A method for preparing iron-based amorphous powder, iron-based amorphous powder and its applications

Abstract

This invention provides a method for preparing iron-based amorphous powder, the iron-based amorphous powder, and its applications. The preparation method includes: weighing iron, silicon, ferroboron master alloy, carbon, erbium, and chromium in a predetermined proportion and adding them to a melting furnace to obtain a molten liquid; holding the molten liquid at a constant temperature and allowing it to stand to obtain an amorphous powder liquid; and subjecting the amorphous powder liquid to water-air combined atomization to obtain spherical amorphous powder. This invention solves the problem in the prior art where the amorphous powder has an irregular shape and sharp edges, which easily leads to the accumulation of losses and affects the performance and stability of the magnetic core.

Description

Technical Field

[0001] This invention relates to the field of soft magnetic alloy materials technology, and in particular to a method for preparing iron-based amorphous powder, the iron-based amorphous powder, and its applications. Background Technology

[0002] Amorphous and nanocrystalline soft magnetic alloys possess high permeability, low coercivity, and excellent high-frequency soft magnetic properties, earning them the title of 21st-century green electronic materials. In recent years, they have received widespread attention and research from academia and industry. With the rapid development of computer network technology, 5G communication, electric vehicles, photovoltaic new energy, and multimedia technology, electronic devices are demanding miniaturization, energy efficiency, and high-frequency operation. This places newer and higher demands on soft magnetic materials, requiring them to possess higher saturation magnetic induction, higher permeability, lower losses, and good high-frequency performance.

[0003] Due to its advantages of low loss and high Bs compared with traditional magnetic powder core materials, iron-based amorphous alloy soft magnetic powder has a huge market potential in energy storage inductors and PFC inductors used in power devices such as new energy vehicles and server power supplies, and has significant performance advantages in the field of integral molded inductors.

[0004] Currently, amorphous alloy soft magnetic powder is produced by crushing amorphous alloy strips. This powder has an irregular shape and sharp edges, which can easily lead to the accumulation of losses. Furthermore, the sharp edges can cause damage to the insulation layer during the later pressing of the magnetic core, affecting the performance and stability of the magnetic core. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a method for preparing iron-based amorphous powder, iron-based amorphous powder and its application, in order to solve the problem that the irregular shape and sharp edges of the amorphous powder in the prior art easily lead to the accumulation of losses, which affects the performance and stability of the magnetic core.

[0006] The embodiments of the present invention are implemented as follows:

[0007] A method for preparing iron-based amorphous powder, the method comprising:

[0008] Weigh out the iron, silicon, ferroborone master alloy, carbon, erbium and chromium in a set ratio and add them to a smelting furnace to obtain molten liquid;

[0009] The molten liquid is kept at a constant temperature and allowed to stand to obtain an amorphous powder liquid. The amorphous powder liquid is then subjected to water-air combined atomization to produce spherical amorphous powder.

[0010] Furthermore, in the above-mentioned method for preparing iron-based amorphous powder, the smelting step includes:

[0011] First, put some carbon sheets and chromium into the bottom of the smelting furnace, then add a certain amount of recycled material to cover it, put in some pure iron, and add the remaining pure iron in batches during the heating and melting process;

[0012] After it is completely melted, add ferroboron and large pieces of metallic silicon. After it is completely melted, add the remaining metallic silicon and carbon sheets, heat to the first preset temperature, and remove the slag after it is completely melted.

[0013] After the solution temperature drops to the second preset temperature, erbium is added to purify the melt, and after complete melting, a molten liquid is obtained.

[0014] Furthermore, in the above-mentioned method for preparing iron-based amorphous powder, the first preset temperature is 1580-1600℃.

[0015] Furthermore, in the above-mentioned method for preparing iron-based amorphous powder, the second preset temperature is 1390–1420°C.

[0016] Another object of the present invention is to provide an iron-based amorphous powder, prepared by any of the iron-based amorphous powder preparation methods described above, wherein the iron-based amorphous powder comprises the following components in terms of atomic ratio:

[0017] Fe (100-x-y-z-a-b) Si x B y C z Cr a Er b ;

[0018] Wherein, 11≤X≤13, 10≤Y≤12, 1≤Z≤5, 1≤a≤5, and 0.5≤b≤5.

[0019] The present invention also proposes an application method for iron-based amorphous powder prepared by any of the above-described preparation methods, the application method comprising:

[0020] The iron-based amorphous powder is subjected to conventional insulating coating treatment, and then the coated iron-based amorphous powder is pressed into a magnetic core under a preset pressure.

[0021] Compared with existing technologies, this method uses iron, silicon, ferroboron-boron master alloys, carbon, and chromium as the base materials for amorphous powder preparation. The addition of the rare earth element erbium deoxidizes and purifies the alloy melt, increasing the surface tension and viscosity of the solution. This makes it easier for the amorphous powder to form spherical particles during the atomization process, avoiding irregular shapes and sharp edges that can lead to loss accumulation. Sharp edges can also damage the insulation layer during later core pressing, affecting the performance and stability of the core. This results in iron-based amorphous alloy powder with low loss, good sphericity, and excellent high-frequency soft magnetic properties. Attached Figure Description

[0022] Figure 1 This is a laser particle size analysis data diagram of the amorphous alloy raw powder prepared by the iron-based amorphous powder preparation method proposed in one embodiment of the present invention;

[0023] Figure 2 This is a SEM image of the amorphous alloy raw powder prepared by the iron-based amorphous powder preparation method proposed in one embodiment of the present invention;

[0024] Figure 3 This is a loss test data graph of a magnetic core made from amorphous alloy raw powder prepared by the iron-based amorphous powder preparation method proposed in one embodiment of the present invention. Detailed Implementation

[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0026] Furthermore, the term "and / or" as used herein includes any and all combinations of one or more of the associated listed items. In the detailed description and claims, a list of items connected by the term "one of" may mean any of the listed items. For example, if items A and B are listed, then the phrase "one of A and B" means only A or only B. In another instance, if items A, B, and C are listed, then the phrase "one of A, B, and C" means only A; only B; or only C. Item A may contain a single element or multiple elements. Item B may contain a single element or multiple elements. Item C may contain a single element or multiple elements. In the detailed description and claims, a list of items connected by the terms "at least one of," "at least one of," or other similar terms may mean any combination of the listed items. For example, if items A and B are listed, then the phrase "at least one of A and B" or "at least one of A or B" means only A; only B; or A and B. In another instance, if items A, B, and C are listed, then the phrase "at least one of A, B, and C" or "at least one of A, B, or C" means only A; or only B; only C; A and B (excluding C); A and C (excluding B); B and C (excluding A); or all of A, B, and C. Item A may contain a single element or multiple elements. Item B may contain a single element or multiple elements. Item C may contain a single element or multiple elements.

[0027] This invention addresses the problem that current amorphous powders often have irregular shapes and sharp edges, which can easily lead to the accumulation of losses and affect the performance and stability of magnetic cores. It proposes a method for preparing iron-based amorphous powder, the iron-based amorphous powder itself, and its applications.

[0028] The method for preparing this iron-based amorphous powder includes:

[0029] Weigh out the iron, silicon, ferroborone master alloy, carbon, erbium and chromium in a set ratio and add them to a smelting furnace to obtain molten liquid;

[0030] The molten liquid is kept at a constant temperature and allowed to stand to obtain an amorphous powder liquid. The amorphous powder liquid is then subjected to water-air combined atomization to produce spherical amorphous powder.

[0031] Understandably, using iron, silicon, ferroboron intermediate alloy, carbon, and chromium as the base materials for amorphous powder preparation, and the addition of the rare earth element erbium, plays a role in deoxidation, purifying the alloy melt, increasing the surface tension of the solution and the viscosity of the melt. As a result, the amorphous powder is more likely to form spherical powder during the atomization preparation process, avoiding irregular shapes and sharp edges, which can easily lead to the accumulation of losses. Furthermore, sharp edges can cause damage to the insulation layer during the later pressing of the magnetic core, affecting the performance and stability of the magnetic core.

[0032] Specifically, the smelting steps include:

[0033] First, put some carbon sheets and chromium into the bottom of the smelting furnace, then add a certain amount of recycled material to cover it, put in some pure iron, and add the remaining pure iron in batches during the heating and melting process;

[0034] After it is completely melted, add ferroboron and large pieces of metallic silicon. After it is completely melted, add the remaining metallic silicon and carbon sheets, heat to the first preset temperature, and remove the slag after it is completely melted.

[0035] After the solution temperature drops to the second preset temperature, erbium is added to purify the melt, and after complete melting, a molten liquid is obtained.

[0036] The first preset temperature is 1580-1600℃, for example, 1580℃, 1590℃ and 1600℃, and the second preset temperature is 1390~1420℃, for example, 1390℃, 1400℃ and 1420℃.

[0037] In another aspect, the present invention provides an iron-based amorphous powder, which is prepared by the above-described method for preparing iron-based amorphous powder. This iron-based amorphous powder comprises the following components by atomic ratio:

[0038] Fe(100-xyzab), Six, By, Cz, Cra, Erb;

[0039] Wherein, 11≤X≤13, 10≤Y≤12, 1≤Z≤5, 1≤a≤5, and 0.5≤b≤5.

[0040] In another aspect, this invention also proposes an application method for the iron-based amorphous powder prepared by the above-described preparation method, the application method comprising:

[0041] The iron-based amorphous powder is subjected to conventional insulating coating treatment, and then the coated iron-based amorphous powder is pressed into a magnetic core under a preset pressure.

[0042] To facilitate understanding of the present invention, several embodiments are given below. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of the present invention will be more thorough and complete.

[0043] Example 1

[0044] According to atomic ratio Fe 72.5 Si 11 B 11 C 2.5 After converting the Cr2Er1 formula to a weight ratio, 60 kg of raw materials were weighed and prepared. First, some carbon flakes (C) and chromium (Cr) were placed at the bottom of the melting furnace, followed by a certain amount of recycled material for covering. Then, some pure iron was added, and the remaining pure iron was added in batches during the melting process. After complete melting, ferroboron and large pieces of metallic silicon were added. After the melt was cleared, the remaining metallic silicon and carbon flakes were added, and the temperature was raised to 1580–1600℃ to remove slag. Once the steel temperature dropped to 1390–1420℃, the rare earth element Er (erbium) was added to purify the melt, and the temperature was maintained before pouring the steel for water-air combined atomization powder production. This yielded spherical amorphous alloy powder.

[0045] In practical applications, the amorphous alloy powders prepared according to the above embodiments of the present invention are dried at 120°C and then subjected to laser particle size analysis and SEM morphology analysis.

[0046] like Figure 1 , Figure 2 As shown, the amorphous alloy powder obtained has a D50 of 15.13 μm, and the vast majority of the powder particles have a near-spherical morphology.

[0047] 100 grams of raw powder was subjected to conventional insulation coating treatment and then pressed into a 12.7×7.6×5mm magnetic core under a pressure of 60MPa for loss testing: 239.81kW / m3@50kHz / 50mT; 571.62kW / m3@100kHz / 50mT. The test results are as follows: Figure 3 As shown.

[0048] In summary, combining the above... Figures 1 to 3The data clearly shows that using iron, silicon, ferroboron-boron intermediate alloys, carbon, and chromium as the base materials for amorphous powder preparation, and the addition of the rare earth element erbium, effectively deoxidizes and purifies the alloy melt, increases the surface tension of the solution, and reduces the melt viscosity. This makes it easier for the amorphous powder to form spherical particles during the atomization process, avoiding irregular shapes and sharp edges that could lead to loss accumulation. Furthermore, sharp edges can damage the insulation layer during later core pressing, affecting the performance and stability of the core. This results in iron-based amorphous alloy powder with low loss, good sphericity, and excellent high-frequency soft magnetic properties.

[0049] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A method for preparing iron-based amorphous powder, characterized in that, This is used to prepare iron-based amorphous powder, wherein the iron-based amorphous powder comprises the following components by atomic ratio: Fairy （100-x-y-z-a-b） ,Say x ,B y ,C z ,Cr a ,Is b ; Wherein, 11≤X≤13, 10≤Y≤12, 1≤Z≤5, 1≤a≤5, 0.5≤b≤5; The preparation method includes: Weigh out the iron, silicon, ferroborone master alloy, carbon, erbium and chromium in a set ratio and add them to a smelting furnace to obtain molten liquid; The molten liquid is kept at a constant temperature and allowed to stand to obtain amorphous powder liquid. The amorphous powder liquid is then subjected to water-air combined atomization powdering to obtain spherical amorphous powder. The smelting process includes: First, put some carbon sheets and chromium into the bottom of the smelting furnace, then add a certain amount of recycled material to cover it, put in some pure iron, and add the remaining pure iron in batches during the heating and melting process; After it is completely melted, add ferroboron and large pieces of metallic silicon. After it is completely melted, add the remaining metallic silicon and carbon sheets, heat to the first preset temperature, and remove the slag after it is completely melted. After the solution temperature drops to the second preset temperature, erbium is added to purify the melt, and the molten liquid is obtained after complete melting. The first preset temperature is 1580-1600℃, and the second preset temperature is 1390~1420℃; Erbium is used for deoxidation, purifying alloy melts, increasing the surface tension of solutions and the viscosity of melts.

2. A method for applying iron-based amorphous powder prepared by the method described in claim 1, characterized in that, The application method includes: The iron-based amorphous powder is subjected to conventional insulating coating treatment, and then the coated iron-based amorphous powder is pressed into a magnetic core under a preset pressure.

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