Fe-based amorphous alloy and thin fe-based amorphous alloy strip

Abstract

An Fe-based amorphous alloy according to one embodiment of the present disclosure has an amorphous structure and contains, in terms of at%, 8.0-18.0% B, 0-2.0% Si, 0.10-5.00% C, 0.10-3.50% P, 0-0.60% Mn, and 78.00-86.00% Fe, with the remainder being impurities.

Description

Fe-based amorphous alloy and Fe-based amorphous alloy ribbon

[0001] The present disclosure relates to an Fe-based amorphous alloy and an Fe-based amorphous alloy ribbon, and in particular to an Fe-based amorphous alloy and an Fe-based amorphous alloy ribbon having excellent soft magnetic properties. This application claims priority to Japanese Patent Application No. 2023-172448, filed on October 4, 2023, the contents of which are incorporated herein by reference.

[0002] Known methods for continuously producing ribbons or wires by rapidly cooling an alloy from a molten state include the centrifugal quenching method, the single-roll method, and the twin-roll method. These methods produce ribbons or wires by ejecting molten metal from an orifice or other device onto the inner or outer peripheral surface of a metal drum rotating at high speed, causing the molten metal to rapidly solidify. Furthermore, by appropriately selecting the alloy composition, it is possible to obtain an amorphous alloy similar to liquid metal, and to produce a material with excellent magnetic properties.

[0003] In particular, among amorphous alloys, Fe-based amorphous alloys are considered promising for use in the iron cores of power transformers and high-frequency transformers. To improve the performance of these applications, there is a strong demand for further reduction in iron loss and further improvement in saturation magnetic flux density of Fe-based amorphous alloys. However, the iron loss W at a magnetic flux density of 1.3 T and a frequency of 50 Hz is １３／５０ It has been extremely difficult to obtain an Fe-based amorphous alloy having a magnetic flux density of 0.105 W / kg or less and a saturation magnetic flux density of 1.60 T or more.

[0004] In Patent Document 1, the alloy composition is Fe ａ Si ｂ B ｃ C ｄ and contains, in atomic %, 76≦a<84%, 0<b≦12%, 8≦c≦18%, 0.01≦d≦3% and inevitable impurities, and when the concentration distribution of C is measured on the free surface, the roll surface, and from the surface to the interior, the peak value of the concentration distribution of C exists within a depth range of 2 to 20 nm.

[0005] In Patent Document 2, the alloy composition is Fe ａ Si ｂ B ｃ C ｄCr ｅ Mn ｆ The peak concentration of carbon (C) segregated at a position 2 to 25 nm from the ribbon surface is represented by p, and the peak concentration of carbon (C) is represented by p, and the peak concentration of carbon (C) segregated at a position 2 to 25 nm from the ribbon surface is represented by p. １ (atomic %), and the carbon content is d. １ An amorphous alloy ribbon having a ratio of .alpha. / d of 1.5 or less is described.

[0006] Patent Document 3 describes an Fe-based amorphous alloy ribbon containing, in atomic %, 5 to 25% B, 1 to 30% Si, 0.001 to 0.2% N, and the remainder being Fe and unavoidable impurities.

[0007] In Patent Document 1, the position and peak value of the C segregation layer on the free surface and roll surface are controlled by controlling the amount of Si and C, the surface roughness of the roll surface, and the amount of gas blown onto the roll, thereby achieving the B ８０ / BS is improved, thermal stability is excellent, and embrittlement is suppressed. １３／５０ There is no consideration whatsoever to make the magnetic flux density 0.105 W / kg or less and the saturation magnetic flux density 1.60 T or more.

[0008] In Patent Document 2, the peak concentration of the C segregation layer is controlled by using a material to which Cr and Mn are added, and the long-term thermal stability is improved by previously subjecting the amorphous alloy ribbon to a predetermined heat treatment. １３／５０ There has been no consideration whatsoever to reduce the magnetic flux density to 0.105 W / kg or less and to increase the saturation magnetic flux density to 1.60 T or more.

[0009] In Patent Document 3, N is contained in Fe-B-Si and Fe-B-Si-C amorphous alloys, and impurity elements (Al, etc.), which are said to be crystallization promoting elements, are concentrated in the surface oxide layer, preventing crack propagation in the amorphous alloy ribbon and improving workability. However, iron loss W １３／５０ There has been no consideration whatsoever to reduce the magnetic flux density to 0.105 W / kg or less and to increase the saturation magnetic flux density to 1.60 T or more.

[0010] JP 2006-45662 A JP 2009-52064 A JP 2006-316348 A

[0011] The present disclosure has been made in view of the above circumstances, and an object of the present disclosure is to provide an Fe-based amorphous alloy and an Fe-based amorphous alloy ribbon having low iron loss and high magnetic flux density.

[0012] The gist of the present disclosure is as follows. (1) An Fe-based amorphous alloy according to one embodiment of the present disclosure contains, in atomic percent, B: 8.0% to 18.0%, Si: 0% to 2.0%, C: 0.10% to 5.00%, P: 0.10% to 3.50%, Mn: 0% to 0.60%, and Fe: 78.00% to 86.00%, with the remainder consisting of impurities, and has an amorphous structure. (2) Preferably, the Fe-based amorphous alloy described in (1) above contains, in atomic percent, Mn: 0.05% to 0.60%. (3) Preferably, the Fe-based amorphous alloy described in (1) above contains, in atomic percent, C: 1.00% to 5.00%, and Mn: 0.05% to 0.60%. (4) Preferably, in the Fe-based amorphous alloy described in (1) above, the C content is 2.00% or more and 5.00% or less, and the Mn content is 0.05% or more and 0.60% or less, in atomic percent. (5) Preferably, in the Fe-based amorphous alloy described in (1) above, the P content is 0.50% or more and 3.50% or less, and the Mn content is 0.05% or more and 0.60% or less, in atomic percent. (6) Preferably, in the Fe-based amorphous alloy described in (1) above, the C content is 1.00% or more and 5.00% or less, the P content is 0.50% or more and 3.50% or less, and the Mn content is 0.05% or more and 0.60% or less, in atomic percent. (7) Preferably, in the Fe-based amorphous alloy described in (1) above, the contents are, in atomic percent, C: 2.00% to 5.00%, P: 0.50% to 3.50%, and Mn: 0.05% to 0.60%. (8) Preferably, in the Fe-based amorphous alloy described in any one of (1) to (7) above, Fe is substituted with at least one element selected from Ni, Cr, and Co in a range of 10.0 atomic percent or less. (9) Preferably, in the Fe-based amorphous alloy described in any one of (1) to (7) above, the iron loss W when magnetized at a frequency of 50 Hz and a magnetic flux density of 1.3 T is １3／５０(10) Preferably, in the Fe-based amorphous alloy described in (8) above, the iron loss W when magnetized at a frequency of 50 Hz and a magnetic flux density of 1.3 T is １3／５０ (11) Preferably, in the Fe-based amorphous alloy described in (10) above, the iron loss W １3／５０ is 0.097 W / kg or less. (12) An Fe-based amorphous alloy ribbon according to another aspect of the present disclosure is made of the Fe-based amorphous alloy according to any one of (1) to (7) above. (13) An Fe-based amorphous alloy ribbon according to another aspect of the present disclosure is made of the Fe-based amorphous alloy according to (8) above. (14) An Fe-based amorphous alloy ribbon according to another aspect of the present disclosure is made of the Fe-based amorphous alloy according to (9) above. (15) An Fe-based amorphous alloy ribbon according to another aspect of the present disclosure is made of the Fe-based amorphous alloy according to (10) above. (16) An Fe-based amorphous alloy ribbon according to another aspect of the present disclosure is made of the Fe-based amorphous alloy according to (11) above.

[0013] According to the present disclosure, it is possible to provide an Fe-based amorphous alloy and an Fe-based amorphous alloy ribbon having low core loss and high magnetic flux density.

[0014] The present inventors have found that by adjusting the contents of amorphous forming elements such as B, C, Si, and P, it is possible to improve the amorphous forming ability and obtain an Fe-based amorphous alloy with excellent soft magnetic properties. １３／５０ They found that it is possible to achieve a magnetic flux density of 0.105 W / kg or less and a saturation magnetic flux density of 1.60 T or more. They also found that by adding Mn in the range of 0.05% or more and 0.60% or less, it is possible to further improve the soft magnetic properties.

[0015] Hereinafter, an Fe-based amorphous alloy and an Fe-based amorphous alloy ribbon according to embodiments of the present disclosure will be described.

[0016] In this embodiment, excellent soft magnetic properties means low iron loss and high saturation magnetic flux density.

[0017] The Fe-based amorphous alloy of this embodiment contains, in atomic %, B: 8.0% to 18.0%, Si: 0% to 2.0%, C: 0.10% to 5.00%, P: 0.10% to 3.50%, Mn: 0% to 0.60%, Fe: 78.00% to 86.00%, with the remainder being impurities, and has an amorphous structure.

[0018] Furthermore, the Fe-based amorphous alloy of this embodiment contains, in atomic %, B: 8.0% or more and 18.0% or less, Si: 0% or more and 2.0% or less, C: 0.10% or more and 5.00% or less, P: 0.10% or more and 3.50% or less, Mn: 0.05% or more and 0.60% or less, and Fe: 78.00% or more and 86.00% or less, with the remainder being impurities, and has an amorphous structure.

[0019] The Fe-based amorphous alloy of this embodiment may have a C content of 1.00% or more and 5.00% or less. The Fe-based amorphous alloy of this embodiment may have a C content of 2.00% or more and 5.00% or less. The Fe-based amorphous alloy of this embodiment may have a P content of 0.50% or more and 3.50% or less. The Fe-based amorphous alloy of this embodiment may have a C content of 1.00% or more and 5.00% or less, and a P content of 0.50% or more and 3.50% or less. The Fe-based amorphous alloy of this embodiment may have a C content of 2.00% or more and 5.00% or less, and a P content of 0.50% or more and 3.50% or less.

[0020] In the Fe-based amorphous alloy of the present embodiment, Fe may be substituted with at least one element selected from Ni, Cr, and Co in an amount of 10.0 atomic % or less. The Fe-based amorphous alloy ribbon of the present embodiment is made of the above-mentioned Fe-based amorphous alloy.

[0021] First, the reasons for limiting the content of each element in the Fe-based amorphous alloy of this embodiment will be described.

[0022] B is included in the Fe-based amorphous alloy of this embodiment to improve amorphous phase formation and the thermal stability of the amorphous phase. By optimizing the content of this element, assuming that other elements are included in the above-mentioned composition ranges, the alloy structure can be stably amorphous, thereby further improving soft magnetic properties. For example, the saturation magnetic flux density can be stably 1.60 T or higher. If the B content is less than 8.0 atomic %, the amorphous phase formation ability is not improved, and the amorphous alloy cannot be stably obtained in the Fe-based amorphous alloy. It becomes difficult to stably achieve a saturation magnetic flux density of 1.60 T or higher while maintaining a stable core loss of 0.105 W / kg or lower. On the other hand, if the B content exceeds 18.0 atomic %, the amorphous phase formation ability is not improved, and it becomes difficult to stably achieve a saturation magnetic flux density of 1.60 T or higher. Therefore, the B content is set to 8.0 atomic % or higher and 18.0 atomic % or lower. The lower limit of B is preferably 10.0 atomic %, more preferably 13.0 atomic %, and the upper limit of B is preferably 16.0 atomic %, more preferably 15.0 atomic %.

[0023] Like B, Si is included in the Fe-based amorphous alloy of this embodiment to improve the formation of an amorphous phase and the thermal stability of the amorphous phase. However, Si is not essential, and the Si content may be 0 atomic %. By optimizing the Si content, assuming that other elements are included in the above-mentioned composition ranges, the alloy structure can be stably formed into an amorphous phase, thereby further improving soft magnetic properties. Even if Si exceeds 2.0 atomic %, the amorphous phase formation ability is not improved, and it becomes difficult to stably maintain iron loss at 0.105 W / kg or less. Therefore, the Si content is set to 0 atomic % or more and 2.0 atomic % or less. The lower limit of Si is preferably greater than 0 atomic %, more preferably 0.1 atomic %, 0.2 atomic %, 0.3 atomic %, or 0.5 atomic %. The upper limit of Si is preferably 1.9 atomic %, 1.8 atomic %, 1.5 atomic %, or 1.3 atomic %, and more preferably 1.0 atomic %.

[0024] Like B and Si, C is included in the Fe-based amorphous alloy of this embodiment to improve amorphous phase formation and the thermal stability of the amorphous phase. By optimizing the C content, assuming that the other elements are included in the above-mentioned composition ranges, the alloy structure can be stably amorphous, thereby further improving soft magnetic properties. If the C content is less than 0.10 atomic %, the amorphous phase formation ability is not improved, and the amorphous alloy cannot be stably obtained in the Fe-based amorphous alloy. It becomes difficult to stably maintain the saturation magnetic flux density at 1.60 T or more while maintaining the iron loss at 0.105 W / kg or less. On the other hand, if the C content exceeds 5.00 atomic %, the amorphous phase formation ability is not improved, and it becomes difficult to stably maintain the iron loss at 0.105 W / kg or less. Therefore, the C content is set to 0.10 atomic % or more and 5.00 atomic % or less. The lower limit of C is preferably 1.00 atomic %, more preferably more than 1.90 atomic %, and even more preferably 2.00 atomic %. The upper limit of C is preferably 4.50 atomic %, and even more preferably 4.00 atomic %.

[0025] Like B, Si, and C, P is added to improve the formation of an amorphous phase and the thermal stability of the amorphous phase. By optimizing the P content, assuming that the other elements are included in the above-mentioned composition ranges, the alloy structure can be stably formed into an amorphous phase, thereby further improving soft magnetic properties. If the P content is less than 0.10 atomic %, the amorphous phase formation ability is not improved, and the amorphous alloy cannot be stably obtained in the Fe-based amorphous alloy, making it difficult to stably maintain the iron loss at 0.105 W / kg or less. On the other hand, if the P content exceeds 3.50 atomic %, the amorphous phase formation ability is not improved, and it becomes difficult to stably maintain the iron loss at 0.105 W / kg or less. Therefore, the P content is set to 0.10 atomic % or more and 3.50 atomic % or less. The lower limit of P is preferably 0.20 atomic %, more preferably 0.50 atomic %. The upper limit of P is preferably 3.00 atomic %, more preferably 2.50 atomic %.

[0026] In this embodiment, the total amount of Si and C, which are elements capable of forming an amorphous structure, may be greater than 3.70 atomic % or may be 4.00 atomic % or greater. In this embodiment, the total amount of C and P, which are elements capable of forming an amorphous structure, may be greater than 4.90 atomic % or may be 5.00 atomic % or greater. In this embodiment, the total amount of Si, C, and P, which are elements capable of forming an amorphous structure, may be greater than 5.90 atomic % or may be 6.00 atomic % or greater.

[0027] Mn is an optional additive element and is not essential. Therefore, the Mn content may be 0 atomic %. On the other hand, Mn can be added to the Fe-based amorphous alloy of this embodiment to further improve soft magnetic properties. By optimizing the Mn content, assuming that other elements are included in the above-mentioned composition ranges, it is possible to stably maintain the saturation magnetic flux density at 1.60 T or more while stably maintaining the iron loss at 0.105 W / kg or less. If the Mn content is 0.02 atomic % or more or 0.05 atomic % or more, it is possible to stably maintain the saturation magnetic flux density at 1.60 T or more while stably maintaining the iron loss at 0.105 W / kg or less. On the other hand, if the Mn content exceeds 0.60 atomic %, it becomes difficult to stably maintain the iron loss at 0.105 W / kg or less. Therefore, it is preferable to set the Mn content to, for example, 0.05 atomic % or more and 0.60 atomic % or less. The lower limit of Mn is preferably 0.10 atomic %, more preferably 0.20 atomic %. The upper limit of Mn is preferably 0.50 atomic %, more preferably 0.40 atomic %. For example, by setting the lower limit of Mn to 0.10 atomic %, the iron loss W １3／５０ can be set to 0.097 W / kg.

[0028] In Fe-based amorphous alloys, if the Fe content is 70 atomic % or more, a saturation magnetic flux density at a practical level for a general iron core can be obtained. However, in order to obtain a high saturation magnetic flux density of 1.60 T or more, it is necessary to make the Fe content 78.00 atomic % or more, provided that the other elements are contained in the above-mentioned composition ranges. On the other hand, if the Fe content exceeds 86.00 atomic %, it becomes difficult to form an amorphous phase, and the good soft magnetic properties (iron loss W) specific to amorphous alloys are lost. １３／５０It becomes difficult to stably obtain a tensile strength (amount of 0.105 W / kg or less). Therefore, in the Fe-based amorphous alloy of this embodiment, the Fe content is set to 78.00 atomic % or more and 86.00 atomic % or less. The lower limit of Fe is preferably 79.00 atomic %, more preferably 80.00 atomic %. The upper limit of Fe is preferably 85.00 atomic %, more preferably 84.00 atomic %.

[0029] In the Fe-based amorphous alloy of this embodiment, a portion of the Fe may be replaced with at least one of Ni, Cr, and Co in a range of 10.0 atomic % or less. In other words, in the Fe-based amorphous alloy of this embodiment, the total content of Fe and the total content of Ni, Cr, and Co may be 78.00 atomic % or more and 86.00 atomic % or less, and the total content of Ni, Cr, and Co may be 0 atomic % or more and 10.0 atomic % or less. By replacing a portion of the Fe with at least one of Ni, Cr, and Co, it is possible to improve soft magnetic properties such as iron loss while maintaining a high saturation magnetic flux density. The reason for setting an upper limit on the amount of substitution by these elements is that if the amount exceeds 10.0 atomic %, the saturation magnetic flux density will decrease and the raw material cost will increase. When Fe is replaced by one or more of Ni, Cr, and Co, the sum of the Ni, Cr, and Co contents and the Fe content may be 78.00 atomic % or more and 86.00 atomic % or less, 79.00 atomic % or more and 85.00 atomic % or less, or 80.00 atomic % or more and 84.00 atomic % or less. The sum of the Ni, Cr, and Co contents may be 0 atomic %, 0.1 atomic % or more, 0.5 atomic % or more, 1.0 atomic % or more, or 3.0 atomic % or more. The sum of the Ni, Cr, and Co contents may be 9.0 atomic % or less, 8.0 atomic % or less, 5.0 atomic % or less, or 2.0 atomic % or less.

[0030] The remainder in the Fe-based amorphous alloy according to this embodiment is impurities. When a steel material is used as the Fe source, the Fe-based amorphous alloy according to this embodiment may contain impurity elements contained in the steel material as impurities in a total amount of less than 0.100 atomic %. For example, the Fe-based amorphous alloy may contain impurities such as O, N, S, Al, Ti, Cu, V, As, Sn, Nb, Mo, Zr, Ca, Mn, Sb, Bi, Mg, As, Se, Te, Pb, REM, Zn, W, Ba, Cd, Pt, Au, In, Ga, Ge, Sc, and Hf in a total amount of less than 0.100 atomic %.

[0031] The chemical composition may be measured by a general analytical method. For example, the chemical composition may be measured using ICP-AES (Inductively Coupled Plasma-Atomic Emission Spectrometry). Specifically, the chemical composition is identified by measuring a test piece taken from an Fe-based amorphous alloy using a predetermined measuring device under conditions based on a pre-created calibration curve. C and S may be measured using a combustion-infrared absorption method, and N may be measured using an inert gas fusion-thermal conductivity method. O may be measured using an inert gas fusion-non-dispersive infrared absorption method.

[0032] The Fe-based amorphous alloy of this embodiment has an amorphous structure. This allows for excellent soft magnetic properties to be obtained. Whether or not the alloy has an amorphous structure can be confirmed, for example, by X-ray diffraction measurement using an X-ray diffractometer with a Cu tube. That is, if no clear diffraction peak is obtained in the X-ray diffraction measurement, it can be confirmed that the Fe-based amorphous alloy has an amorphous structure. Here, "no clear diffraction peak is obtained in the X-ray diffraction measurement" means that the α-Fe(110) diffraction peak does not have a half-width of 4° or less.

[0033] When the saturation magnetic flux density and iron loss of the Fe-based amorphous alloy and Fe-based amorphous alloy ribbon of this embodiment are measured by the method described below, the saturation magnetic flux density is 1.60 T or more, more preferably 1.61 T or more, and the iron loss (iron loss W １３／５０ ) is 0.105 W / kg or less, and the soft magnetic properties are excellent. １３／５０is preferably 0.100 W / kg or less, 0.097 W / kg or less, or 0.095 W / kg or less.

[0034] Iron loss is measured using a single strip tester (SST). The iron loss measurement conditions are a magnetic flux density of 1.3 T and a frequency of 50 Hz. Samples for iron loss measurement are collected from six locations along the entire length of one lot of ribbon. The samples for iron loss measurement are ribbon samples cut to a length of 120 mm. These ribbon samples for iron loss measurement are annealed in a magnetic field (magnetic field: 800 A / m, applied in the casting direction) at a predetermined temperature selected from the range of 320 to 380°C for one hour before measurement. The atmosphere during annealing is a nitrogen atmosphere. Meanwhile, saturation magnetic flux density is measured using a vibrating sample magnetometer (VSM). A BH full loop is measured at a maximum magnetizing force of 10 kOe, and the saturation magnetic flux density is calculated by averaging the maximum magnetic polarization values ​​on the positive and negative sides. The samples for the VSM device are thin sections collected from the width center of each of the six ribbon samples.

[0035] The Fe-based amorphous alloy and the method for producing the Fe-based amorphous alloy ribbon according to this embodiment will be described below. The Fe-based amorphous alloy according to this embodiment can usually be obtained in the form of a ribbon. This Fe-based amorphous alloy ribbon can be produced by melting an alloy consisting of the components described in the above embodiment, ejecting the molten metal through a slot nozzle or the like onto a cooling plate moving at high speed, and rapidly solidifying the molten metal, for example, by a single-roll method or a twin-roll method. The rolls used in these roll methods are made of metal, and the alloy can be rapidly solidified by rotating the rolls at high speed and causing the molten metal to collide with the surface or inner surface of the roll.

[0036] Single-roll equipment includes centrifugal quenching equipment that uses the inner wall of a drum, equipment that uses an endless belt, and improved versions of these, such as auxiliary rolls and equipment equipped with roll surface temperature control devices, as well as casting equipment that operates under reduced pressure, in a vacuum, or in an inert gas.

[0037] In this embodiment, the dimensions of the ribbon, such as the thickness and width, are not particularly limited, but the ribbon thickness is preferably, for example, 10 μm or more and 100 μm or less. The ribbon width is preferably 10 mm or more. The Fe-based amorphous alloy ribbon obtained as described above can be used for applications such as iron cores in power transformers and high-frequency transformers.

[0038] The Fe-based amorphous alloy of this embodiment can also be in the form of a powder, in addition to a ribbon. To obtain a powdered Fe-based amorphous alloy, a method can be employed in which the molten alloy or droplets of the molten alloy are ejected at high speed from the nozzle of a crucible filled with the molten alloy of the above composition into a rotating roll or a liquid such as cooling water, thereby causing rapid solidification.

[0039] By the above-mentioned method, it is possible to obtain an Fe-based amorphous alloy powder having excellent soft magnetic properties.

[0040] The Fe-based soft magnetic alloy powder obtained as described above can be compacted in a mold or the like to form a desired shape, and if necessary, sintered to form an integrated body, and can be used for applications such as power transformers, high-frequency transformers, and coil cores.

[0041] As described above, according to the Fe-based amorphous alloy and Fe-based amorphous alloy ribbon of this embodiment, by optimizing the contents of B, Si, C, and P and further setting the Fe content to 78.00% or more, the iron loss (iron loss W １３／５０) is 0.105 W / kg or less, and the saturation magnetic flux density is 1.60 T or more, thereby exhibiting excellent soft magnetic properties and suitable for use as parts for passive elements that utilize electromagnetic induction of a coil. The Fe-based amorphous alloy and Fe-based amorphous alloy ribbon of this embodiment can also be suitable for use as parts for motors. Specifically, they can be suitable for use as transformer cores, inductor cores, choke cores, reactor cores, etc. They can also be suitable for use as stator cores or rotor cores for motors. Therefore, the Fe-based amorphous alloy of this embodiment is preferably an Fe-based amorphous alloy for passive elements that utilize electromagnetic induction of a coil or an Fe-based amorphous alloy for motors. Similarly, the Fe-based amorphous alloy ribbon of this embodiment is preferably an Fe-based amorphous alloy ribbon for passive elements that utilize electromagnetic induction of a coil or an Fe-based amorphous alloy for motors. Furthermore, the amorphous alloy or the amorphous alloy ribbon is preferably an Fe-based alloy for use in a magnetic core of a transformer, an inductor, a choke, a reactor, or a motor.

[0042] Hereinafter, examples of the present disclosure will be described.

[0043] Example 1: Fe-based amorphous alloy ribbons were produced by melting alloys of the various compositions shown in Tables 1A, 1B, and 1C in an argon atmosphere, quenching them in a single-roll apparatus, and casting them. The values ​​in the "Fe (atomic %)" column in Tables 1A, 1B, and 1C include the impurity content. The casting atmosphere was air. The single-roll apparatus used consisted of a copper alloy cooling roll with a diameter of 300 mm, a high-frequency power source for melting the sample, and a quartz crucible with a slot nozzle attached to its tip. In this experiment, a slot nozzle with a length of 10 mm and a width of 0.6 mm was used. The peripheral speed of the cooling roll was 24 m / s. The resulting ribbon had a thickness of approximately 20 μm, a width of 10 mm (depending on the length of the slot nozzle), and a length of approximately 100 m.

[0044] X-ray diffraction measurement was performed on the obtained Fe-based amorphous alloy ribbon to obtain an X-ray diffraction pattern. The X-ray source for the X-ray diffraction measurement was Cu-Kα (wavelength λ = 1.5406 Å), and the scan range was 2θ = 10 deg or more and 120 deg or less. Whether or not a crystalline phase was formed in the metal structure was determined from the shape of the X-ray diffraction pattern. The X-ray diffraction peak by CuKα ray was separated into Kα1 ray and Kα2 ray, and the intensity data after removing the Kα2 ray was evaluated.

[0045] The saturation magnetic flux density and iron loss of the Fe-based amorphous alloy ribbon were measured using an SST (Single Strip Tester). The iron loss measurement conditions were a magnetic flux density of 1.3 T and a frequency of 50 Hz. The samples for iron loss measurement were collected from six locations along the entire length of one lot of ribbon. The samples for iron loss measurement were ribbon samples cut to a length of 120 mm. These ribbon samples for iron loss measurement were annealed at 360°C for 1 hour in a magnetic field (magnetic field: 800 A / m, applied in the casting direction) and then used for measurement. The atmosphere during annealing was a nitrogen atmosphere. Meanwhile, the samples for the VSM device were thin sections collected from the width center of each of the ribbon samples from the six locations.

[0046] The results of the measurements of saturation magnetic flux density and iron loss are shown in Tables 1A, 1B and 1C as average values ​​of data at six points.

[0047]

[0048]

[0049]

[0050] As shown in Tables 1A, 1B, and 1C, in Examples 1 to 8, 11 to 27, and 60 to 65, the alloy compositions all satisfied the ranges of the present disclosure, and therefore the saturation magnetic flux density was 1.60 T or more, and the iron loss (iron loss W １３／５０ ) was 0.105 W / kg or less, and high saturation magnetic flux density and low iron loss were simultaneously achieved. On the other hand, in Comparative Examples 1 to 9 and 11 to 21, the alloy compositions did not satisfy the range of the present disclosure, and therefore the iron loss (iron loss W １３／５０) exceeded 0.105 W / kg or the saturation magnetic flux density became less than 1.60 T.

[0051] In Comparative Examples 1 and 11, the Fe content was less than 78.00%, resulting in low saturation magnetic flux density and increased iron loss. In Comparative Examples 2 and 12, the Fe content exceeded 86.00%, resulting in increased iron loss. In Comparative Examples 3 and 13, the B content was less than 8.00%, resulting in increased iron loss. In Comparative Examples 4 and 14, the B content exceeded 18.0%, resulting in increased iron loss. In Comparative Examples 5 and 15, the Si content exceeded 2.0%, resulting in increased iron loss. In Comparative Examples 6 and 16, the C content was less than 0.10%, resulting in increased iron loss. In Comparative Examples 7 and 17, the C content exceeded 5.00%, resulting in increased iron loss. In Comparative Examples 8 and 18, the P content was less than 0.10%, resulting in increased iron loss. In Comparative Examples 9 and 19, the P content exceeded 3.50%, resulting in increased iron loss. In Comparative Example 20, the Mn content was less than 0.05%, resulting in increased iron loss. In Comparative Example 21, the Mn content exceeded 0.60%, and the iron loss increased.

[0052] In addition, when X-ray diffraction measurement was performed on the Fe-based amorphous alloy ribbons, no clear diffraction peaks were observed in any of Examples 1 to 8, Examples 11 to 27, and Examples 60 to 65, and Comparative Examples 1 to 9 and 11 to 21. Therefore, it cannot be said that a crystalline phase was generated in the metal structure, and the entire structure was an amorphous phase.

[0053] Example 2 For the alloys shown in Example 1 in Table 1A and the alloys shown in Examples 11 and 24 in Table 1B, alloys of various compositions in which part of the Fe was replaced with at least one of Ni, Cr, and Co were used to cast ribbons using the same equipment and conditions as in Example 1. The specific compositions of the alloys used are shown in Tables 2A and 2B. As a result, the thickness, width, and length of the obtained ribbons were approximately 20 μm, 10 mm, and approximately 100 m, respectively. The saturation magnetic flux density and core loss of the obtained ribbons were evaluated. The sample collection method and measurement conditions used for these property evaluations were the same as in Example 1. The measurement results are shown in Tables 2A and 2B. The notation in Tables 2A and 2B is the same as in Tables 1A and 1B.

[0054]

[0055]

[0056] As is clear from the results of Examples 31 to 37 and 41 to 54 in Tables 2A and 2B, even when a part of Fe is replaced with at least one of Ni, Cr, and Co in the range of 10.0 atomic % or less, the saturation magnetic flux density is 1.60 T or more, and the iron loss is W １３／５０ Furthermore, no clear diffraction peaks were observed in the X-ray diffraction measurements of any of the samples, confirming that they were amorphous.

[0057] As is clear from the above examples, according to the Fe-based amorphous alloy and Fe-based amorphous alloy ribbon of the present disclosure, by optimizing the contents of B, Si, C, and P and further setting the Fe content to 78.00% or more, it is possible to reduce the iron loss (iron loss W １３／５０ ) is 0.105 W / kg or less, the saturation magnetic flux density is 1.60 T or more, and it has become clear that excellent soft magnetic properties can be exhibited and that the material can be suitably used for the iron cores of power transformers and high-frequency transformers.

Claims

1. An Fe-based amorphous alloy containing, in atomic percentages, B: 8.0% or more and 18.0% or less, Si: 0% or more and 2.0% or less, C: 0.10% or more and 5.00% or less, P: 0.10% or more and 3.50% or less, Mn: 0% or more and 0.60% or less, Fe: 78.00% or more and 86.00% or less, the remainder being impurities, and having an amorphous structure.

2. The Fe-based amorphous alloy according to claim 1, comprising, in atomic percent, Mn: 0.05% or more and 0.60% or less.

3. The Fe-based amorphous alloy according to claim 1, comprising, in atomic percent, C: 1.00% or more and 5.00% or less, Mn: 0.05% or more and 0.60% or less.

4. The Fe-based amorphous alloy according to claim 1, comprising, in atomic percent, C: 2.00% or more and 5.00% or less, Mn: 0.05% or more and 0.60% or less.

5. The Fe-based amorphous alloy according to claim 1, comprising, in atomic percent, P: 0.50% or more and 3.50% or less, and Mn: 0.05% or more and 0.60% or less.

6. The Fe-based amorphous alloy according to claim 1, having, in atomic percentages, C: 1.00% or more and 5.00% or less, P: 0.50% or more and 3.50% or less, and Mn: 0.05% or more and 0.60% or less.

7. The Fe-based amorphous alloy according to claim 1, comprising, in atomic percent, C: 2.00% or more and 5.00% or less, P: 0.50% or more and 3.50% or less, and Mn: 0.05% or more and 0.60% or less.

8. An Fe-based amorphous alloy according to any one of claims 1 to 7, in which Fe is replaced by at least one element selected from the group consisting of Ni, Cr and Co in an amount of 10.0 atomic % or less.

9. Iron loss W when magnetized at a frequency of 50 Hz and a magnetic flux density of 1.3 T １3／５０ The Fe-based amorphous alloy according to claim 1 , wherein the magnetic moment of magnetization is 0.105 W / kg or less and the saturation magnetic flux density is 1.60 T or more.

10. Iron loss W when magnetized at a frequency of 50 Hz and a magnetic flux density of 1.3 T １3／５０ The Fe-based amorphous alloy according to claim 8, wherein the magnetic flux density is 0.105 W / kg or less and the saturation magnetic flux density is 1.60 T or more.

11. Iron loss W １3／５０ The Fe-based amorphous alloy according to claim 10, wherein the strength is 0.097 W / kg or less.

12. An Fe-based amorphous alloy ribbon comprising the Fe-based amorphous alloy according to any one of claims 1 to 7.

13. An Fe-based amorphous alloy ribbon comprising the Fe-based amorphous alloy according to claim 8.

14. An Fe-based amorphous alloy ribbon comprising the Fe-based amorphous alloy according to claim 9.

15. An Fe-based amorphous alloy ribbon comprising the Fe-based amorphous alloy according to claim 10.

16. An Fe-based amorphous alloy ribbon comprising the Fe-based amorphous alloy according to claim 11.

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