Claims
- 1. A soft magnetic Fe—Co alloy comprising, in weight %,
Fe and Co such that the difference between the Fe and Co is at least 2%, at least 35% Co, and 2.5%≦(V+Mo+Nb), wherein 0.4%≦Mo and/or 0.4%≦Nb.
- 2. The alloy of claim 1, comprising 1.5 to 8% V.
- 3. The alloy of claim 1, comprising at least 3% V.
- 4. The alloy of claim 1, further comprising 0.001 to 0.02% B and/or 0.01 to 0.1% C.
- 5. The alloy of claim 1, comprising 0.4 to 3% Mo and/or 0.4 to 2% Nb.
- 6. The alloy of claim 1, further comprising 1 to 5% W.
- 7. The alloy of claim 1, further comprising 0.5 to 2% Ni.
- 8. The alloy of claim 1, further comprising 0.3 to 2% Ti.
- 9. The alloy of claim 1, comprising 35 to 51% Co, 0 to 8% V and at least one of the following: 0.001 to 0.02% B; 0 to 0.1% C; 0.4 to 3% Mo; 0.4 to 2% Nb; 1 to 5% W; 1 to 2% Ni; 0.3 to 2% Ti; 1 to 2 wt. % Cr; 0.25 to 3 wt. % Mn and 0.5 to 1.5% Al.
- 10. The alloy of claim 1, wherein the alloy exhibits a room temperature ultimate tensile strength of at least 800 MPa, a room temperature yield strength of at least 600 MPa, a yield strength at 600° C. of at least 500 MPa, a rupture life at 600° C. under a stress of at least 500 MPa of at least 24 hours and/or a total elongation at room temperature of at least 3.5%.
- 11. The alloy of claim 1, wherein the alloy exhibits a total elongation at 600° C. of at least 7.5% and/or room temperature saturization magnetization of at least 190 emu/g.
- 12. The alloy of claim 1, wherein the alloy has an oxide dispersoid content of 0.5 to 4 wt. % and/or an average grain size of 1 to 30 μm.
- 13. The alloy of claim 1, wherein the alloy exhibits creep resistance at 600° C. under a stress of at least 500 MPa of 6×10−7/sec or lower, a weight gain of 1.5 mg/cm2 or less when exposed to air for 100 hours at 600° C. and/or an electrical resistivity at 600° C. of at least 55 μohm-cm.
- 14. The alloy of claim 1, comprising a part of a high performance transformer, a laminated part of an electrical generator, a pole tip of a high field magnet, a magnetically driven actuator of a device such as an impact printer, a diaphragm of a telephone handset, a solenoid valve of an armature-yoke system of a diesel injection engine, a magnetostrictive transducer, an electromagnetically controlled intake or exhaust nozzle, a flux guiding part of an inductive speed counter of an anti-lock brake system, a magnetic lens, a solenoid core of a magnetic switch or part of a magnetically excited circuit.
- 15. A vanadium-free high strength soft magnetic Fe—Co alloy comprising, in weight %, at least 15% Co, and a difference between Fe and Co of at least 2%, the alloy further satisfying at least one of inequalities (1) or (2):
(1) 0.1%≦Nb and 0.1%≦W (2) 0.25%≦Mn.
- 16. The alloy of claim 15, wherein the alloy has an oxide dispersoid content of 0.5 to 4 wt. % and/or an average grain size of 1 to 30 μm.
- 17. The alloy of claim 15, wherein the alloy includes 15 to 20% Co and up to 0.5% Al, up to 3% Mn, up to 3% W, up to 2% Nb and up to 0.1% B.
- 18. The alloy of claim 15, wherein the alloy includes 0.001 to 0.1% B.
- 19. The alloy of claim 15, wherein the alloy exhibits a room temperature ultimate tensile strength of at least 800 MPa, a room temperature yield strength of at least 600 MPa, a yield strength at 600° C. of at least 500 MPa and/or a total elongation at room temperature of at least 3.5%.
- 20. The alloy of claim 15, wherein the alloy exhibits a total elongation at 600° C. of at least 7.5%, room temperature saturization magnetization of at least 190 emu/g, creep resistance at 600° C. under a stress of at least 500 MPa of at least 6×107/sec or better, weight gain of 1.5 mg/cm2 or less when exposed to air for 100 hours at 600° C. and/or electrical resistivity at 600° C. of at least 80 μohm-cm.
- 21. The alloy of claim 15, comprising a part of a high performance transformer, a laminated part of an electrical generator, a pole tip of a high field magnet, a magnetically driven actuator of a device such as an impact printer, a diaphragm of a telephone handset, a solenoid valve of an armature-yoke system of a diesel injection engine, a magnetostrictive transducer, an electromagnetically controlled intake or exhaust nozzle, a flux guiding part of an inductive speed counter of an anti-lock brake system, a magnetic lens, a solenoid core of a magnetic switch or part of a magnetically excited circuit.
- 22. A method of manufacturing the alloy of claim 1, comprising preparing a powder mixture by mixing powder of the alloy with a binder, forming the powder mixture into a sheet, forming a sintered sheet by heating the sheet so as to remove the binder and sinter the powder, forming a rolled sheet by cold rolling the sintered sheet, and heat treating the rolled sheet.
- 23. A method of manufacturing the alloy of claim 1, comprising plasma spraying powder of the alloy into a plasma sprayed sheet, forming a cold rolled sheet by cold rolling the plasma sprayed sheet and heat treating the cold rolled sheet.
- 24. A method of manufacturing the alloy of claim 1, comprising mechanically alloying powder of the alloy with oxide particles to form an alloyed powder, forming the alloyed powder into a sheet, forming a cold rolled sheet by cold rolling the sheet, and age hardening the cold rolled sheet.
- 25. A method of manufacturing the alloy of claim 24, wherein the alloyed powder has an oxide dispersoid content of 0.5 to 4 wt. % and/or an average grain size of 1 to 30 μm.
- 26. A method of manufacturing the alloy of claim 1, comprising forming the alloy into coated sheets having an insulating coating thereon, the insulating coating having a thickness of 1 to 10 microns, and overlapping the coated sheets to form a laminated article optionally in the form of a stator or rotor of a starter/generator for an aircraft jet engine.
- 27. A method of manufacturing the alloy of claim 1, comprising forming the alloy into a magnetic bearing by casting the alloy or sintering powders of the alloy.
- 28. A method of manufacturing the alloy of claim 1, comprising forming the alloy into a part of a high performance transformer, a laminated part of an electrical generator, a pole tip of a high field magnet, a magnetically driven actuator of a device such as an impact printer, a diaphragm of a telephone handset, a solenoid valve of an armature-yoke system of a diesel injection engine, a magnetostrictive transducer, an electromagnetically controlled intake or exhaust nozzle, a flux guiding part of an inductive speed counter of an anti-lock brake system, a magnetic lens, a solenoid core of a magnetic switch or part of a magnetically excited circuit.
- 29. A method of manufacturing the alloy of claim 1, comprising strengthening the alloy through solid solution hardening and/or precipitation strengthening.
- 30. A method of manufacturing the alloy of claim 1, comprising forming a hot worked article by hot working the alloy at a temperature of at least 900° C., annealing the hot worked article in the temperature range of 900° C. to 1100° C. for 10 min. followed by quenching the hot worked article in an ice brine solution and cold rolling the hot worked article.
- 31. A method of manufacturing the alloy of claim 1, comprising casting the alloy at an oxygen partial pressure less than 0.005%.
- 32. A method of manufacturing the alloy of claim 1, comprising forming the alloy into a sheet and rolling the sheet to a thickness of 5 to 100 mils.
- 33. A method of manufacturing the alloy of claim 1, comprising forming the alloy into a sheet, hot rolling the sheet at a temperature of at least 950° C., quenching the sheet from at least 950° C., and then cold rolling the sheet to a thickness in the range of 0.002 to 0.03 inches.
- 34. A method of manufacturing the alloy of claim 1, comprising forming the alloy into a sheet and annealing the sheet at a temperature of at least about 950° C. during cold rolling of the sheet.
- 35. A method of manufacturing the alloy of claim 1, comprising casting the alloy and forging or rolling the cast alloy into a sheet at a temperature greater than 1000° C. so as to break down the cast microstructure.
- 36. A method of manufacturing the alloy of claim 1, comprising forming the alloy into powder having a particle size of 100 nanometers to 30 microns.
- 37. A method of manufacturing the alloy of claim 1, optionally cold rolling the alloy followed by annealing the alloy at a temperature in the range of 850 to 1000° C., water quenching the alloy, and aging the alloy at a temperature in the range of 600 to 700° C. so as to provide the alloy with a room temperature yield stress of at least 800 MPa and a room temperature ultimate tensile strength of at least 1000 MPa.
RELATED APPLICATION
[0001] This application is a continuation-in-part of co-pending U.S. application Ser. No. 09/757,625, filed on Jan. 11, 2001.
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
09757625 |
Jan 2001 |
US |
Child |
10314993 |
Dec 2002 |
US |