Fe-based amorphous alloy having high formability, and powder and core manufactured therefrom

Abstract

The present invention relates to: an Fe-based amorphous alloy having high formability; and a powder and a core manufactured therefrom. The present invention provides an Fe-based amorphous alloy having high formability, the Fe-based amorphous alloy having the composition Fe100-a-b-c-d-xSiaBbPcCdMox, wherein 0<a≤10, 0<b≤10, 0<c≤5, 0<d≤5, and 1<x<4 are satisfied, and the composition contains (100-a-b-c-d-x) at% of Fe, a at% of Si, b at% of B, c at% of P, d at% of C, and x at% of Mo.

Description

FE-based high-performance amorphous alloys, powders and cores manufactured therefrom

[0001] The present invention relates to an alloy having excellent amorphous forming ability, a powder manufactured therefrom, and a core.

[0002] Recently, there has been a growing demand for low power consumption and high efficiency in electronic, information, and communication devices. To achieve these goals, soft magnetic alloys with favorable magnetic properties (low coercivity and high saturation flux density) are in demand.

[0003] Among them, amorphous soft magnetic alloys, which are used as materials for components used in electronic devices, are widely used in the form of metal powder.

[0004] Common methods for manufacturing these metal powders include the pulverization method, which involves crushing solid metal; the wet method, which involves chemical precipitation; and the spray method, which involves melting the metal material and spraying it using a spray nozzle. Among these, the spray method is primarily used to manufacture alloy powders rather than pure metals. Depending on the cooling medium used, this method can be categorized into the water spray method, which uses a liquid such as water, and the gas spray method, which uses gas.

[0005] Because the water-based method uses water as a cooling medium, it boasts a high cooling rate and, consequently, can produce powders with a high degree of amorphousness. However, during water-based spraying, oxides are formed on the powder surface due to the reaction between the water and the molten metal. This necessitates a reduction process, and due to the nature of the process, powders of irregular shapes are produced.

[0006] Meanwhile, the method of manufacturing metal powder by gas atomization generally manufactures metal powder by spraying an inert gas such as argon or nitrogen at room temperature while flowing molten metal through a spray nozzle. Unlike powder manufactured by the water atomization method, powder manufactured by the gas atomization method can produce very clean powder by using an inert gas as the spray medium, and the shape of the powder is also spherical. However, because the cooling medium is gas, the typical cooling speed is relatively slower than that of the water atomization method, and the powder manufactured accordingly has the problem of cooling slowly and forming crystals.

[0007] Accordingly, there is a need for an alloy for manufacturing amorphous metal powder with high amorphousness, spherical shape, and cleanness using a gas injection method.

[0008] Patent Document: Republic of Korea Patent Publication No. 10-1426017 (registered on July 28, 2014)

[0009] The technical problem to be solved by the present invention is to provide an alloy having excellent amorphous forming ability, and a powder and core manufactured therefrom.

[0010] However, the problems to be solved by the present invention are not limited to the problems mentioned above, and other problems not mentioned will be clearly understood by those skilled in the art from the description below.

[0011] According to one aspect of the present invention, Fe100-abcd-xSi a B b P c C d Mo x An alloy having a composition of , wherein in the composition, 0 <a≤10, 0<b≤10, 0<c≤5, 0<d≤5, 1<x<4를 만족하는 것으로, 상기 Fe는 (100-a-b-c-d-x) at%, Si는 a at%, B는 b at%, P는 c at%, C는 d at%, Mo는 x at%의 함량으로 포함되는 Fe계 고형성능 비정질 합금이 제공된다.

[0012] According to another aspect of the present invention, an amorphous powder having a saturation magnetization of 1.2 T or more is provided, which is manufactured by induction heating the alloy to a molten metal temperature of 1000°C to 1500°C, completely melting it, and then treating it with a gas injection method in which gas is injected at a pressure of 50 bar to 100 bar.

[0013] According to another aspect of the present invention, a magnetic core is provided, which is manufactured by classifying the amorphous powder into a particle size of 45 μm or less and then pressurizing it under conditions of 1000 Mpa at room temperature, and has an investment rate of 30 μa or more.

[0014] The present invention with the above configuration can expect the following effects.

[0015] The alloy according to the present invention has excellent amorphous forming ability, so that even when producing large-diameter powder using a gas injection method, it has the effect of producing a powder with a high degree of amorphousness.

[0016] In addition, the powder according to the present invention may have excellent magnetic properties due to its high amorphousness.

[0017] In addition, the magnetic core according to the present invention may have excellent magnetic properties due to its high amorphousness.

[0018] The effects of the present invention are not limited to the effects described above, and effects not mentioned will be clearly understood by those skilled in the art from the present specification and the attached drawings.

[0019] When a part in this specification is said to "include" a certain component, this does not mean that it excludes other components, but rather that it may include other components, unless otherwise specifically stated.

[0020] Hereinafter, the present invention will be described in more detail.

[0021] According to one embodiment of the present invention, Fe100-abcd-xSi a B b P c C d Mo x An alloy having a composition of , wherein in the composition, 0 <a≤10, 0<b≤10, 0<c≤5, 0<d≤5, 1<x<4를 만족하는 것인 합금이 제공된다.

[0022] In the composition formula of the above alloy, the letters expressed as subscripts may indicate the content of each element in the alloy in at%. That is, Fe may be included in the alloy in a content of (100-abcdx) at%, Si in a at%, B in b at%, P in c at%, C in d at%, and Mo in x at%.

[0023] That is, Si may be included in an alloy according to one embodiment of the present invention in a content of 10 at % or less, B in a content of 10 at % or less, P in a content of 5 at % or less, C in a content of 5 at % or less, and Mo in a content of more than 1 at % and less than 4 at %.

[0024] An alloy according to an embodiment of the present invention may satisfy 2≤x≤3 in the above composition. That is, an alloy according to an embodiment of the present invention may include Mo in an amount of 2 at % to 3 at %. When Mo is included in a content within the above range, the alloy may have excellent amorphous forming ability. Specifically, the alloy may have excellent amorphous forming ability when the crystallization energy retention rate described below is greater than 90% and the relative coercive force described below is less than 20.

[0025] An alloy according to one embodiment of the present invention may satisfy 5≤a≤9, 7≤b≤10, 3≤c≤7, and 1≤d≤4. That is, an alloy according to one embodiment of the present invention may include Si in an amount of 5 at % to 9 at %, B in an amount of 7 at % to 10 at %, P in an amount of 3 at % to 7 at %, and C in an amount of 1 at % to 4 at %. When Si, B, P, and C are included in contents within the above ranges, there may be an effect of forming an amorphous phase under high-cooling conditions.

[0026] An alloy according to one embodiment of the present invention may contain 70 to 90 at% Fe. When Fe is contained in a content within the above range, the basic properties of the alloy can be achieved, and in particular, when the alloy is used as a magnetic material, magnetic properties can be secured.

[0027] An alloy according to one embodiment of the present invention comprises Fe 73 Si a B b P5C3Mo x An alloy having a composition of , which can satisfy 5≤a≤9, 7≤b≤10 and 2≤x≤3. That is, it can contain Si in an amount of 5 at % to 9 at %, B in an amount of 7 at % to 10 at %, and Mo in an amount of 2 at % to 3 at %.

[0028] When Si, B, and Mo are included in the content within the above range, the amorphous forming ability of the alloy may be increased, which has the effect of lowering the required cooling rate for amorphous formation.

[0029] An alloy according to one embodiment of the present invention has excellent amorphous forming ability, and thus has the effect of being able to produce a powder with a high degree of amorphousness even when producing a powder with a large diameter using a gas injection method.

[0030] The term “amorphous forming ability” used in this specification refers to how well an alloy can form an alloy with a high degree of amorphousness. If an alloy with a relatively high degree of amorphousness can be formed under the same conditions, it can be said to have excellent amorphous forming ability.

[0031] Meanwhile, alloy ribbons generally tend to exhibit lower amorphousness as their thickness increases. As thickness increases, cooling rates slow, which in turn reduces amorphousness. Therefore, an alloy with excellent amorphous-forming properties can exhibit high amorphousness in both thin and thick ribbon shapes.

[0032] According to one embodiment of the present invention, the amorphous forming ability can be evaluated through various measurements. The amorphous forming ability can be compared by comparing the high and low values ​​of parameters including measurements of physical properties that vary depending on the degree of amorphousness. Parameters such as the examples described below can be used, although the present invention is not limited to the examples listed below.

[0033] A property that varies depending on the degree of amorphousness, for example, crystallization energy, can be employed. Crystallization energy is the heat energy generated when an amorphous alloy ribbon crystallizes. A high crystallization energy means that the amorphous alloy ribbon must crystallize more, which may result in a high amorphous fraction in the alloy ribbon. For example, the crystallization energy of an alloy with a high amorphous fraction may be approximately 70 J / g or more. On the other hand, a low crystallization energy means that crystallization can be completed even if the amorphous alloy ribbon is only slightly crystallized, which may result in a low amorphous fraction in the alloy ribbon.

[0034] Therefore, for alloys with excellent amorphous forming ability, the crystallization energy can be high even in a relatively thick ribbon shape.

[0035] In summary of these matters, the amorphous forming ability can be evaluated by comparing the crystallization energy of a ribbon-shaped alloy with a relatively thin thickness and a ribbon-shaped alloy with a relatively thick thickness, and specifically, the amorphous forming ability can be evaluated by the crystallization energy retention rate expressed by the following Equation 1.

[0036] [Formula 1]

[0037] GFA energy (%) = 100 * B / A

[0038] In the above equation 1, GFA energy is the crystallization energy retention rate, B is the crystallization energy measured by manufacturing the alloy into a ribbon with a thickness of 120 μm, a width of 2 mm, and a length of 2 mm and heating it from room temperature to 800°C at a heating rate of 40 K / s using a DSC (Differential Scanning Calorimetery) device, and A is the crystallization energy measured by manufacturing the alloy into a ribbon with a thickness of 70 μm, a width of 2 mm, and a length of 2 mm and heating it from room temperature to 800°C at a heating rate of 40 K / s using a DSC (Differential Scanning Calorimetery) device.

[0039] The closer the crystallization energy retention rate expressed by the above formula 1 is to 100%, the more an alloy ribbon with a high degree of amorphousness can be formed even if the thickness increases. Accordingly, an alloy according to one embodiment of the present invention may satisfy the following formula 2.

[0040] [Formula 2]

[0041] 40 < GFA energy < 100

[0042] In addition, an alloy according to one embodiment of the present invention may satisfy the following equation 3.

[0043] [Formula 3]

[0044] 90 < GFA energy < 100

[0045] In the above equations 2 and 3, GFA energy is the crystallization energy retention rate.

[0046] That is, since the crystallization energy retention rate of the alloy according to one embodiment of the present invention is greater than 40% or greater than 90%, the amorphousness is maintained without a significant decrease in crystallization energy even when the thickness of the alloy ribbon increases from 70 μm to 120 μm, and thus the amorphous formation ability can be very excellent.

[0047] According to one embodiment of the present invention, a property that varies depending on the degree of amorphousness for evaluating the amorphous forming ability of an alloy may be employed, for example, coercivity. In general, the higher the degree of amorphousness of an alloy, the lower the coercivity tends to be.

[0048] That is, the lower the coercive force, the higher the amorphous fraction of the alloy. For example, the coercive force of an alloy with a high amorphous fraction may be about 10 Oe or less. Conversely, the higher the coercive force, the lower the amorphous fraction of the alloy.

[0049] Therefore, for alloys with excellent amorphous forming ability, the coercivity may be low even in a relatively thick ribbon shape.

[0050] In summary of these matters, the amorphous forming ability can be evaluated by comparing the coercivity of a ribbon-shaped alloy with a relatively thin thickness and a ribbon-shaped alloy with a relatively thick thickness, and specifically, the amorphous forming ability can be evaluated by the relative coercivity expressed by Equation 4 below.

[0051] [Formula 4]

[0052] GFA coercivity (Oe) = C2 / D

[0053] In the above equation 4, GFA coercivityis the relative coercivity, C is the coercivity measured under conditions of an applied magnetic field of -15 kOe to 15 kOe using a VSM (Vibrating Sample Magnetometer, Lakeshore) device after manufacturing the alloy into a ribbon having a thickness of 120 μm, a width of 2 mm, and a length of 2 mm, and D is the coercivity measured under conditions of an applied magnetic field of -15 kOe to 15 kOe using a VSM (Vibrating Sample Magnetometer) device after manufacturing the alloy into a ribbon having a thickness of 70 μm, a width of 2 mm, and a length of 2 mm.

[0054] The relative coercive force expressed by the above formula 4 is such that the lower the coercive force, the more amorphous an alloy ribbon can be formed even if the thickness increases. Since the coercive force itself needs to be lowered even if the thickness of the ribbon increases, unlike the above formula 1, the amorphous forming ability can be evaluated by calculating the relative coercive force as the square of the coercive force when the ribbon shape is 120 μm thick.

[0055] An alloy according to one embodiment of the present invention may satisfy the following formula 5.

[0056] [Formula 5]

[0057] 0 < GFA coercivity < 150

[0058] In addition, an alloy according to one embodiment of the present invention may satisfy the following equation 6.

[0059] [Formula 6]

[0060] 0 <GFA coercivity < 20

[0061] In the above equations 5 and 6, GFA coercivity is the relative force.

[0062] That is, since the relative coercive force of the alloy according to one embodiment of the present invention has a value of less than 150 Oe or less than 20 Oe, even if the thickness of the alloy ribbon increases from 70 μm to 120 μm, the coercive force does not increase significantly and the amorphousness is maintained, so that the amorphous forming ability can be very excellent.

[0063] According to another embodiment of the present invention, an amorphous powder having a saturation magnetization of 1.2 T or more is provided, which is manufactured by induction heating the alloy to a molten metal temperature of 1000°C to 1500°C, completely melting it, and then treating it with a gas injection method in which gas is injected at a pressure of 50 bar to 100 bar.

[0064] Even if the above amorphous powder is manufactured by a gas injection method, it can have a high degree of amorphousness because it is manufactured using the alloy as a raw material, and accordingly, the powder can have a high degree of spheroidization and a high degree of amorphousness at the same time.

[0065] The amorphous powder described above may be manufactured by induction heating an alloy and completely melting it, and treating the molten metal with a gas atomization method. The gas atomization method may be performed using equipment used in conventional gas atomization methods, and the amorphous powder may be manufactured using the gas atomization method in a specific manner as exemplified below.

[0066] According to one embodiment of the present invention, the amorphous powder can be manufactured by a method including the steps of: forming a molten metal by placing an alloy into a crucible; discharging the molten metal from the crucible through a tube; spraying the discharging molten metal using a gas to form droplets; and rapidly cooling the droplets to manufacture an amorphous powder.

[0067] Below, each step is explained in detail in order.

[0068] First, an alloy according to one embodiment of the present invention is placed into a crucible to form a molten metal. To melt the alloy, the temperature of the heating crucible may be heated to a temperature higher than the melting point of the alloy composition. At this time, the heating crucible for forming the molten metal may be a general melting crucible, and is not limited thereto as long as it can be used at a temperature higher than the melting point of the alloy.

[0069] Additionally, the molten metal may be formed by heating the alloy to a temperature of about 1000°C to 1500°C or 1000°C to 1100°C.

[0070] Next, the molten metal is discharged from the crucible through a tube. At this time, the tube is preferably heated to a temperature of 150 to 1600°C. This is to prevent the molten metal from rapidly cooling when discharged through the tube. In addition, the diameter of the tube is preferably 0.5 to 5 mm.

[0071] Next, the molten metal is sprayed using gas to form droplets. Specifically, this is a step of forming droplets by spraying the molten metal using high-pressure gas through a jet nozzle at a supersonic speed.

[0072] As the high-pressure gas, a less reactive gas such as an inert gas can be used, and helium, argon, nitrogen, etc. can be used.

[0073] Additionally, the pressure of the high-pressure gas may be 20 to 300 bar or 50 to 100 bar, for example, 80 bar. By injecting the high-pressure gas within the above pressure range through a nozzle at a supersonic speed, the cooling rate of the molten metal can be maximized. Accordingly, the production of amorphous powder is possible, and the production yield can also be improved.

[0074] Additionally, it is preferable that the high-pressure gas be supplied at a flow rate of two to four times the volume of the molten metal sprayed through the nozzle.

[0075] Next, the droplets can be rapidly cooled to produce an amorphous powder. At this time, the droplets can be rapidly cooled at a rate of 100°C / sec or more, thereby preventing crystals from forming within the powder and producing an amorphous powder.

[0076] In addition, the cooling may utilize cooling equipment used in conventional gas injection methods, but is not limited thereto.

[0077] According to one embodiment of the present invention, the amorphous powder may have a spheroidization degree of 1.5 or less. Spheroidization degree refers to the ratio of the major axis to the minor axis of a particle, and the closer it is to 1, the closer it is to a true spherical shape. Since the spheroidization degree is 1.5 or less, the filling ratio can be high when manufacturing parts such as cores using the powder, and thus, iron loss can be low and magnetic properties can be excellent.

[0078] According to one embodiment of the present invention, the amorphous powder may have a particle size of 35 μm or less. By having a particle size within the above range, it may be effective in reducing eddy current loss during core manufacturing.

[0079] According to one embodiment of the present invention, the amorphous powder may have a saturation magnetization of 1.2 T or more. The amorphous powder may be manufactured using a gas injection method, which is a cheaper process, without the saturation magnetization being lowered.

[0080] According to another embodiment of the present invention, a magnetic core is provided, which is manufactured by classifying the amorphous powder into a particle size of 45 μm or less and then pressurizing it under conditions of 1000 Mpa at room temperature, and having a magnetic permeability of 30 μa or more.

[0081] The above magnetic core is manufactured using the above powder as a raw material, and thus can have a high degree of amorphousness, and accordingly, can have the effect of low iron loss and excellent magnetic overlapping characteristics even at high frequencies.

[0082] According to one embodiment of the present invention, the magnetic core may have excellent low iron loss characteristics, with an iron loss of 660 mW / cc or less under 100 kHz, 0.1 T conditions.

[0083] Hereinafter, the present invention will be described in detail using specific embodiments. However, the embodiments according to the present invention may be modified in various ways, and the scope of the present invention is not limited to the embodiments described below. The embodiments described herein are provided to more fully explain the present invention to those of ordinary skill in the art.

[0084] Example 1

[0085] Fe 73 Si7B 10 After preparing a master alloy (Korea Vacuum Metallurgy) having a composition of P5C3Mo2, the interior of the chamber was replaced with a low-reactivity gas such as Ar, N2 or He, and the alloy was melted through induction heating, and the gas was injected to melt it. At this time, the wheel speed was set to 1000 rpm or 300 rpm, respectively, to manufacture an alloy ribbon having a thickness of 70 μm or 120 μm.

[0086] Example 2 and Comparative Examples 1 to 3

[0087] Alloy ribbons of Example 2 and Comparative Examples 1 to 3 were manufactured in the same manner as Example 1, except that a master alloy having a composition according to Table 1 below was used.

[0088] Composition comparison example 1Fe 73 Si8B 10 P5C3Mo1Example 1Fe 73 Si7B 10 P5C3Mo2Example 2Fe 73 Si6B10 P5C3Mo3 comparative example 2Fe 73 Si5B 10 P5C3Mo4 comparative example 3Fe 73 Si9B 10 P5C3

[0089] Experimental Example 1: Evaluation of amorphous formation ability using crystallization energy parameters

[0090] 0.1 g of an alloy ribbon having a thickness of 70 μm or 120 μm manufactured in Examples 1 to 2 and Comparative Examples 1 to 3 was loaded onto a sample dish of a differential scanning calorimeter (DSC), and the temperature was increased at a heating rate of 0.3 °C / sec in a temperature range of 25 to 800°C for 1200 seconds, and the experiment was performed twice in the above section to record a DSC curve graph.

[0091] In the obtained DSC curve graph, the crystallization energy was derived from the height of the highest peak point and is shown in Table 2.

[0092] Additionally, the crystallization energy and crystallization energy retention of alloy ribbons having a thickness of 70 μm or 120 μm were calculated according to Equation 1 below.

[0093] [Formula 1]

[0094] GFA energy (%) = 100 * B / A

[0095] In the above equation 2, GFA energyis the crystallization energy retention rate, B is the crystallization energy measured by heating the alloy manufactured in the examples or comparative examples into a ribbon with a thickness of 120 μm, width of 2 mm, and length of 2 mm using a DSC (Differential Scanning Calorimetery) device from room temperature to 800°C at a heating rate of 40 K / s, and A is the crystallization energy measured by heating the alloy manufactured in the examples or comparative examples into a ribbon with a thickness of 70 μm, width of 2 mm, and length of 2 mm using a DSC (Differential Scanning Calorimetery) device from room temperature to 800°C at a heating rate of 40 K / s.

[0096] 70μmCrystallization energy(J / g)120μmCrystallization energy(J / g)Crystallization energy retention(%)Comparative example 155.020.040.07Example 165.3218.1127.72Example 287.4685.9698.28Comparative example 251.52.24.27Comparative example 376.080.080.1

[0097] Referring to Table 2 above, it can be confirmed that Examples 1 and 2 have very high amorphous forming ability by including Mo in a content of more than 1 at% and less than 4 at%. On the other hand, in the case of Comparative Examples 1 to 3, it can be confirmed that the amorphous forming ability is very low, as the alloy ribbon becomes crystallized even when the ribbon thickness becomes slightly thicker due to not including Mo, including too little Mo, or including too much Mo.

[0098] Experimental Example 2: Evaluation of amorphous formation ability using coercive force parameters

[0099] The alloy ribbons having a thickness of 70 μm or 120 μm manufactured in Examples 1 to 2 and Comparative Examples 1 to 3 were cut into 2 mm x 2 mm pieces and mounted on a vibrating sample magnetometer (VSM, Lakeshore). When the alloy ribbon was vibrated at a frequency of 40 Hz within a range of -15 kOe to 15 kOe, the magnetic moment according to the applied magnetic field measured by the Hall sensor was measured to obtain a magnetic hysteresis curve graph of the alloy ribbon.

[0100] In the obtained magnetic hysteresis curve graph, the coercive force data obtained from the distance between points where the slope of the curve changes abruptly are shown in Table 3.

[0101] Additionally, the coercivity of the alloy ribbon having a thickness of 70 μm or 120 μm and the relative coercivity were calculated according to Equation 3 below.

[0102] [Formula 4]

[0103] GFA coercivity (Oe) = C2 / D

[0104] In the above equation 4, GFA coercivity is the relative coercivity, C is the coercivity of the 120 μm thick alloy ribbon manufactured in the examples or comparative examples, and D is the coercivity of the 70 μm thick alloy ribbon manufactured in the examples or comparative examples.

[0105] 70μm coercivity (Oe)120μm coercivity (Oe)Relative coercivity (Oe)Comparative example 19.91227.045201Example 17.6710.8415.32Example 26.696.706.71Comparative example 297.81100.95104.19Comparative example 38.17193.834598

[0106] Referring to Table 3 above, the amorphous forming ability according to Examples 1 and 2 is a value of less than 20 Oe, and it can be confirmed that the amorphous forming ability is high because the coercive force is low even when the thickness of the ribbon increases.

[0107] On the other hand, in the case of Comparative Example 2, when Mo is included in excess and the ribbon thickness becomes thicker, the alloy ribbon crystallizes and the coercive force increases, confirming that the amorphous forming ability is low. In particular, in the case of Comparative Examples 1 and 3, even when Mo is not included or is included in too little and the ribbon thickness becomes slightly thicker, the alloy ribbon crystallizes and the coercive force increases significantly, confirming that the amorphous forming ability is very low.

[0108] Experimental Example 3: Analysis of crystallinity through XRD pattern analysis

[0109] XRD patterns of the alloy ribbons of Example 2 and Comparative Examples 2 to 3 were obtained using an X-ray diffractometer (Rigaku D / Max-2500VL / PC) under conditions of 2θ= 30 to 70o.

[0110] The alloy ribbons of Example 2 and Comparative Example 2 including Mo did not show any peaks corresponding to the crystalline phase at both the thicknesses of 70 μm and 120 μm, and showed a broad halo pattern around 40 to 50°, which is a typical XRD pattern of an amorphous phase. However, in the alloy ribbon of Comparative Example 3, it can be confirmed that crystalline peaks corresponding to Fe(Si) appear clearly as the thickness increases. The higher the corresponding peaks are observed, the higher the crystallinity. That is, it can be confirmed that the alloy ribbon of Comparative Example 3 has an internal structure that is crystallized under the thick 120 μm condition, and it can be seen that the composition of Example 2 including Mo maintains an amorphous phase even under the conditions of a thick ribbon and a low cooling rate, and is a composition with high amorphous formation ability.

[0111] Example 3: Preparation of powder

[0112] Based on the alloy composition manufactured in Example 2, 25 kg of the master alloy was prepared by induction melting, and this was placed in a batch. The molten metal at the bottom of the batch was maintained at a temperature of 1000 to 1100°C, and argon gas was sprayed at a pressure of 80 bar with a nozzle diameter of 2.5 mm to manufacture an amorphous powder.

[0113] Reference Example 1

[0114] As a commercially available powder, powder of the Kuamet6B2 model from Epson Atmix (particle size <45 μm, saturation magnetization 1.22 T) was prepared.

[0115] Experimental Example 4: Evaluation of Powder Characteristics

[0116] Check the SEM image of the powder

[0117] A scanning electron microscope (SEM) image of the powder manufactured in Example 3 was taken at 5000x magnification using a Field Emission Scanning Electron Microscopy (FE-SEM, Tescan MIRA3 LM) device under an applied voltage of 15 kV, and it was confirmed that the particles of the formed powder were spherical.

[0118] Particle size analysis of powder

[0119] A graph of the volume occupied by each particle size of the powder manufactured in Example 3 is shown.

[0120] Additionally, through SEM image analysis, the sphericity of the powder was calculated as the value obtained by dividing the major axis length of the powder by the minor axis length.

[0121] Referring to FIG. 7, it can be confirmed that about 80% of the powder manufactured in Example 3 has a particle size of about 10 μm to 50 μm, and the average particle size (D50) is about 27.49 μm.

[0122] XRD analysis of powder

[0123] The XRD pattern of the powder manufactured in Example 3 was derived using an X-ray diffractometer (Rigaku D / Max-2500VL / PC) under the condition of 2θ = 30 to 70o.

[0124] The powder manufactured in Example 3 exhibits a broad halo pattern and does not exhibit a peak corresponding to a crystal, confirming that it is a typical amorphous crystal phase.

[0125] Evaluation of magnetic properties of powder

[0126] The powders of Example 3 and Reference Example 1, 0.1 g, were mounted on a vibrating sample magnetometer (VSM, Lakeshore), and when vibration was applied to the alloy ribbon at a frequency of 40 Hz within the range of -15 kOe to 15 kOe, the magnetic moment according to the applied magnetic field measured by the Hall sensor was measured to obtain a magnetic hysteresis curve graph of the alloy powder.

[0127] The magnetic hysteresis curve graphs of the powders of Example 3 and Reference Example 1 are shown.

[0128] Additionally, data on coercivity, saturation magnetic moment, and saturation magnetization were obtained from the magnetic hysteresis curve graph and are shown in Table 4.

[0129] Coercive force (Oe) Saturation magnetic moment (emu / g) Saturation magnetization (T) Example 37.669128.151.21 Reference example 17.383139.011.22

[0130] Referring to Table 4 above, the powder of Example 3 has the advantage of being able to have a low price of powder by applying a general gas injection process while exhibiting a saturation magnetization level similar to that of the powder of Reference Example 1, which is a commercially available powder.

[0131] Example 4: Preparation of core

[0132] The powder manufactured in Example 3 was sieved to 45 μm or less, mixed with 1 to 2 wt% of organic binder, and then pressed at room temperature with a single-axis press machine at a pressure of 80 t, and hardened at 150°C to manufacture a core.

[0133] Reference Example 2

[0134] The commercially available powder was sieved to 45 μm or less, mixed with 1 to 2 wt% of organic binder, and then pressed at room temperature with a single-axis press machine at a pressure of 80 t, and cured at 150°C to manufacture a core.

[0135] Experimental Example 5: Evaluation of Core Characteristics

[0136] Core investment rate evaluation

[0137] The permeability of the core manufactured in Example 4 and the core of Reference Example 2 was evaluated under a frequency condition of 100 Hz to 1 MHz using an LCR meter (Wainker Electronics, 3265B) by applying only the primary winding to the manufactured core.

[0138] The core manufactured in Example 4 exhibits a higher investment rate than the core manufactured in Reference Example 2. This is because the powder manufactured by the SWAP (Spinning water atomization) method does not form a perfect sphere, whereas the powder manufactured by the gas injection method is close to a sphere, resulting in a higher filling rate under the same molding conditions.

[0139] Core loss evaluation

[0140] The primary and secondary windings were wound around the cores manufactured in Example 4 and Reference Example 2, and the iron loss due to the core was measured by measuring the current induced in the secondary winding while applying current to the primary winding using a BH analyzer (IWATSU SY-8219).

[0141] The iron loss according to frequency under the condition of Bm=0.1 T of the cores manufactured in Example 4 and Reference Example 2 was represented as a log exponential graph.

[0142] It was confirmed that the core manufactured in Example 4 had a lower iron loss than the core manufactured in Reference Example 2.

Claims

1. Fe100-abcd-xSi a B b P c C d Mo x As an alloy having the composition of 0 in the above composition <a≤10, 0<b≤10, 0<c≤5, 0<d≤5, 1<x<4를 만족하는 것으로, An Fe-based high-performance amorphous alloy containing Fe in an amount of (100-abcdx) at%, Si in an amount of a at%, B in an amount of b at%, P in an amount of c at%, C in an amount of d at%, and Mo in an amount of x at%.

2. In paragraph 1, An Fe-based high-performance amorphous alloy satisfying the following equations 1 and 2: [Formula 1] GFA energy (%) = 100 * B / A [Formula 2] 40 < GFA energy < 100 In the above equations 1 and 2, GFA energy is the crystallization energy retention rate, B is the crystallization energy measured by manufacturing the above alloy into a ribbon with a thickness of 120 μm, width of 2 mm, and length of 2 mm and heating it from room temperature to 800°C at a heating rate of 40 K / s using a DSC (Differential Scanning Calorimetery) device. A is the crystallization energy measured by manufacturing the above alloy into a ribbon with a thickness of 70 μm, width of 2 mm, and length of 2 mm and heating it from room temperature to 800°C at a heating rate of 40 K / s using a DSC (Differential Scanning Calorimetery) device.