large glass formation ability of the said alloy system, amorphous powder can be prepared by atomization method, wherein a magnetic powder core can be made thereof. 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. Moreover, a Fe-based amorphous alloy system disclosed by Chinese Patent Publication No. CN1487536A at least contains elements of P, C, B and a small amount of elements such as Cr, Mo, W, V, Nb, etc. 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.
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.
Another object of the present invention is to provide a magnetic powder core with excellent high frequency properties and method for making them thereof.
In order to achieve the objects mentioned above, the present invention involves the following aspects:
In one aspect, the present invention provides an amorphous alloy powder with excellent soft magnetic properties in high frequency. The compositions of said alloy powder by atomic percent 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 selected from 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. Preferably; 0.01≦x≦0.12, 9≦a≦12, 10≦b≦23 and 1≦c≦5, 22≦(a+b+c)≦38.
The reduced glass transition temperature Trg of said amorphous alloy powder satisfies Trg≧0.53, wherein Trg=Tg/Tm, Tg represents glass transition temperature, Tm represents melting point of alloy. The supercooled liquid region ΔTx≧20K, wherein ΔTx=Tx−Tg, Tx represents crystallization temperature. The oxygen content of the powder is below 4000 ppm.
In another aspect, the present invention provides a method for making an amorphous alloy powder with excellent soft magnetic properties in high frequency. The alloy components mentioned above are used to prepare the alloy powder by atomization method, wherein said atomization is water atomization and/or gas atomization, while said gas atomization is one of vacuum gas atomization, non-vacuum gas atomization, adjustable gas atomization or their combination.
The loose packed density of the powder ρ obtained by the process should satisfy the relation: ρ≧2.4 g/cm3.
In the third aspect, the present invention provides an amorphous magnetic powder core with excellent soft magnetic properties in high frequency, comprising the components by weight percentage as follows: 0.2%-7% of insulating agent, 0.01%-5% of adhesives, 0.01%-2% of lubricants, the rest is said amorphous alloy powder.
Wherein, said insulating agent is at least one selected from following groups of substances:
Said adhesives are organic adhesives and/or inorganic adhesives, wherein, the organic adhesives are at least one selected from epoxy resins, the inorganic adhesives are at least one selected from phosphates.
Said lubricants are one or a combination selected from stearates and talc powder.
The magnetic properties of said magnetic powder core shall satisfy the requirements of at least one, several or their combination of the followings:
In the fourth aspect, the present invention provides a method for making the amorphous magnetic powder core with excellent soft magnetic properties in high frequency. Said method comprises the following steps:
(a) Using said amorphous alloy powder and a required content of insulating agent, adhesives and lubricants, mixing them and then drying them to obtain dry powder;
(b) Compacting said dried powder under a pressure of 500 MPa-3000 MPa to make magnetic powder core;
(c) Annealing said molded magnetic powder core below the crystallization temperature of said amorphous powder.
After step (c), the process further including: (d) spray painting magnetic powder core and (e) testing the properties of magnetic powder core.
In step (c), the temperature for annealing said magnetic powder core is between (Tx-100° C.) and Tx, wherein Tx represents the crystallization temperature of said alloy powder; annealing time is from 5 minutes to 300 minutes; the atmosphere is one of vacuum, nitrogen and argon.
In step (c), the annealing temperature is between (Tx-70° C.) and (Tx-20° C.), wherein Tx represents the crystallization temperature of said alloy powder.
The magnetic properties of magnetic powder core obtained by said process shall satisfy the requirements of at least one, or their combination of the followings:
To sum up, the present invention provides a technical solution for making amorphous alloy powder and amorphous magnetic powder core, wherein the antioxidation properties and glass formation ability of the alloy are enhanced by the improvement of the components of the alloy, therefore, the amorphous alloy powder can be made by atomization method. Said powder is prepared into dried powder after insulating treatment and mixing with a small amount of adhesives, then molded into core. After proper heat treating, magnetic powder core can be obtained. The detailed procedures will be described hereinafter.
The iron element is the main component of the amorphous alloy powder of the present invention and a small amount of Co and Ni is included thereof, so soft magnetic properties are improved and antioxidation properties of powder are enhanced in the presence of Co and Ni; meanwhile the present invention contains more glass formation elements such as P, Al, C, B and Si, thus amorphous alloy powder is formed. Moreover, the present invention contains more than one kind of elements such as Sn, Cr, Mn, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd, Au, etc., which will further improve the glass formation ability of alloy and antioxidation properties. For instance, the glass formation ability is improved in presence of the elements such as Sn, Zr, etc., and the addition of Cr and Mo and some other elements can not only improve glass formation ability, but also enhance the antioxidation properties of powder as well.
In said amorphous alloy powder of the present invention, the compositions of atomic percent of the alloy should satisfy 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 selected from Sn, Cr, Mn, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd and Au; and all by atomic percentage 0.01≦x≦0.16; 8≦a≦15; 10≦b≦25; 0.5≦c≦6.
As to the amorphous alloy powder of the present invention, the content of Co and Ni is preferably from 1 at. % to 12 at. %; the content of P is preferably from 9 at. % to 12 at. %; the content of Al, C, B and Si is preferably from 10 at. % to 23 at. %; the content of Sn, Cr, Mn, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd and Au is preferably from 1 at. % to 5 at. %.
As to the amorphous alloy powder of the present invention, the sum of elements of Fe, Co and Ni is preferably from 62 at. % to 78 at. %; the sum of elements of P, Al, C, B, Si, Sn, Cr, Mn, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd and Au is preferably from 22 at. % to 38 at. %.
The alloy of the present invention will inevitably contain a small amount of 0 and other impurities, wherein the total quantity of these impurities is no more than 0.5 wt. %.
The amorphous alloy powder of the present invention has large glass formation ability, so amorphous alloy powder can be prepared by atomization method; the supercooled liquid region ΔTx≧20K(ΔTx=Tx−Tg, wherein Tx represents crystallization temperature and, Tg represents glass transition temperature, the reduced glass transition temperature Trg≧0.53 (Trg=Tg/Tm, wherein Tm represents melting point of alloy).
The amorphous alloy powder of the present invention can be prepared by water atomization method under non-vacuum condition, wherein the maximum particle size of said amorphous alloy powder is greater than 75 μm and the oxygen content of the powder is below 4000 ppm. The loose packed density of said water atomized amorphous alloy powder is characterized in that, when the particle size is between −200 mess (about 74 μm) and +300 mess (about 49 μm), the loose packed density of powder is more than 2.7 g/cm3; when the particle size is between −300 mess (about 49 μm) and +400 mess (about 38 μm), the loose packed density of powder is more than 2.6 g/cm3; when the particle size is below −400 mess (about 38 μm) and over 5 μm, the loose packed density of powder is over 2.5 g/cm3.
In the present invention, the water atomized amorphous alloy powder is used to make magnetic powder core, wherein oxygen content is below 4000 ppm. If the oxygen content is too high, magnetic properties of powder will deteriorate. If properties of magnetic powder core prepared by using said powder are not fine which results in the decrease of permeability and increase of coercive force of magnetic powder core.
In the present invention, the water atomized amorphous alloy powder is used to prepare a magnetic powder core, wherein the loose packed density of the amorphous alloy powder is over 2.5 g/cm3. If the loose packed density is too small, properties of magnetic powder core will not be fine. Too small loose packed density is generally resulted from small particle size of powder or complicated shapes of powder or much more pores contained in powder. The magnetic powder core prepared by using said powder has the drawbacks of low density, large air gaps distributed in magnetic powder core, low magnetic permeability of powder core, larger coercive force and high core losses. The loose packed density of amorphous alloy powder of the present invention is over 2.5 g/cm3, preferably over 2.8 g/cm3.
Compared with water atomization, gas atomization has lower cooling rate. In the alloy system of the present invention, the nearly ball-shaped amorphous alloy powder is made by vacuum gas atomization, non-vacuum gas atomization and adjustable gas atomization (a method that alloy liquid is atomized to prepare powder by gas and then the powder particles are cooled by water) and so on, wherein the particle size of said amorphous alloy powder is greater than 50 μm and the oxygen content of the powder is below 1500 ppm. The loose packed density of gas atomized amorphous alloy powder is over 3.5 g/cm3.
In the present invention, the gas atomized amorphous alloy powder is used to prepare magnetic powder core, wherein the oxygen content is below 1500 ppm. The magnetic powder core prepared by using said amorphous alloy powder has good magnetic properties, high magnetic permeability and low coercive force. Compared with water atomized powder, magnetic powder core prepared by using gas atomized powder has a higher cost and advanced properties, which will satisfy the requirements of some high-level products.
The process for preparing magnetic powder core by using amorphous alloy powder of the present invention comprises the following steps:
1. Mixing the powder with insulating agent, adhesives and lubricant and then drying them to made dried powder;
2. Pressing the powder to form magnetic powder core;
3. Annealing magnetic powder core;
4. Spray painting magnetic powder core;
5. Testing properties of magnetic powder core.
The amorphous alloy powder prepared is screened by test sieve, standard spanking vibration sieve, other types of vibration sieves and pneumatic powder classifier equipments. Magnetic powder core is prepared according to the following steps:
In order to increase the resistivity of the magnetic powder core, reduce eddy current losses and enhance magnetic permeability in high frequency, the present invention shall preferably select the following types of insulating agent and amorphous alloy powder to mix and insulate: 1. Oxide powder, such as SiO2, CaO, Al2O3, TiO2, etc., generally, oxide powder has the advantages of stable properties, excellent properties of insulation and heat-resistance and low cost. 2. Silicates, phosphates, etc. 3. Other mineral powder such as mica powder, kaolinite, etc. 4. Surface film chemically formed or surface oxide occurred.
If said insulating agent is used to insulate the amorphous alloy powder, the weight percentage of insulating agent should be between 0.2 wt. % and 7 wt. % of the total mixture weight. If the insulating agent is less, the amorphous alloy powder will be difficult to be fully separated, thus resulting in more contact surface; if the insulating layer is too thin, the insulating layer between powder will easily breakdown, losing insulating effect under the action of electromagnetic induction, causing larger losses of magnetic powder core and low magnetic permeability in high frequency. If too much insulating agent is provided, the gap between powders will be too large, resulting in a decrease of magnetic permeability of the magnetic powder core. The weight percentage of insulating agent more preferably is from 0.5 wt. % to 5 wt. %.
Molding properties of amorphous alloy powder are not good. The molding of gas atomized powder is especially difficult. So the following types of adhesive substances are preferable to serve as the adhesives for the present invention: 1. Organic adhesives, such as epoxy resin, which has been commonly used in industrial product and the mixing with curing agent shall have better effect on sticking. 2. Inorganic adhesives, such as phosphates, etc., inorganic adhesives have the advantages of good heat-resistant properties and excellent insulation properties in itself and dual functions of insulation and sticking, and an additional proper amount will make the powder fully adhesive.
The content of adhesive shall not more than 5% of the total weight while using said adhesive materials. If too much adhesive is added, properties of magnetic powder core will deteriorate and so will magnetic permeability.
The mixture of lubricant functions as: 1. The powder is easy to flow while pressing the powder, thus increase the density of magnetic powder core; 2. Magnetic core is not prone to stick with press mold, thus demolding becomes easier. Stearates and talc powder is selected preferably as lubricant substances for the present invention, wherein the weight is no more than 2 wt. % of total weight of mixture. If too much lubricant is added, the density of amorphous alloy powder in magnetic powder core will decrease, resulting in the deterioration of magnetic properties and reduction of magnetic permeability.
In order to obtain fully insulated and mixed amorphous magnetic powder and excellent magnetic properties, the insulating substances, adhesives and lubricants preferably occupy from 0.5 wt. % to 10 wt. % of total weight of mixture for the present invention, more preferably from 1 wt. % to 7 wt. %.
The molding pressure of the amorphous alloy powder of the present invention should be preferably from 500 MPa to 3000 MPa. If the pressure is less than 500 MPa, the powder will be difficult to mold or cracks will still exist after molding, the magnetic permeability will be low and the properties of magnetic powder core will not be good. If the pressure is over 3000 MPa, the withstand pressure of mold will be large, thus the mold will be easily destroyed, and the powder will be difficult to insulate, losses of powder core will be high and the quality factor will not be fine. The molding pressure of magnetic powder core is more preferably from 800 MPa to 2500 MPa.
The cooling rate of amorphous alloy powder is comparatively large during the preparation process, so stress will inevitably exist inside said powder; magnetic powder core shall have stress inside it while preparing under the action of stirring and compression and these stress shall influence the properties of magnetic powder core. The internal stress of powder and magnetic powder core can be eliminated and the magnetic properties can be improved by annealing the amorphous magnetic powder core. The temperature of annealing amorphous magnetic powder core shall satisfy the requirements of: 1. Annealing temperature should be below the crystallization temperature of said alloy powder. The crystallization of amorphous alloy powder in said powder core results in magnetic permeability and the increase in losses. 2. Annealing temperature shall not be below (Tx-100° C.), wherein Tx represents the crystallization temperature of said alloy powder. 3. The annealing temperature of powder shall preferably be between (Tx-70° C.) and (Tx-20° C.). Since if the annealing temperature of the powder core is too low, heat disturbance will be un-uniform, the internal stress in amorphous powder core will not be eliminated and the magnetic properties will not be fully enhanced.
The annealing time of amorphous powder core shall satisfy the requirements of: 1. The annealing time of powder core is less than 3 hours since the manufacture cost will increase with too long annealing time and low effectiveness. 2. The annealing time of the powder core is more than 5 minutes since uniform treatment cannot be achieved while batch processing and the properties of powder core cannot be uniform if the annealing time is too short. 3. The annealing time of the powder core shall preferably be between 30 minutes and 90 minutes. For the present invention, the annealing process mentioned above should preferably be carried out in a protective atmosphere, which can be vacuum, hydrogen, nitrogen and argon atmosphere.
In order to protect magnetic powder core from powder dropping and being eroded by air and from the deterioration of magnetic properties, the magnetic powder core is protected by spray painting. The spray painting materials shall preferably be of epoxy resin or a mixture of epoxy resin and estrodur compounds with relatively small curing stress. The thickness of the spray painting is preferably from 50 μm to 300 μm.
Various parameters of properties of amorphous magnetic powder core for the present invention is tested respectively by the following methods: 1. Test method for inductance and quality factor Q, using enameled copper wires with diameter of 0.2 mm to wind 10 turns uniformly and to measure by Agilent 4294A precision impedance analyzer; magnetic permeability of magnetic powder core is calculated by the formula
wherein
The magnetic powder core prepared by alloy powder of the present invention via said method has excellent soft magnetic properties in high frequency. In detail, the properties of amorphous magnetic powder core satisfy the following requirements: the quality factor is larger than 50 and the magnetic permeability is larger than 40 at 500 kHz; the quality factor is larger than 30 and the magnetic permeability is larger than 40 at 1 MHz; the quality factor of magnetic powder core is larger than 20 and the magnetic permeability is larger than 40 at 3 MHz; while the decrease of magnetic permeability should be less than 10% in the frequency range from 100K to 1M.
The amorphous alloy prepared according to the technical solution of the present invention has large glass formation ability and good antioxidation properties. Said alloy is characterized in large glass formation ability, good antioxidation properties and excellent soft magnetic properties. By preparing amorphous alloy powder with low oxygen content via atomization method, the amorphous alloy powder with excellent high-frequency magnetic properties, low oxygen content and low cost and corresponding magnetic powder core can be obtained.
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.
The morphology of the powder having composition of Fe72Ni2Al4Sn2P10C2B4Si4 is shown in
The X-ray diffraction pattern of powder having composition of Fe72Ni2Al4Sn2P10C2B4Si4 is shown in
The DSC thermogram of Fe72Ni2Al4Sn2P10C2B4Si4 powder is shown in
The analysis of oxygen content of the powder indicates that the oxygen content of the powder is 3500 ppm, which implies that alloy bears stronger antioxidation properties and lower oxygen content.
The amorphous alloy powder of −300 mess obtained by screening is isothermal annealed for 30 minutes at a temperature of 440° C., wherein the annealing process is in nitrogen atmosphere. Said amorphous alloy powder uniformly mixes with 1.5 wt. % of SiO2 powder, 1 wt. % of epoxy resin and 0.3 wt. % of zinc stearate and then the mixture is dried in the help of alcohol as a co-solvent. The molding of the magnetic powder core is pressed under the pressure of 2 GPa. The magnetic powder core is annealed under vacuum condition. The annealing temperature is 400° C. and the annealing time is 90 minutes. The epoxy resin and estrodur compounds are used to spray and paint the surface of magnetic powder core. The thickness of the spray painting layer is 100 μm.
Static magnetic hysteresis loop of said magnetic powder core with the maximum magnetic field of 2000 A/m is shown in
The measuring result of magnetic permeability of said magnetic powder core is given in
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.
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.
In the amorphous alloy powder with the composition mentioned above, the oxygen content and the loose packed density of amorphous alloy powder of −300 mess are listed in Table 2. As can be seen in this table, except for the Comparison 1 of said series alloy, the loose packed density of said series alloy is over 2.5 g/cm3 and the average oxygen content is below 3900 ppm, which implies that the alloy has stronger antioxidation properties.
The amorphous alloy powder of −300 mess obtained by screening the amorphous alloy powder with the compositions mentioned above is isothermal annealed for 30 minutes at 440° C., wherein annealing process is in vacuum protection. Said amorphous alloy powder uniformly mixes with 1 wt. % of SiO2 powder, 1.5 wt. % of epoxy resin and 0.3 wt. % of zinc stearate and then the mixture is dried in the help of alcohol as co-solvent. The mold magnetic powder core is pressed under the pressure of 2 GPa. The magnetic powder core is annealed under vacuum situation. The annealing temperature is 440° C. and annealing time is 60 minutes. The epoxy resin and estrodur compounds are used to spray and paint the surface of magnetic powder core. The thickness of spray painting layer is 100 μm.
The properties of amorphous alloy powder core prepared by said method mentioned above are also listed in Table 2, wherein the atomization method is not suitable for Comparison 1, which will get the amorphous alloy powder with high oxygen content and low loose packed density. It can be concluded from Table 2 that the magnetic powder core made of amorphous alloy powder with lower coercive force and higher magnetic permeability compared with Comparison 1. Magnetic properties of composition 10 deteriorate because of crystallization; coercive force of alloy with other compositions (except 10 and Comparison 1) is below 60 A/m, the average magnetic permeability is over 35 which is 98% or more than the magnetic permeability at 100 kHz and 90% or more at 1 MHz, wherein the quality factor is over 40 at 1 MHz.
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.
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.
3
In the amorphous alloy powder with the compositions mentioned above, the oxygen content and the loose packed density of amorphous alloy powder of −300 mess are listed in Table 4. As shown in this table, the average loose packed density of said series alloy is not less than 2.5 g/cm3 and the average oxygen content is below 3300 ppm, which implies that the alloy has stronger antioxidation properties.
The amorphous alloy powder of −300 mess obtained by screening the amorphous alloy powder with the compositions mentioned above is isothermal annealed for 30 minutes at a temperature of 440° C., wherein annealing process is in vacuum protection. Said amorphous alloy powder uniformly mixes with 1 wt. % of SiO2 powder, 1.5 wt. % of epoxy resin and 0.3 wt. % of zinc stearate and then the mixture is dried in the help of alcohol as co-solvent. The molding of magnetic powder core is pressed under the pressure of 2 GPa. The magnetic powder core is annealed under vacuum situation. The annealing temperature is 440° C. and annealing time is 60 minutes. The epoxy resin and estrodur compounds are used to spray and paint the surface of magnetic powder core. The thickness of spray painting layer is 100 μm.
The properties of amorphous alloy magnetic powder core prepared by said method mentioned above are also listed in Table 4. It can be seen from Table 4 that, except that composition 20 is in a crystallization process and properties of magnetic powder core deteriorate, other compositions all have more excellent magnetic properties and magnetic permeability is not less than 45.
The coercive force of alloy with other compositions (except 10 and Comparison 1) is below 60 A/m, the average magnetic permeability is over 35 which is 98% or more than the magnetic permeability at 100 kHz and 90% or more at 1 MHz, wherein the quality factor is over 60 at 1 MHz.
In said embodiment, amorphous Fe—Co—Ni—Sn—Al—P—C—B—Si series alloy powder is prepared by non-vacuum gas atomization method. The raw materials are Fe, Co, Ni, Cr, Sn, Al, P—Fe alloy, graphite, B—Fe alloy and Si.
The nominal compositions of said embodiment are listed in Table 5. 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 also listed in Table 5 respectively. As shown in this table, except that composition 25 cannot be fully formed into amorphous materials, alloy with other compositions of said series alloy 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.
In the amorphous alloy powder with the components mentioned above, the oxygen content and the loose packed density of amorphous alloy powder of −350 mess are given in Table 6. As can be seen in this table, the average loose packed density of said series alloy is not less than 3.6 g/cm3 and the average oxygen content is below 2000 ppm.
The amorphous alloy powder of −350 mess obtained by screening the amorphous alloy powder with the composition mentioned above is isothermal annealed for 30 minutes at a temperature of 400° C., wherein annealing process is in vacuum protection. Said amorphous alloy powder uniformly mixes with 1 wt. % of SiO2 powder, 2 wt. % of epoxy resin and 0.3 wt. % of zinc stearate and then the mixture is dried in the help of alcohol as co-solvent. The molding of magnetic powder core is pressed under the pressure of 2.4 GPa. The magnetic powder core is annealed under vacuum situation. The annealing temperature is 440° C. and annealing time is 60 minutes. The epoxy resin and estrodur compounds are used to spray and paint the surface of magnetic powder core. The thickness of spray painting layer is 100 μm.
The properties of amorphous alloy magnetic powder core prepared by said method mentioned above are given in Table 6. It can be concluded from Table 6 that, except that composition 25 is in a crystallization process and properties of magnetic powder core deteriorate, the coercive force of alloy with other components is below 40 A/m, the average magnetic permeability is over 60 which is 98% or more than the magnetic permeability at 100 kHz and 90% or more at 1 MHz, wherein the quality factor is over 60 at 1 MHz.
Q100 kHz
Amorphous alloy powder is prepared by the same method as embodiment 1. The procedures for preparing magnetic powder core are also the same. The only difference is the change of temperature of heat treatment.
The dependence of the quality factor on annealing temperature is similar to that of magnetic permeability. The difference is that the maximum quality factor of magnetic powder core appears under the annealing temperature of 380° C. The maximum quality factor is about 75 at 100 kHz; the maximum quality factor is about 35 at 1 MHz.
| Number | Date | Country | Kind |
|---|---|---|---|
| 200510114933.4 | Nov 2005 | CN | national |
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.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11558478 | Nov 2006 | US |
| Child | 12471482 | US |
