Soft magnetic alloy, soft magnetic alloy ribbon, method for producing the same, magnetic core, and component

Abstract

To provide a soft magnetic alloy that has high saturation magnetic flux density and a low iron loss, a soft magnetic alloy ribbon composed of the alloy and a method of manufacturing the same, a magnetic core using the soft magnetic alloy ribbon, and a component.SOLUTION: The soft magnetic alloy of the present disclosure is represented by a composition formula of FeaSibBcCudMe, where M is at least one element selected from the group consisting of Nb, Mo, V, Zr, Hf, and W, satisfying 82.5≤a≤86, 0.3≤b≤3, 12.5≤c≤15.0, 0.05≤d≤0.9, 0≤e<0.4. The soft magnetic alloy includes a structure that has crystal grains with a grain diameter of 60 nm or less in an amorphous phase.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to soft magnetic alloys, soft magnetic alloy ribbons, methods for manufacturing the same, magnetic cores, and components.

Background Art

[0002] Soft magnetic alloys having a nanocrystalline structure exhibit excellent magnetic properties and are used in transformers, electronic components, motors, etc. Those transformers, electronic components, motors, etc. are required to be miniaturized and have higher efficiency. Therefore, further improvement in properties is required for the soft magnetic alloys used in those components (transformers, electronic components, motors, etc.). The properties required for such soft magnetic alloys include high saturation magnetic flux density and low iron loss. Among those components, many are increasing their operating frequencies and promoting miniaturization with the increase in the frequency of semiconductors, etc., and Fe-based amorphous alloys and Fe-based nanocrystalline alloys with low iron loss have attracted attention. In order to achieve commercial spread, soft magnetic alloys excellent in price, productivity, and heat treatability are required.

[0003] In Patent Document 1, the composition formula is Fe 100-a-b-c B a Cu b M’ c where M’ is at least one element selected from Nb, Mo, Ta, W, Ni, and Co, having a composition satisfying 10 ≦ a ≦ 16, 0 < b ≦ 2, and 0 ≦ c ≦ 8, and heating an alloy having an amorphous phase at a heating rate of 10 °C / second or more, and holding it for 0 to 80 seconds at a temperature equal to or higher than the crystallization start temperature and lower than the formation start temperature of the Fe-B compound, a method for manufacturing a soft magnetic material having both high saturation magnetization and low coercive force is described.

[0004] In Patent Document 2, the composition formula is ((Fe (1-(α+β)) X1 α X2 β ) (1-(a+b+c+d+e)) B a Si b C c Cu d M eA soft magnetic alloy comprising: X1 is one or more selected from the group consisting of Co and Ni; X2 is one or more selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Bi, N, O and rare earth elements; M is one or more selected from the group consisting of Nb, Hf, Zr, Ta, Ti, Mo, W and V; 0.140 < a ≦ 0.240, 0 ≦ b ≦ 0.030, 0 < c < 0.080, 0 < d ≦ 0.020, 0 ≦ e ≦ 0.030, α ≧ 0, β ≧ 0, 0 ≦ α + β ≦ 0.50. It is described that this soft magnetic alloy is a soft magnetic alloy having a high saturation magnetic flux density, a low coercive force and a high magnetic permeability μ´ simultaneously.

[0005] In Patent Document 3, Fe 100-x-y-z A x M y X z is represented by, where A is at least one element selected from Cu and Au, M is at least one element selected from Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, X is at least one element selected from B and Si, in atomic %, 0 < x ≦ 5, 0.4 ≦ y < 2.5, 10 ≦ z ≦ 20, and a soft magnetic alloy having a saturation magnetic flux density of 1.7 T or more and a coercive force of 15 A / m or less is disclosed.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0007] According to the soft magnetic material described in Patent Document 1, a soft magnetic material having high saturation magnetization is disclosed. However, since the soft magnetic material described in Patent Document 1 does not contain Si, the SiO 2 film is not formed on the material surface, making it difficult to prevent rust and the like.

[0008] In the soft magnetic alloy described in Patent Document 2, the saturation magnetic flux density (Bs) is not very high. Generally, as the Fe content increases, the saturation magnetic flux density increases. However, in Example 6 where the Fe content is 84 at%, the saturation magnetic flux density (Bs) is 1.76 T. Also, since the B content is relatively high, it is considered that the heat treatability is insufficient.

[0009] In the soft magnetic alloy described in Patent Document 3, since it contains a large amount of M elements such as expensive Nb, the price is high. Also, anisotropy is imparted in the casting direction, and since the ratio of the magnetic flux density when a magnetic field of 80 A / m is applied in the casting direction to the magnetic flux density when a magnetic field of 80 A / m is applied in a direction perpendicular to the casting direction is large, it is not suitable for applications that require isotropy.

[0010] It is desirable to provide a soft magnetic alloy having a high saturation magnetic flux density and low iron loss, a soft magnetic alloy ribbon made of the soft magnetic alloy and a manufacturing method thereof, a magnetic core using the soft magnetic alloy ribbon, and components.

Means for Solving the Problems

[0011] Specific means for solving the above problems include the following aspects. <1> A soft magnetic alloy represented by the composition formula Fe a Si b B c Cu d M e where M is at least one element selected from Nb, Mo, V, Zr, Hf, and W, and 82.5 ≦ a ≦ 86, 0.3 ≦ b ≦ 3, 12.5 ≦ c ≦ 15.0, 0.05 ≦ d ≦ 0.9, 0 ≦ e < 0.4 in atomic percentage, and the soft magnetic alloy has a structure in which crystal grains with a particle size of 60 nm or less are present in an amorphous phase. <2> In <1>, a soft magnetic alloy where 83 ≦ a ≦ 86, 0.3 ≦ b ≦ 2, 0.4 ≦ d ≦ 0.9, and 0 ≦ e ≦ 0.3. <3> In <1> or <2>, a soft magnetic alloy where 13.0 ≦ c ≦ 14.0. <4> In any one of <1> to <3>, a soft magnetic alloy in which part of Fe is replaced by at least one element of Co and Ni in the range of up to 6 atomic %. <5> In any one of <1> to <4>, a soft magnetic alloy having a saturation magnetic flux density of 1.75 T or more. <6> In any one of <1> to <5>, a soft magnetic alloy having a density of 7.45 g / cm 3 or more.

[0012] <7> The alloy composition is represented by the composition formula Fe a Si b B c Cu d M e and M is at least one element selected from Nb, Mo, V, Zr, Hf, and W, and it is a soft magnetic alloy ribbon where 82.5 ≦ a ≦ 86, 0.3 ≦ b ≦ 3, 12.5 ≦ c ≦ 15.0, 0.05 ≦ d ≦ 0.9, and 0 ≦ e < 0.4 in atomic %. The soft magnetic alloy ribbon has a structure in which crystal grains with a particle size of 60 nm or less are present in the amorphous phase, and has a saturation magnetic flux density of 1.75 T or more and an iron loss of 25 W / kg or less at 1 kHz and 1 T. <8> In the soft magnetic alloy ribbon according to <7>, a soft magnetic alloy ribbon having a density of 7.45 g / cm 3 or more. <9> In the soft magnetic alloy ribbon according to <7> or <8>, a soft magnetic alloy ribbon having an occupancy ratio of 86% or more. <10> In the soft magnetic alloy ribbon according to any one of <7> to <9>, a soft magnetic alloy ribbon having a thickness of 25 μm or more. <11> In the soft magnetic alloy ribbon according to any one of <7> to <10>, a soft magnetic alloy ribbon having an occupancy ratio of 88% or more. <12> In the soft magnetic alloy ribbon according to any one of <7> to <11>, the ratio (L / W) of the magnetic flux density L when a magnetic field of 80 A / m is applied in the casting direction of the soft magnetic alloy ribbon to the magnetic flux density W when a magnetic field of 80 A / m is applied in a direction perpendicular to the casting direction of the soft magnetic alloy ribbon is 0.7 to 1.3. A soft magnetic alloy ribbon. <13> In the soft magnetic alloy ribbon according to any one of <7> to <12>, a soft magnetic alloy ribbon having a saturation magnetostriction of 20 ppm or less. <14> In the soft magnetic alloy ribbon according to any one of <7> to <13>, 83 ≦ a ≦ 86, 0.3 ≦ b ≦ 2, 0.4 ≦ d ≦ 0.9, 0 ≦ e ≦ 0.3, and a saturation magnetic flux density of 1.77 T or more. A soft magnetic alloy ribbon. <15> In the soft magnetic alloy ribbon according to any one of <7> to <14>, a soft magnetic alloy ribbon having 13.0 ≦ c ≦ 14.0. <16> In the soft magnetic alloy ribbon according to any one of <7> to <15>, a soft magnetic alloy ribbon in which a part of Fe is substituted with at least one element of Co and Ni in a range of up to 6 atomic%.

[0013] <17> A manufacturing method for obtaining the soft magnetic alloy ribbon according to any one of <7> to <16>, comprising a ribbon manufacturing step of ejecting a molten alloy onto a rotating cooling roll and cooling the molten alloy on the cooling roll to obtain an alloy ribbon, wherein the outer peripheral portion of the cooling roll is made of a Cu alloy having a thermal conductivity of 120 W / (m·K) or more. A method for manufacturing a soft magnetic alloy ribbon. <18> In a method for manufacturing a soft magnetic alloy ribbon having a structure in which crystal grains having a particle size of 60 nm or less are present in an amorphous phase by heat-treating an alloy ribbon, In the heat treatment, a temperature 10 to 140 °C lower than the bccFe crystallization start temperature is defined as temperature T1, and a temperature 30 to 120 °C lower than the FeB precipitation start temperature is defined as temperature T2. Heat from room temperature to temperature T1 at a heating rate of 50 °C / sec or more. Heat from temperature T1 to temperature T2 at a heating rate slower than the heating rate to temperature T1 and 400 °C / sec or less. Cool after reaching temperature T2, or A method for manufacturing a soft magnetic alloy ribbon, which comprises maintaining at a temperature between T2 - 50°C and T2 for 0.5 to 60 seconds after reaching temperature T2, and then cooling. <19> The alloy ribbon before the heat treatment is obtained by ejecting an alloy melt onto a rotating cooling roll and cooling the alloy melt on the cooling roll, and the outer peripheral part of the cooling roll is made of a Cu alloy having a thermal conductivity of 120 W / (m·K) or more. The method for manufacturing a soft magnetic alloy ribbon according to <18>. <20> The method for manufacturing a soft magnetic alloy ribbon according to <18> or <19>, wherein when the density of the alloy ribbon before the heat treatment is M1 and the density of the alloy ribbon after the heat treatment is M2, M2 / M1 is 1.005 or more. <21> The alloy composition of the soft magnetic alloy ribbon is represented by the composition formula FeaSibBcCudMe, where M is at least one element selected from Nb, Mo, V, Zr, Hf, and W, and 82.5 ≦ a ≦ 86, 0.3 ≦ b ≦ 3, 12.5 ≦ c ≦ 15.0, 0.05 ≦ d ≦ 0.9, 0 ≦ e < 0.4 in atomic%. The method for manufacturing a soft magnetic alloy ribbon according to any one of <18> to <20>.

[0014] <22> A magnetic core composed of the soft magnetic alloy ribbon according to any one of <7> to <16>. <23> A component including the magnetic core according to <22> and a winding.

Advantages of the Invention

[0015] According to one aspect of the present disclosure, a soft magnetic alloy and a soft magnetic alloy ribbon having a high saturation magnetic flux density and low iron loss can be obtained. Also, according to one aspect of the present disclosure, an isotropic soft magnetic alloy ribbon can be obtained. Further, according to a magnetic core and a component using the soft magnetic alloy ribbon of one aspect of the present disclosure, a magnetic core and a component having a high saturation magnetic flux density and low iron loss characteristics can be obtained.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Mode for Carrying Out the Invention

[0017] Hereinafter, embodiments of the present disclosure will be described in detail. The present disclosure is not limited to the following embodiments, and can be implemented with appropriate modifications within the scope of the object of the present disclosure.

[0018] In the present disclosure, a numerical range indicated by using "~" indicates a range including the numerical values described before and after "~" as the lower limit value and the upper limit value, respectively. In the numerical ranges described stepwise in the present disclosure, the upper limit value or the lower limit value described in a certain numerical range may be replaced with the upper limit value or the lower limit value of the numerical range described in other stepwise descriptions. Further, in the numerical ranges described in the present disclosure, the upper limit value or the lower limit value described in a certain numerical range may be replaced with the value shown in the examples. In the present disclosure, a combination of two or more preferred modes is a more preferred mode.

[0019] The soft magnetic alloy of the present disclosure has a composition formula Fe a Si b B c Cu d M e and is represented by M is at least one element selected from Nb, Mo, V, Zr, Hf, and W, and is a soft magnetic alloy having 82.5 ≦ a ≦ 86, 0.3 ≦ b ≦ 3, 12.5 ≦ c ≦ 15.0, 0.05 ≦ d ≦ 0.9, and 0 ≦ e < 0.4 in atomic percentage, The soft magnetic alloy has a structure in which crystal grains having a particle size of 60 nm or less are present in the amorphous phase.

[0020] First, regarding the composition of the present disclosure, it will be described in detail below. Fe (iron) is 82.5% or more and 86% or less in atomic percentage. By setting the Fe content to 82.5% or more, a saturation magnetic flux density of 1.75 T or more can be achieved. Preferably it is 83% or more, more preferably 83.5% or more, and even more preferably 84% or more. Also, when the Fe content exceeds 86%, it becomes difficult to form an amorphous state, so the Fe content is set to 86% or less. Preferably it is 85.5% or less.

[0021] Si (silicon) is 0.3% or more and 3% or less in atomic percentage. By containing Si, an oxide film of SiO with a thickness of several tens of nm can be formed on the alloy surface. 2 This can improve the corrosion resistance of the soft magnetic alloy. To obtain this effect of improving the corrosion resistance, Si is contained at 0.3% or more. Preferably it is 1.0% or more. When the Si content exceeds 3%, it becomes difficult to obtain a saturation magnetic flux density exceeding 1.75 T, and it also becomes difficult to increase the thickness of the soft magnetic alloy strip. Therefore, the Si content is set to 3% or less. Preferably it is 2% or less, and more preferably 1.4% or less.

[0022] B (boron) is 12.5% or more and 15.0% or less in atomic percentage. When the B content is less than 12.5%, it becomes difficult to form an amorphous state, so the B content is set to 12.5% or more. Preferably it is 13.0% or more, and more preferably 13.5% or more. When the B content exceeds 15.0%, the difference between the bccFe (αFe) crystallization start temperature and the FeB precipitation start temperature becomes small, and the range of the optimum heat treatment temperature becomes narrow. For this reason, it becomes difficult to obtain a uniform and fine nanocrystalline structure that can achieve an iron loss of 25 W / kg or less at 1 T and 1 kHz. Therefore, the B content is set to 15.0% or less. Preferably it is 14.5% or less, more preferably 14.4% or less, and even more preferably 14.0% or less.

[0023] Cu (copper) is 0.05% or more and 0.9% or less in atomic percentage. If the Cu content is less than 0.05%, it becomes difficult to obtain a uniform and fine nanocrystalline structure capable of achieving an iron loss of 25 W / kg or less at 1 T and 1 kHz. Therefore, the Cu content should be 0.05% or more. Preferably it is 0.2% or more, more preferably 0.4% or more, and even more preferably 0.5% or more. When the Cu content exceeds 0.9%, it tends to embrittle, making it difficult to increase the thickness of the soft magnetic alloy ribbon. Therefore, the Cu content should be 0.9% or less. Preferably it is 0.7% or less, more preferably 0.6% or less.

[0024] The M element is at least one element selected from Nb, Mo, V, Zr, Hf, and W, and is 0% or more and less than 0.4% in atomic percentage. The M element may be 0%, but by containing the M element, the precipitation start temperature of the FeB compound that significantly deteriorates the magnetic properties can be shifted to the higher temperature side. Thereby, the difference between the bccFe(αFe) crystallization start temperature and the FeB precipitation start temperature can be widened, which has the effect of expanding the range of the optimum heat treatment temperature and can relax the heat treatment conditions. Preferably it is 0.1% or more, more preferably 0.15% or more. Since the M element is expensive, the price increases according to the content. Therefore, it is preferable to have a small content. Accordingly, the content of the M element should be less than 0.4%. Preferably it is 0.3% or less, more preferably 0.25% or less.

[0025] In the soft magnetic alloy of the present disclosure, part of Fe may be substituted with at least one element of Co and Ni in the range up to a maximum of 6 atomic %. In the soft magnetic alloy of the present disclosure, it is also possible to substitute part of Fe with at least one element of Co and Ni in the range up to a maximum of 5 atomic %.

[0026] The soft magnetic alloy of the present disclosure may contain C (carbon). C is preferably 1 mass% or less.

[0027] The soft magnetic alloy of the present disclosure has the composition formula Fe a Si b Bc Cu d M e In addition to the elements represented by, it may contain impurities other than Co, Ni, and C described above. As impurities, elements other than the elements described above are targeted. For example, S (sulfur), O (oxygen), N (nitrogen), Cr, Mn, P, Ti, Al, etc. may be mentioned. For example, the content of S is preferably 200 mass ppm or less, the content of O is preferably 5000 mass ppm or less, and the content of N is preferably 1000 mass ppm or less. The total content of impurities is preferably 0.5 mass% or less. Also, as long as it is within the above range, elements corresponding to impurities may be added.

[0028] The soft magnetic alloy of the present disclosure has a structure in which crystal grains with a particle size of 60 nm or less are present in the amorphous phase. This structure in which crystal grains with a particle size of 60 nm or less are present in the amorphous phase is also referred to as a nanocrystalline structure. Also, a crystal with a crystal grain size of 60 nm or less is also referred to as a nanocrystal. One feature of the soft magnetic alloy of the present disclosure is that it has a nanocrystalline structure. Also, in the soft magnetic alloy of the present disclosure, the ratio of nanocrystals is preferably 50% or more by volume ratio. This volume ratio can be calculated, for example, by observing the alloy cross-section using a transmission electron microscope (TEM) to observe the nanocrystals and the amorphous phase and estimating the approximate ratio. That is, it is possible to determine whether it is 50% or more from the observed image. Also, when observing the alloy cross-section, in a specific field-of-view area, the area ratio of crystal grains with a crystal grain size of 60 nm or less is preferably 50% or more (value with the specific field-of-view area as 100%). The soft magnetic alloy of the present disclosure includes crystal grains with a crystal grain size of 60 nm or less and an amorphous phase, and the area ratio of crystal grains with a crystal grain size of 60 nm or less is preferably 50% or more. By observing the alloy cross-section using, for example, a transmission electron microscope (TEM), the crystal grains and the amorphous phase can be observed and the area ratio can be determined.

[0029] In the soft magnetic alloy of the present disclosure, the saturation magnetic flux density is preferably 1.75 T or more. Further, in the soft magnetic alloy of the present disclosure, the saturation magnetic flux density is preferably 1.77 T or more. The soft magnetic alloy of the present disclosure has a density of 7.45 g / cm 3 or more, which is preferable. When the density is 7.45 g / cm 3 or more, the volume fraction of the nanocrystals increases, and the saturation magnetic flux density increases.

[0030] In the soft magnetic alloy of the present disclosure, the iron loss at 1 kHz and 1 T is preferably 25 W / kg or less. Further, this iron loss is preferably 18 W / kg or less. Further, this iron loss is preferably 15 W / kg or less. Further, in the soft magnetic alloy of the present disclosure, the saturation magnetostriction is preferably 20 ppm or less. Thereby, isotropy is easily obtained. According to the soft magnetic alloy of the present disclosure, a soft magnetic alloy having a high saturation magnetic flux density and a low iron loss can be obtained.

[0031] The soft magnetic alloy of the present disclosure can be in the form of an alloy ribbon described below, a pulverized powder obtained by pulverizing the alloy ribbon, or a powder produced using an atomization method or the like.

[0032] The soft magnetic alloy ribbon of the present disclosure can be obtained by ejecting a molten alloy having the above-described soft magnetic alloy composition onto a rotating cooling roll, rapidly solidifying it on the cooling roll to obtain an alloy ribbon, and heat-treating the alloy ribbon. The molten alloy can be prepared by blending each element source (pure iron, ferroboron, ferrosilicon, etc.) to obtain the target alloy composition, heating it in an induction heating furnace, and melting it to a temperature above the melting point to obtain a molten alloy.

[0033] The molten alloy is ejected from a slit-shaped nozzle of a predetermined shape onto a rotating cooling roll, and the molten alloy is rapidly solidified on the cooling roll to obtain an alloy ribbon. At this time, the cooling roll can have an outer diameter of 350 to 1000 mm, a width of 100 to 400 mm, and a peripheral speed of rotation of 20 to 35 m / s. It is preferable that this cooling roll is provided with a cooling mechanism (such as water cooling) inside to suppress the temperature rise of the outer peripheral portion. Also, it is preferable that the outer peripheral portion of the cooling roll is made of a Cu alloy having a thermal conductivity of 120 W / (m·K) or more. By setting the thermal conductivity of the outer peripheral portion to 120 W / (m·K) or more, the cooling rate when the molten alloy is cast into the alloy ribbon can be increased. By doing so, embrittlement of the alloy ribbon can be suppressed, thickening of the alloy ribbon becomes possible, and coarsening of crystal grains during heat treatment can be suppressed by suppressing surface crystallization during casting, and iron loss can be reduced. Also, the thermal conductivity of the outer peripheral portion of the cooling roll is preferably 150 W / (m·K) or more, and more preferably 180 W / (m·K) or more. In particular, when the thickness of the soft magnetic alloy ribbon is 30 μm or more, it is preferable that the thermal conductivity of the outer peripheral portion is 150 W / (m·K) or more. Note that the outer peripheral portion of the cooling roll is the portion in contact with the molten alloy, and its thickness may be about 5 to 15 mm, and a structural material for maintaining the roll structure may be used inside.

[0034] After rapidly solidifying the molten alloy on the cooling roll to produce an alloy ribbon, a soft magnetic alloy ribbon having a nanocrystalline structure can be obtained by subjecting the alloy ribbon to heat treatment. During this heat treatment, it is preferable to raise the temperature to a temperature equal to or higher than the bccFe(αFe) crystallization start temperature and adjust the temperature so that the alloy ribbon does not reach the FeB precipitation start temperature, and then perform the heat treatment. Conventional heat treatment of alloy ribbons is generally carried out in a heat treatment process of heating from room temperature to a temperature 30 to 100 °C lower than the FeB precipitation start temperature at a heating rate of 10 °C / sec. or more and holding for several seconds after heating. However, in the case of an alloy ribbon with reduced Cu and Nb and increased Fe content to obtain a high saturation magnetic flux density, the temperature difference between the bccFe(αFe) crystallization start temperature and the FeB precipitation start temperature becomes small, and the range of the optimal heat treatment temperature (maximum temperature) becomes very narrow. For this reason, there has arisen a problem that the heat treatment temperature (maximum temperature) must be adjusted within a narrow temperature range. Further, in the case of a wide alloy ribbon manufactured in actual production, since cooling in the width direction, thickness variation, and composition variation for each lot occur, it is even more difficult to adjust the heat treatment temperature within a narrow temperature range, and there has been a problem that it is difficult to perform uniform heat treatment.

[0035] In the heat treatment of the alloy ribbon of the present disclosure, a temperature 10 to 140 °C lower than the bccFe(αFe) crystallization start temperature is defined as temperature T1, and a temperature 30 to 120 °C lower than the FeB precipitation start temperature is defined as temperature T2. Heating is performed from room temperature to temperature T1 at a heating rate of 50 °C / sec or more, and from temperature T1 to temperature T2 at a heating rate slower than the heating rate from room temperature to temperature T1 and 400 °C / sec or less, and then cooling is preferably performed. After reaching temperature T2, it may be cooled as it is, or after reaching temperature T2, it may be held at a temperature between temperature T2 - 50 °C and temperature T2 for 0.5 to 60 seconds, and then cooled. T1 may be a temperature 10 to 120 °C lower than the bccFe(αFe) crystallization start temperature. T2 may be a temperature 10 to 120 °C lower than the FeB precipitation start temperature, or 10 to 100 °C lower than the FeB precipitation start temperature. Here, the heating rate is the average heating rate between those temperatures. For example, the heating rate from room temperature to temperature T1 can be calculated with the time (seconds) from room temperature to temperature T1 as the denominator and the temperature obtained by subtracting room temperature (25 °C) from temperature T1 as the numerator. According to the heat treatment method of the alloy ribbon of the present disclosure, a soft magnetic alloy ribbon with a high saturation magnetic flux density and low iron loss can be stably manufactured. Incidentally, the heat treatment of the alloy ribbon of the present disclosure can also be performed after processing the alloy ribbon into a magnetic core shape. This magnetic core shape includes a ribbon obtained by processing the alloy ribbon into a magnetic core shape by pressing or the like, a magnetic core formed by laminating the ribbon of the magnetic core shape, a wound magnetic core formed by winding the ribbon, and the like.

[0036] FIG. 1 shows an example of a heat treatment pattern and a comparative example of a heat treatment pattern according to an embodiment of the present disclosure. In FIGS. 2 (comparative example of heat treatment pattern) and 3 (one embodiment of the present disclosure), the holding temperature at that time is taken as the X-axis, and the magnetic flux density B when a magnetic field of 8000 A / m is applied 8000 and the iron loss (CL) at 1 T and 1 kHz are taken as the Y-axis, and the heat treatment conditions and B at that time are shown in Table 1 (comparative example of heat treatment pattern) and Table 2 (one embodiment of the present disclosure) 8000 , and the values of the iron loss are shown. The alloy composition of this sample is the same as No. 3 in Table 3 described below, the crystallization start temperature of bccFe(αFe) is 460 °C, and the precipitation start temperature of FeB is 580 °C. As shown in FIGS. 2 and Table 1, in the heat treatment patterns of Comparative Examples C1 to C5, as the holding temperature increases from 470 °C to 500 °C, B 8000 also gradually increases from 1.76 T to 1.83 T. The iron loss when the holding temperature is 500 °C was significantly higher than that when the holding temperature was 470 °C to 490 °C. When B 8000 exceeds 1.82 T, the iron loss increases rapidly above the holding temperature, and the temperature range that can achieve both a high saturation magnetic flux density and a low iron loss is very narrow. On the other hand, as shown in FIGS. 3 and Table 2, in the heat treatment patterns of Embodiments E1 to E4 of the present disclosure, T1 of E1, E2, E3, and E4 is, in order, 100 °C, 90 °C, 80 °C, and 50 °C lower than the crystallization start temperature of bccFe(αFe) (460 °C), and T2 of E1, E2, E3, and E4 is, in order, 90 °C, 80 °C, 70 °C, and 40 °C lower than the precipitation start temperature of FeB (580 °C). The holding time of T1 in the heat treatment patterns of E1 to E4 was 0 sec., and the holding time of T2 was 0.5 sec. In the heat treatment patterns of Embodiments E1 to E4 of the present disclosure, when the holding temperature of T2 is 490 °C to 540 °C, B 8000 shows a substantially stable high value of 1.82 T to 1.83 T, and the iron loss also shows substantially the same value between 9.8 W / kg and 11 W / kg. From this, B 8000It exceeds 1.82 T, and there is a temperature range of 50°C or more for the holding temperature at which the iron loss is 25 W / kg or less, and a high saturation magnetic flux density and a low iron loss can be stably obtained. The sample obtained by the heat treatment pattern of one embodiment of the present disclosure had a structure in which crystal grains with a particle size of 60 nm or less were present in the amorphous phase. Further, when each sample was observed in cross section, the area ratio of crystal grains with a crystal grain size of 60 nm or less was 50% or more (value with the observation field area as 100%). In FIG. 3 and Table 2, the holding temperature is T2.

[0037]

Table 1

[0038]

Table 2

[0039] The heating rate during heat treatment is preferably fast from the viewpoints of heat treatment productivity, the nucleation density generated, and suppression of crystal grain coarsening. However, if the heating rate is too fast, crystallization occurs in a short time, the heat generation amount per unit time increases, the temperature of the alloy ribbon rises too much, reaches the FeB precipitation start temperature, induces FeB precipitation, or even if it does not reach the FeB precipitation start temperature, the temperature rises, the growth of crystal grains is accelerated, and the iron loss deteriorates. Therefore, in the heat treatment of the present disclosure, the heating rate is suppressed from the first temperature T1 to suppress FeB precipitation. Further, by suppressing the heating rate, crystal growth can be suppressed and crystal variation can be suppressed. As a result, it is possible to improve shape defects that occur during heat treatment, such as an increase in iron loss and wrinkles caused by shrinkage differences. The heating rate from room temperature to temperature T1 is preferably as fast as possible, for example, 50°C / sec. or more. It may be selected according to the equipment capacity. Preferably it is 200°C / sec. or more, more preferably 300°C / sec. or more, and still more preferably 400°C / sec. or more. Also, the heating rate from temperature T1 to temperature T2 is 400 °C / sec or less, preferably 200 °C / sec or less, more preferably 150 °C / sec or less, and even more preferably 100 °C / sec or less. Further, the heating rate from temperature T1 to temperature T2 is preferably 10 °C / sec or more, more preferably 30 °C / sec or more, and even more preferably 50 °C / sec or more. When the heating rate from room temperature to temperature T1 is 200 °C / sec or more, the heating rate from temperature T1 to temperature T2 is less than 200 °C / sec, preferably 150 °C / sec or less, and more preferably 100 °C / sec or less. When the heating rate from temperature T1 to temperature T2 is 300 °C / sec or more, the heating rate from temperature T1 to temperature T2 is less than 300 °C / sec, preferably 200 °C / sec or less, more preferably 150 °C / sec or less, and most preferably 100 °C / sec or less.

[0040] In the soft magnetic alloy ribbon of the present disclosure, as described above, heat treatment is performed at a high heating rate, and the heat treatment at a high heating rate is carried out up to a temperature below the temperature at which the temperature rise due to the crystallization of bccFe(αFe) starts. Below the temperature at which the temperature rise due to the crystallization of bccFe(αFe) starts, the heating rate is slower than the previous heating rate and 400 °C / sec or less. By controlling the heat generation due to crystallization, the precipitation of FeB compounds and the grain growth of αFe crystals are suppressed. Thereby, in the soft magnetic alloy ribbon of the present disclosure, the heat treatment temperature range in which a high saturation magnetic flux density and low iron loss can be obtained can be widened by the heat treatment method of the present disclosure, the temperature range to be controlled becomes wider, and a soft magnetic alloy ribbon excellent in heat treatability can be obtained.

[0041] In the soft magnetic alloy ribbon of the present disclosure, when the density of the alloy ribbon before heat treatment is M1 and the density of the alloy ribbon after heat treatment is M2, it is preferable that M2 / M1 is 1.005 or more. By the heat treatment method of the present disclosure described above, the density of the alloy ribbon can be improved. Thereby, a high saturation magnetic flux density can be obtained.

[0042] The soft magnetic alloy ribbon of the present disclosure has a high saturation magnetic flux density and low iron loss. As this saturation magnetic flux density, 1.75 T or more can be obtained, and as the iron loss, 25 W / kg or less at 1 kHz and 1 T can be obtained. Further, it is preferable that this iron loss is 18 W / kg or less. Further, the soft magnetic alloy ribbon of the present disclosure has a density of 7.45 g / cm 3 or more, preferably. When the density is 7.45 g / cm 3 or more, the volume fraction of nanocrystals increases, and the saturation magnetic flux density increases. Further, the soft magnetic alloy ribbon of the present disclosure preferably has a saturation magnetic flux density of 1.77 T or more. Further, the soft magnetic alloy ribbon of the present disclosure preferably has an iron loss at 1 kHz and 1 T of 15 W / kg or less.

[0043] Further, the soft magnetic alloy ribbon of the present disclosure preferably has a saturation magnetostriction of 20 ppm or less. Thereby, isotropy is easily obtained.

[0044] Further, the soft magnetic alloy ribbon of the present disclosure has the above-described configuration and characteristics of the soft magnetic alloy. Since their descriptions overlap, the above description is applied. Further, the soft magnetic alloy ribbon of the present disclosure preferably has a thickness of 15 μm or more, more preferably 20 μm or more, still more preferably 25 μm or more, and still more preferably 30 μm or more. For example, when the thickness is 25 μm or more, the man-hours and manufacturing costs for manufacturing a magnetic core by laminating soft magnetic alloy ribbons can be reduced. Even more preferably, it is 32 μm or more. Further, as the thickness of the soft magnetic alloy ribbon increases, it becomes difficult to manufacture the alloy ribbon. Therefore, 50 μm or less is preferable. More preferably, it is 35 μm or less. Further, for applications where it is necessary to further reduce iron loss in a high-frequency band exceeding 1 kHz, a soft magnetic alloy ribbon having a plate thickness of about 15 to 25 μm is preferable.

[0045] In addition, the soft magnetic alloy ribbon of the present disclosure can achieve a high packing ratio. In the soft magnetic alloy ribbon of the present disclosure, the packing ratio can be 86% or more. Further, the soft magnetic alloy ribbon of the present disclosure preferably has a packing ratio of 88% or more, and more preferably 90% or more. Due to the high packing ratio, when the soft magnetic alloy ribbons are stacked, compared with alloy ribbons having a low packing ratio, even with the same number of stacked layers, the stacking thickness can be reduced, contributing to the miniaturization of the magnetic core and the miniaturization of components. Note that the packing ratio can be measured by the following method in accordance with JIS C 2534:2017. Twenty ribbons cut to a length of 120 mm are stacked on a flat sample stage, and a flat anvil with a diameter of 16 mm is placed on the stacked ribbons under a pressure of 50 kPa, and the height is measured at intervals of 10 mm in the width direction. The maximum height at that time is defined as hmax (μm), and the packing ratio LF is obtained from the following calculation formula. LF (%) = weight of sample (g) / density (g / cm 3 ) / hmax (μm) / sample length (240 cm) / ribbon width (cm) × 10000 At this time, the density (g / cm 3 ) is the density of the alloy ribbon after heat treatment.

[0046] In addition, for the soft magnetic alloy ribbon of the present disclosure, the ratio (L / W) of the magnetic flux density L when a magnetic field of 80 A / m is applied in the casting direction of the soft magnetic alloy ribbon and the magnetic flux density W when a magnetic field of 80 A / m is applied in the direction perpendicular to the casting direction of the soft magnetic alloy ribbon is preferably 0.7 to 1.3. By having the ratio (L / W) in the range of 0.7 to 1.3, a soft magnetic alloy ribbon with high isotropy can be obtained.

[0047] Generally, in an alloy ribbon produced by ejecting an alloy melt onto a rotating cooling roll as described above and rapidly solidifying it, anisotropy is introduced in the casting direction. Note that the casting direction is the direction along the rotation direction of the cooling roll and becomes the longitudinal direction of the continuously cast alloy ribbon. As described above, in the soft magnetic alloy ribbon in which anisotropy in the casting direction is introduced during casting, the introduced anisotropy also affects the properties after heat treatment (after heat treatment to form a nanocrystalline structure). In particular, when the volume fraction of the amorphous phase is high, the magnetic flux density differs between the casting direction of the alloy ribbon (the longitudinal direction of the alloy ribbon) and the direction perpendicular to the casting direction (the direction perpendicular to the longitudinal direction and corresponding to the width direction of the alloy ribbon), and anisotropy remains even after heat treatment.

[0048] However, there are also applications such as motor applications that require an isotropic soft magnetic alloy ribbon. Therefore, it is preferable to perform a heat treatment to increase the volume fraction of crystals so that the difference in magnetic flux density between the casting direction and the direction perpendicular to the casting direction is within a certain range. On the other hand, in order to increase the volume fraction of nanocrystals, when the temperature is increased or the heat treatment time is extended, FeB compounds precipitate under certain conditions, and the magnetic properties deteriorate. In particular, in soft magnetic alloy ribbons with a large amount of Fe, the temperature range for heat treatment to achieve isotropy is narrow, and there has been a problem that it is difficult to obtain a soft magnetic alloy ribbon having a high saturation magnetic flux density, low iron loss, and a nanocrystalline structure with isotropy.

[0049] According to the present disclosure, it is possible to solve the above problems, suppress the precipitation of FeB compounds, and obtain a soft magnetic alloy ribbon having both a high saturation magnetic flux density and low iron loss. Furthermore, it is possible to obtain a soft magnetic alloy ribbon having isotropy.

[0050] In the soft magnetic alloy ribbon of the present disclosure, the allowable range of the heat treatment temperature during heat treatment for obtaining desired properties is wide, and mass productivity is high even considering variations during mass production. In particular, in the case of a wide alloy ribbon used for a motor core or the like, since temperature variations during heat treatment are likely to occur, it is effective that the allowable range of the heat treatment temperature during heat treatment is wide.

[0051] Generally, when the heating rate or temperature variation occurs within the alloy ribbon, it becomes impossible to control the heat generation due to partial crystallization, and variations occur in the shrinkage during crystallization, which can cause wrinkles in the alloy ribbon, etc., and problems such as a decrease in the occupation ratio when used as a magnetic core are likely to occur. However, in the soft magnetic alloy ribbon of the present disclosure, as described above, the allowable range with respect to temperature variation during heat treatment is wide, wrinkles are suppressed, a soft magnetic alloy ribbon with a high packing factor and high smoothness can be obtained. The smoothness can be defined as (hmax - hmin) / 20 from the maximum value hmax and the minimum value hmin of the thickness in the width direction measured during the packing factor measurement. This smoothness is preferably 4 μm or less. More preferably, it is 3 μm or less.

[0052] By using the soft magnetic alloy ribbon of the present disclosure to form a magnetic core used in a transformer, electronic components, a motor, etc., a magnetic core having excellent characteristics can be obtained. When forming a magnetic core, the magnetic core can be formed by cutting the alloy ribbon into a predetermined shape and stacking it, winding the alloy ribbon, stacking and bending the alloy ribbon, etc. Also, the soft magnetic alloy ribbon of the present disclosure can be pulverized into a powder form, and a magnetic core can be formed using the powder. Further, using the atomization method, a powder made of the soft magnetic alloy of the present disclosure can be produced, and a magnetic core can be formed using the powder. Also, by combining the magnetic core of the present disclosure and a winding, components such as a transformer, electronic components, a motor, etc. can be formed, and components having excellent characteristics can be obtained. In this case, the magnetic core of the present disclosure and a magnetic core made of other magnetic materials may be combined.

Example

[0053] 〔Example 1〕 Element sources were blended to obtain the respective compositions shown in Table 3, and heated to 1300 °C to produce an alloy melt. The alloy melt was ejected onto a cooling roll having an outer diameter of 400 mm and a width of 200 mm rotating at a peripheral speed of 30 m / s, and rapidly solidified on the cooling roll to produce an alloy ribbon. Each alloy ribbon was heat-treated under the heat treatment conditions shown in Table 4 to produce a soft magnetic alloy ribbon having a nanocrystalline structure. The width and thickness of the produced alloy ribbon are shown in Table 4. Note that the outer peripheral portion of the cooling roll is made of a Cu alloy having a thermal conductivity of 150 W / (m·K), and is provided with a cooling mechanism for controlling the temperature of the outer peripheral portion inside.

[0054] In Tables 3 and 4, No.1 to 6, No.10 to 23 correspond to the soft magnetic alloy ribbons of the present disclosure, and No.51 to 53 correspond to the comparative examples. For each sample, B 8000 , the iron loss, density, bccFe(αFe) crystallization start temperature, FeB precipitation start temperature, temperature T1, temperature T2, heating rate from room temperature to temperature T1, and heating rate between T1 - T2 at 1T / 1kHz are shown in Table 4. The heating rate from room temperature to temperature T1 was 400 - 500 °C / sec. The density is the density after heat treatment. In addition, each of the samples No.1 to 6, No.10 to 23 had a structure in which crystal grains with a particle size of 60 nm or less were present in the amorphous phase. Also, when each sample was observed in cross-section, the area ratio of crystal grains with a crystal grain size of 60 nm or less was 50% or more (value with the observed field area as 100%).

[0055] [bccFe(αFe) crystallization start temperature, FeB precipitation start temperature] The bccFe(αFe) crystallization start temperature and FeB precipitation start temperature change with the heating rate. However, the upper limit of the heating rate of a general thermal analyzer is about 2 °C / sec., and since the heating rate during the heat treatment of the present disclosure cannot be measured, the values at a heating rate of 50 °C / sec. were obtained by the following method and used as the bccFe(αFe) crystallization start temperature and FeB precipitation start temperature. Using Rigaku DSC8231, the bccFe(αFe) crystallization start temperature and FeB precipitation start temperature were measured at three points with heating rates of 5 °C / min. (0.083 °C / sec.), 20 °C / min. (0.333 °C / sec.), and 50 °C / min. (0.833 °C / sec.). The values were plotted with the logarithm of the X-axis heating rate and the bccFe(αFe) crystallization start temperature or FeB precipitation start temperature on the Y-axis, and the value at a heating rate of 50 °C / sec. was obtained by extrapolating from the approximate curve.

[0056] Using the soft magnetic alloy ribbon after heat treatment, the saturation magnetic flux density (B 8000 ), iron loss, and density were measured. [Saturation magnetic flux density (B 8000 )] Using the direct current magnetization characteristic test device manufactured by Metoron Giken, a magnetic field of 8000 A / m was applied to the soft magnetic alloy thin strip (single plate sample) after heat treatment, and the maximum magnetic flux density at that time was measured, denoted as B 8000 Since the soft magnetic alloy thin strip of the present disclosure has relatively easy saturation characteristics, it is saturated at the time of applying a magnetic field of 8000 A / m, and B 8000 and the saturation magnetic flux density are almost the same value, so the saturation magnetic flux density is denoted as B 8000 . 〔Iron loss〕 Using the alternating current magnetic measurement device TWM18SR manufactured by Toei Industry Co., Ltd., the iron loss was measured under the conditions of a magnetic flux density of 1 T and a frequency of 1 kHz using the soft magnetic alloy thin strip (single plate sample) after heat treatment. 〔Density〕 Using the dry type densitometer AccuPyc1330 manufactured by Shimadzu Corporation, a core-shaped sample with dimensions that can be inserted into a cylindrical sample cell with a diameter of 17 mm and a height of 33 mm was created by the constant volume expansion method, its volume was measured, and the value obtained by dividing the weight of the core by its volume was calculated as the density. The density obtained for the alloy thin strip before heat treatment is density M1, and the density obtained for the alloy thin strip after heat treatment is density M2.

[0057]

Table 3

[0058]

Table 4

[0059] In the examples (No. 1 to 6, 10 to 23) of the present disclosure, a high saturation magnetic flux density and a low iron loss were obtained. Also, the density was 7.45 g / cm 3 or higher. In Comparative Examples No. 51 and 52, the saturation magnetic flux density is low. In Comparative Example No. 53, the iron loss is slightly high, but the characteristic values are almost the same as those of the examples of the present disclosure. However, since the Si content is low, rusting occurred after several days of storage in the air, causing problems in handling.

[0060] The ratio (L / W) of the magnetic flux density L when a magnetic field of 80 A / m is applied in the casting direction of the soft magnetic alloy thin strips (single plate samples) of No. 1 to 6, No. 20 to 22, and No. 51 to 53, and the magnetic flux density W when a magnetic field of 80 A / m is applied in the direction perpendicular to the casting direction, and M1 represents the density of the alloy thin strip before heat treatment, and M2 represents the density of the alloy thin strip after heat treatment. M2 / M1 is shown in Table 5.

[0061] 〔Magnetic flux density L, W〕 Using the direct current magnetization characteristic test device developed by Metron Technology, a magnetic field of 80 A / m was applied to the soft magnetic alloy thin strip (single plate sample) after heat treatment in the casting direction and the direction perpendicular to the casting direction respectively, and the magnetic flux densities at that time were set as L and W respectively. The anisotropy was evaluated by the ratio (L / W) of L and W.

[0062] In the examples (No. 1 to 6, 20 to 22) of the present disclosure, the ratio (L / W) is in the range of 0.7 to 1.3, a soft magnetic alloy thin strip with high anisotropy is obtained, and the density ratio (M2 / M1) is also 1.005 or more. For No. 51 and 53 in the comparative examples, the ratio (L / W) exceeded 1.3.

[0063]

Table 5

[0064] The values of the saturation magnetostriction of No. 1 to 4, 12, 15, 20 to 23 are shown in Table 6. 〔Saturation magnetostriction〕 A magnetic field of 5 kOe was applied to the sample with a strain gauge attached by a Republic Electric Industry electromagnet, the electromagnet was rotated 360°, and when the direction of the magnetic field applied to the sample was changed by 360°, the maximum change amount of the elongation and contraction of the sample was measured from the change in the electrical resistance value of the strain gauge. The saturation magnetostriction was set as 2 / 3 × the maximum change amount.

[0065] In the examples (No. 1 to 4, 12, 15, 20 to 23) of the present disclosure, the saturation magnetostriction was 20 ppm or less.

[0066]

Table 6

[0067] [[Example 2]] Fe 82.93 Si 2.30 B 13.70 Nb 0.38 Cu 0.69 Element sources were blended to have a composition consisting of these elements, and the molten alloy heated to 1300 °C was injected onto a cooling roll with an outer diameter of 400 mm and a width of 300 mm rotating at a peripheral speed of 30 m / s, and rapidly solidified on the cooling roll to produce alloy ribbons. Each alloy ribbon was heat-treated under the heat treatment conditions shown in Table 8 to produce a soft magnetic alloy ribbon having a nanocrystalline structure. The width and thickness of the produced alloy ribbons are shown in Table 7. The outer peripheral part of the cooling roll is made of a Cu alloy with a thermal conductivity of 150 W / (m·K), and a cooling mechanism for controlling the temperature of the outer peripheral part is provided inside. The heating rate from room temperature to temperature T1 was 400 to 500 °C / sec. Also, the density is the density after heat treatment. In addition, Samples No. 7 to 9 had a structure in which crystal grains with a grain size of 60 nm or less existed in the amorphous phase. Further, when each sample was observed in cross section, the area ratio of crystal grains with a crystal grain size of 60 nm or less was 50% or more (value with the observed field area taken as 100%).

[0068] The heat treatment conditions of each sample, the occupancy ratio, smoothness, B 8000 , iron loss, and density of the samples after heat treatment are shown in Tables 7 and 8. No. 54 is a sample with heat treatment conditions where the temperature of T2 is 140 °C lower than the FeB precipitation start temperature and the temperature of T1 is 160 °C lower than the bccFe crystallization start temperature, and No. 55 is a sample with heat treatment conditions where T2 is set to a temperature 20 °C lower than the FeB precipitation start temperature, and the resulting values are also shown in Tables 7 and 8. The sample of No. 54 has a low B 8000 of 1.74 T and the heat treatment is insufficient. In the sample of No. 55, the iron loss increased significantly and could not be measured under the conditions of 1 T and 1 kHz. From this, it is considered that No. 55 has characteristic deterioration due to the precipitation of FeB. Also, in the sample of No. 55, wrinkles occurred during heat treatment, so the occupancy ratio was 80% and the smoothness was significantly deteriorated to 6.3 μm. Examples (Nos. 7 to 9) of the present disclosure had a high saturation magnetic flux density, low iron loss, and an occupation ratio of 86% or more. Also, they had a high density and good smoothness.

[0069]

Table 7

[0070]

Table 8

[0071] 〔Occupation ratio〕 Measurement was carried out by the following method in accordance with JIS C 2534:2017. Twenty thin strips cut to a length of 120 mm were stacked and set on a flat sample stage, and a flat anvil with a diameter of 16 mm was placed on the stacked thin strips under a pressure of 50 kPa, and the height was measured at intervals of 10 mm in the width direction. The maximum height at that time was taken as hmax (μm), and the occupation ratio LF was obtained from the following calculation formula. LF (%) = weight of sample (g) / density (g / cm 3 ) / hmax (μm) / sample length (240 cm) / width of thin strip (cm) × 10000

[0072] As described above, according to the present disclosure, a soft magnetic alloy thin strip having a high saturation magnetic flux density and low iron loss was obtained. Also, according to the present disclosure, a soft magnetic alloy thin strip in which anisotropy was suppressed and which had isotropy was obtained. Also, according to the present disclosure, a soft magnetic alloy thin strip having a high density, a high occupation ratio, and good smoothness was obtained. When a magnetic core is configured using the soft magnetic alloy thin strip of the present disclosure, the magnetic core can be configured by known means. And, a magnetic core configured using the soft magnetic alloy thin strip of the present disclosure is configured with a high saturation magnetic flux density, low iron loss, and further isotropy that the soft magnetic alloy thin strip of the present disclosure has, and a magnetic core having excellent characteristics is obtained. Furthermore, by constructing a component including a magnetic core composed of the soft magnetic alloy strip of the present disclosure and a winding, a component having a high saturation magnetic flux density, low iron loss, and further isotropy, which the soft magnetic alloy strip of the present disclosure has, is constructed, and a component having excellent characteristics can be obtained.

Claims

1. The alloy composition is represented by the composition formula Fe a Si b B c Cu d M e where M is at least one element selected from Nb, Mo, V, Zr, Hf, and W, and is a soft magnetic alloy ribbon with 82.5 ≦ a ≦ 86, 0.3 ≦ b ≦ 3, 12.5 ≦ c ≦ 15.0, 0.05 ≦ d ≦ 0.9, and 0 ≦ e < 0.4 in atomic percent. The soft magnetic alloy ribbon has a structure in which crystal grains with a particle size of 60 nm or less are present in an amorphous phase, a saturation magnetic flux density of 1.75 T or more, and an iron loss of 25 W / kg or less at 1 kHz and 1 T. The volume ratio of the crystal grains with a particle size of 60 nm or less is 50% or more. A soft magnetic alloy ribbon with an occupancy rate of 86% or more.

2. In the soft magnetic alloy ribbon according to claim 1, the density is 7.45 g / cm 3 or more of the soft magnetic alloy ribbon.

3. The soft magnetic alloy ribbon according to Claim 1 or 2, having a thickness of 25 μm or more.

4. The soft magnetic alloy ribbon according to any one of Claims 1 to 3, having an occupancy rate of 88% or more.

5. In the soft magnetic alloy ribbon according to any one of Claims 1 to 4, the ratio (L / W) of the magnetic flux density L when a magnetic field of 80 A / m is applied in the casting direction of the soft magnetic alloy ribbon to the magnetic flux density W when a magnetic field of 80 A / m is applied in a direction perpendicular to the casting direction of the soft magnetic alloy ribbon is 0.7 to 1.

3.

6. The soft magnetic alloy ribbon according to any one of Claims 1 to 5, having a saturation magnetostriction of 20 ppm or less.

7. In the soft magnetic alloy ribbon according to any one of Claims 1 to 6, 83 ≦ a ≦ 86, 0.3 ≦ b ≦ 2, 0.4 ≦ d ≦ 0.9, 0 ≦ e ≦ 0.3, and the saturation magnetic flux density is 1.77 T or more.

8. The soft magnetic alloy ribbon according to any one of Claims 1 to 7, having 13.0 ≦ c ≦ 14.

0.

9. In the soft magnetic alloy ribbon according to any one of Claims 1 to 8, a part of Fe is replaced with at least one element of Co and Ni in the range of up to 6 atomic%.

10. A manufacturing method for obtaining the soft magnetic alloy ribbon according to any one of Claims 1 to 9, having a ribbon manufacturing step of ejecting a molten alloy onto a rotating cooling roll and cooling the molten alloy on the cooling roll to obtain an alloy ribbon, wherein the outer peripheral portion of the cooling roll is made of a Cu alloy having a thermal conductivity of 120 W / (m·K) or more.

11. In a method for manufacturing a soft magnetic alloy ribbon by heat-treating an alloy ribbon to have a structure in which crystal grains with a particle size of 60 nm or less are present in an amorphous phase, in the soft magnetic alloy ribbon, the volume ratio of the crystal grains with a particle size of 60 nm or less is 50% or more. The alloy composition of the soft magnetic alloy ribbon is represented by the composition formula Fe a Si b B c Cu d M e, where M is at least one element selected from Nb, Mo, V, Zr, Hf, and W, and 82.5 ≦ a ≦ 86, 0.3 ≦ b ≦ 3, 12.5 ≦ c ≦ 15.0, 0.05 ≦ d ≦ 0.9, and 0 ≦ e < 0.4 in atomic percentage. In the heat treatment, a temperature 10 to 140 °C lower than the bccFe crystallization start temperature is defined as temperature T1, and a temperature 30 to 120 °C lower than the FeB precipitation start temperature is defined as temperature T2. Heat from room temperature to temperature T1 at a heating rate of 50 °C / sec or more. Heat from temperature T1 to temperature T2 at a heating rate slower than the heating rate to temperature T1 and at a heating rate of 400 °C / sec or less. Cool after reaching temperature T2, or After reaching temperature T2, hold at a temperature between temperature T2 - 50 °C and temperature T2 for 0.5 to 60 seconds, and then cool. A method for manufacturing a soft magnetic alloy ribbon.

12. The alloy ribbon before the heat treatment is obtained by ejecting an alloy melt onto a rotating cooling roll and cooling the alloy melt on the cooling roll. The outer peripheral portion of the cooling roll is made of a Cu alloy having a thermal conductivity of 120 W / (m·K) or more. The method for manufacturing a soft magnetic alloy ribbon according to claim 11.

13. When the density of the alloy ribbon before the heat treatment is M1 and the density of the alloy ribbon after the heat treatment is M2, M2 / M1 is 1.005 or more. The method for manufacturing a soft magnetic alloy ribbon according to claim 11 or 12.

14. A magnetic core composed of the soft magnetic alloy ribbon according to any one of claims 1 to 9.

15. A component comprising the magnetic core according to claim 14 and a winding.

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