Amorphous alloy laminate having shear processed surface

Abstract

To provide an amorphous alloy laminate having a shear processed surface which is excellent in productivity and has high flatness.SOLUTION: There is provided an amorphous alloy laminate having a shear processed surface in which a plurality of amorphous alloy layers are inter-layer joined by a resin layer, wherein at least a part of a lamination surface has a shear processed surface whose the shear surface and the fracture surface are confirmed, in the shear processed surface of the amorphous alloy layer positioned on the top layer, the shear surface is formed, and the fracture surface is formed at its tip, and the shear processed surface of the amorphous alloy layer except for the top layer is a substantially fracture surface.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an amorphous alloy laminate having a sheared surface formed by shearing.

Background Art

[0002] Amorphous alloys are known to exhibit excellent properties such as mechanical properties, magnetic properties, and corrosion resistance. In particular, Fe-based and Co-based amorphous alloys are known to be soft magnetic materials with low coercive force because grain boundaries are not formed. In addition, amorphous alloys can be produced by rapidly solidifying an alloy melt. For example, the alloy melt can be supplied to the surface of a rotating cooling roll, and the alloy melt can be continuously solidified on the roll surface. This is a manufacturing method called the single-roll method, which can produce amorphous alloys in the form of ribbons.

[0003] Recently, there has been a movement to improve productivity and handleability by laminating a plurality of such amorphous alloy ribbons and forming an amorphous alloy laminate. And there are also attempts to efficiently produce cores of various shapes by punching such an amorphous alloy laminate into a predetermined shape. For example, Patent Document 1 discloses punching an amorphous alloy laminate in which a plurality of amorphous alloy ribbons are laminated between layers with a thermosetting resin having a thickness of 0.5 μm or more and 2.5 μm or less. And examples of applications include core materials for rotating machines, reactors, antennas, and the like. In addition, Patent Document 2 proposes a die component including a punch and a die for punching an amorphous alloy ribbon alone or a laminate.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] The method of punching an amorphous alloy laminate in which a plurality of layers are joined by a resin described in Patent Document 1 or Patent Document 2 is useful in terms of improving productivity and handleability as described above. On the other hand, in the amorphous alloy laminate obtained by such punching, for the surface formed by punching, that is, the shearing surface, practical optimization such as flatness is required.

[0006] An object of the present invention is to provide an amorphous alloy laminate having a shearing surface with high flatness and excellent productivity in view of the above problems.

Means for Solving the Problems

[0007] The present invention is an amorphous alloy laminate in which a plurality of amorphous alloy layers are joined by a resin layer, at least a part of the laminated surface has a shearing surface where a shearing surface and a fracture surface can be confirmed, and the shearing surface of the amorphous alloy layer located in the uppermost layer has a shearing surface formed, and the tip thereof has a fracture surface formed, and the shearing surface of the amorphous alloy layer excluding the uppermost layer is substantially a fracture surface, and it is an amorphous alloy laminate having a shearing surface.

Effects of the Invention

[0008] According to the present invention, it is possible to provide an amorphous alloy laminate having a shearing surface that can effectively utilize high productivity and handleability while maintaining the characteristics as a laminate.

Brief Description of the Drawings

[0009]

Figure 1

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Figure 7

Mode for Carrying Out the Invention

[0010] The present inventor conducted various studies to obtain an amorphous alloy laminate having a predetermined shape by punching, and obtained the following results. First, when punching an amorphous alloy laminate joined between multiple layers with resin, a unique fracture surface with a pattern called a vein pattern can be formed at the tip of the sheared surface. Different from ordinary metal materials, such a fracture surface has a smooth surface, so there are few problems with roughness of the sheared surface due to the unevenness of the fracture surface.

[0011] In ordinary metal materials, since the sheared surface is relatively flat with respect to the fracture surface, generally, in order to obtain flatness of the sheared surface, formation of the fracture surface has been avoided and a sheared surface as wide as possible has been tried to be ensured.

[0012] On the other hand, the above results indicate that in the case of an amorphous alloy laminate joined between multiple layers with resin, expansion of the sheared surface is not necessarily required for flatness. If expansion of the sheared surface can be avoided, it becomes possible to widen the clearance of the tool, and improvement of the tool life can also be expected. The above findings are the starting point of the idea of the present invention.

[0013] Hereinafter, embodiments of the amorphous alloy laminate having a sheared surface according to the present invention will be described in detail. This embodiment is directed to an amorphous alloy laminate in which a plurality of amorphous alloy layers are joined to each other by a resin layer.

[0014] The presence of the resin layer integrates the amorphous alloy laminate and can improve handleability and productivity. Further, it is presumed that this configuration suppresses the generation of step differences between the amorphous alloy layers during shearing, and has the effect of forming a fracture surface with less roughness by breaking integrally.

[0015] Further, in this embodiment, at least a part of the laminated surface is assumed to have a sheared surface where a sheared surface and a fracture surface can be confirmed. This means that in the amorphous alloy laminate of this embodiment, it is not necessarily the case that the entire end face is a sheared surface. For example, it does not exclude those having end faces different from the above regulations, such as an end face as cast or an end face by laser processing. In the case of forming a contour line by shearing such as punching, the end face becomes a continuous single sheared surface.

[0016] Here, the sheared surface is a cut surface obtained by shearing such as punching or trimming. Further, in this embodiment, the sheared surface is defined as a surface with streak-like scratches, and the other surfaces are defined as fracture surfaces.

[0017] In this embodiment, in the sheared surface of the amorphous alloy layer located in the uppermost layer, a sheared surface is formed, and a fracture surface is formed at the tip thereof. Forming a sheared surface serves as a starting point for shearing and is necessary to promote the subsequent formation of a fracture surface.

[0018] Here, the outermost layer means the layer where the cutting edge of tools such as punches and dies first enters. For example, in the case of applying punching using a punch and a die, when the amorphous alloy laminate on the punch side is punched as the object (product), the outermost layer is formed on the die side of the punched amorphous alloy laminate. On the other hand, when the amorphous alloy laminate on the die side remains as the object (product), the outermost layer is formed on the punch side of the remaining amorphous alloy laminate.

[0019] The punching using a punch and a die and the outermost layer in the case of punching will be described with reference to FIG. 5. FIG. 5(a) is a schematic diagram showing that, with the punch 2 and the die 3 as a punching die, the amorphous alloy laminate 1 is placed on the die 3 and the punch 2 is moved in the direction of the arrow in the figure to punch the amorphous alloy laminate 1. Here, the amorphous alloy laminate 1 has a lamination plane 4 in its thickness direction. FIG. 5(b) is a schematic diagram showing the state after the amorphous alloy laminate 1 has been punched by the punch 2, indicating that the amorphous alloy laminate 1 is separated into the amorphous alloy laminate 1a on the die side and the amorphous alloy laminate 1b on the punch side.

[0020] At this time, when the amorphous alloy laminate 1b on the punch side becomes the object (product), the outermost layer 5b (gray part) is formed on the die side, and when the amorphous alloy laminate 1a on the die side becomes the object (product), the outermost layer 5a (gray part) is formed on the punch side.

[0021] FIG. 6 is a schematic diagram showing a cross-section of the punched amorphous alloy laminate 1b on the punch side. In the amorphous alloy laminate 1b, the amorphous alloy layer 6 is joined between layers by the resin layer 7, a shearing process surface 8 is formed in the thickness direction of the amorphous alloy laminate 1b, and a sheared surface 9 and a fracture surface 10 are formed on the shearing process surface 8.

[0022] As described above, this embodiment is based on the finding that it is not always necessary to expand the sheared surface for flatness. In this embodiment, the shearing process surface of the amorphous alloy layer excluding the outermost layer may be substantially a fracture surface.

[0023] In addition, the amorphous alloy laminate applied in this embodiment can be applied, for example, when the number of laminate layers is 4 or more and the total thickness as a laminate is 100 μm or more. Typically, considering handling properties as well, it is preferable that the number of laminate layers is 4 to 8 and the total thickness is 100 to 200 μm.

[0024] In addition, the amorphous alloy applied in this embodiment does not limit the shape, composition, etc. For example, as the amorphous alloy layer of this embodiment, an amorphous alloy ribbon manufactured by the above-described single-roll method can be applied. The amorphous alloy ribbon manufactured by this manufacturing method typically has a thickness of 50 μm or less, more typically a thickness of 10 to 35 μm.

[0025] In addition, as a typical amorphous alloy, if it is Fe-based, Fe-semimetal group-based materials such as Fe-Si-B-based, Fe-B-based, and Fe-P-C-based can be applied.

[0026] In addition, the resin applied in this embodiment does not limit its type. For example, it can be selected from polyimide-based resins, epoxy resins, ketone-based resins, polyamide-based resins, nitrile-based resins, thioether-based resins, polyester-based resins, allylate-based resins, sulfone-based resins, imide-based resins, amide-imide-based resins, polyethylene-based resins, polypropylene resins, acrylic resins, etc. Among these, epoxy resins have the advantages of high heat resistance, low cost, and easy availability. In particular, in the case of one-component epoxy resins, it is also easy and useful to manage the working environment and safety. In addition, polyethylene-based resins are also easy to remove even if the equipment used for laminate adhesion gets dirty, and are also easy to store and manage.

Examples

[0027] Examples related to the embodiments of the present invention are shown below. (Example 1) First, 2605HB1M (registered trademark) manufactured by Proterial Co., Ltd., which is an Fe-Si-B-based amorphous alloy ribbon manufactured by the single-roll method, was prepared. The plate thickness is 25 μm and the width is 30 mm.

[0028] Next, resin was applied to the main surface of the amorphous alloy ribbon and laminated, and then sufficiently cured to produce a five-layer amorphous alloy laminated ribbon joined between layers by the resin layer. A polyethylene-based resin was used as the resin. The total thickness of the obtained amorphous alloy laminated ribbon was measured at multiple locations, and the representative value was 140 μm.

[0029] Next, punching was performed using a punching die composed of a microparticle cemented carbide punch and die mainly made of tungsten carbide (WC) with an AlCrSiN-based coating, to produce a sample of the amorphous alloy laminate having the shape shown in Fig. 7. The dimensions of the produced sample were a rectangle of 15 mm × 5 mm, and chamfers with a curvature radius R of 0.5 mm were provided at the corners. Also, as shown in Fig. 7, the sample had a sheared surface 8 in its thickness direction. At this time, the clearance between the punch and the die was 10 μm.

[0030] Fig. 1 shows a metal micrograph obtained by photographing the sheared surface 8 of the amorphous alloy laminate having the sheared surface of Example 1 from the front with a laser microscope. Also, Fig. 2 shows a metal micrograph obtained by embedding the cross-section of the sheared surface 8 in resin, polishing it, and photographing it with a laser microscope.

[0031] Here, the laser microscope used was a shape analysis laser microscope VK-X1100 manufactured by Keyence Corporation. The measurement mode was the laser confocal mode, the magnification was 50 times, the measurement size was 2048 × 1536 pixels, and the observation was performed with a pitch of 0.1 μm.

[0032] As shown in Fig. 1, in the uppermost layer where the die cutting edge first entered, a shear cross-section 9 with streak-like scratches was confirmed, and a fracture cross-section 10 could be confirmed at its tip. Also, no shear cross-section 9 was confirmed in the other layers except the uppermost layer, and it was confirmed that the fracture cross-section 10 was formed. Also, it can be seen that a fracture cross-section with a vein-like pattern is formed on the fracture cross-section 10. Also, in the second layer adjacent to the uppermost layer, although its formation is unclear, a striped pattern was observed in the width direction.

[0033] In Fig. 2, in the shear processed surface, although deformation is recognized at the tip of each layer from the uppermost layer in the thickness direction (lamination direction), it is confirmed that the laminated amorphous alloys form an integral shear processed surface without forming a large step between them. That is, the tip of each layer is deformed so as to cover the tip of the adjacent lower layer side, forming a flat shear processed surface as a whole. Also, as shown in Fig. 2, no large roughness was confirmed on the shear processed surface, especially no unevenness on the fracture cross-section, and it was confirmed that a flat shear processed surface was formed.

[0034] Here, it can be confirmed from Fig. 2 that the lowermost layer has a wedge-shaped tip shape different from the other layers. It is presumed that such a form suppresses the occurrence of large sagging and protrusion to the surface of the lowermost layer, and also suppresses the dimensional variation in the thickness direction (lamination direction) of the tip of each layer. Note that this form is presumed to be because the fracture in the lowermost layer occurs due to uniaxial tensile stress and the shrinkage of the amorphous alloy ribbon that occurs after fracture, different from the fracture due to the bending stress received by the layers other than the lowermost layer.

[0035] (Example 2) Example 2 is an amorphous alloy laminate produced in the same manner as Example 1 except that the clearance between the punch and the die is 15 μm. Here, the punch used is the same as that in Example 1, and the die was replaced with a die whose contour was machined larger than the die used in Example 1 to increase the clearance.

[0036] Fig. 3 shows a metallomicrograph of the sheared surface 8 of the amorphous alloy laminate having the sheared surface of Example 2, taken with a laser microscope from the front. Fig. 4 shows a metallomicrograph of the cross section of the sheared surface 8, filled with resin and polished, and taken with a laser microscope.

[0037] From Fig. 3, as in Fig. 1, a sheared cross section 9 with streak-like scratches is confirmed in the uppermost layer where the die edge first entered, and a fracture surface 10 is confirmed beyond that. Also, no sheared cross section 9 is confirmed outside the uppermost layer, and it can be seen that the other layers exhibit a fracture surface 10. Also, as in Fig. 1, it is confirmed that a fracture surface with a vein-like pattern is formed on the fracture surface 10.

[0038] Also, from Fig. 4, as in Fig. 2, no significant roughness can be confirmed on the sheared surface. Also, at the lowermost layer, a wedge-like tip shape as seen in Fig. 2 can be confirmed.

[0039] From the above, according to the present invention, an amorphous alloy laminate having a sheared surface with excellent productivity and high flatness can be obtained.

Explanation of Reference Numerals

[0040] 1, 1a, 1b Amorphous alloy laminate 2 Punch 3 Die 4 Laminated surface 5a, 5b Uppermost layer 6 Amorphous alloy layer 7 Resin layer 8 Sheared surface 9 Sheared cross section 10 Fracture surface R Radius of curvature

Claims

【Claim 1】 An amorphous alloy laminate in which a plurality of amorphous alloy layers are joined to each other by a resin layer, wherein at least a part of the laminated surface has a shearing processed surface where a shear cross-section and a fracture cross-section can be confirmed, the shearing processed surface of the amorphous alloy layer located in the uppermost layer has a shear cross-section formed therein and a fracture cross-section formed at its tip, and the shearing processed surface of the amorphous alloy layer excluding the uppermost layer is substantially a fracture cross-section, and the amorphous alloy laminate having the shearing processed surface is characterized thereby.

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