Amorphous Alloy Ribbon Crystallization via Segmented Heating
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Solution Overview
Problem
Existing methods for crystallizing amorphous alloy ribbons to produce nanocrystalline alloy ribbons face challenges such as non-uniform thickness, burr formation, sagging, and uneven magnetic properties due to temperature distribution issues during the crystallization process, limiting productivity and resulting in varied magnetic properties across the alloy ribbon.
Innovation Solution
A method involving the formation of a laminated body with shifted thick portions, initial heating to a temperature below the crystallization start, and subsequent heating of end portions to or above the crystallization temperature, while maintaining the ambient temperature to ensure uniform crystallization, adhering to the heat balance formula Q1+Q2+Q3≥Q4, to prevent heat concentration and promote uniform magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the laminated body is heated from both ends with plates to suppress temperature rise, then the temperature distribution is improved, but the thickness of the laminated body is restricted and productivity decreases
Solution Approach 1:
The heating process is segmented into two distinct stages: first heating the entire laminated body to a temperature below the crystallization starting point, then selectively heating only the end portions to or above the crystallization temperature. This segmentation allows different regions of the laminated body to undergo different thermal processes, enabling uniform crystallization throughout while maintaining high productivity and avoiding the thickness restrictions of conventional single-stage heating methods.
Solution Approach 2:
The laminated body is preliminarily heated to a temperature close to but below the crystallization starting temperature before the end portions are heated to or above the crystallization temperature. This preliminary heating action prepares the entire laminated body for uniform crystallization by reducing the temperature gradient and ensuring that when the end portions are heated, the heat distributes uniformly throughout the structure, enabling simultaneous crystallization of all ribbons.
2Temperature
If amorphous alloy ribbons are heated and crystallized independently one by one, then the temperature rise influence is reduced, but the productivity becomes low
Solution Approach 1:
Multiple amorphous alloy ribbons are combined into a laminated body structure and heated simultaneously in a unified thermal field. The first heating step heats the entire laminated body uniformly, and the second step heats the end portions, causing crystallization heat to distribute throughout all ribbons at once. This merging approach enables simultaneous crystallization of many ribbons, dramatically improving productivity compared to independent one-by-one heating while maintaining effective temperature control through the two-stage process.
3Manufacturing precision
If the laminated body is heated uniformly, then the crystallization is uniform, but the thick portions concentrate heat and cause non-uniform magnetic properties
Solution Approach 1:
Different regions of the laminated body are subjected to different heating conditions: the entire laminated body receives gentle heating to a temperature below crystallization in the first step, while only the end portions receive intense heating to or above crystallization temperature in the second step. This local differentiation in heating quality allows the thick portions to benefit from the gentle preliminary heating that prevents heat concentration, while still achieving uniform crystallization throughout when the end portions are selectively heated.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances productivity by ensuring uniform crystallization and magnetic properties across the alloy ribbon, reducing the formation of coarsened crystals and compound phases, thereby maintaining consistent soft magnetic properties.
Implementation Method 1
heating an end portion in a lamination direction of the laminated body to a second temperature range equal to or more than a crystallization starting temperature
Implementation Method 2
a heat amount generated when the laminated body crystallizes is Q3
Data Source
AI summary
There is provided a method for manufacturing an alloy ribbon that suppresses different magnetic properties at each position of the alloy ribbon obtained by crystallizing an amorphous alloy ribbon. The method for manufacturing an alloy ribbon includes: heating a laminated body in which positions of thick portions of a plurality of amorphous alloy ribbons are shifted to a first temperature range less than a crystallization starting temperature; and heating an end portion in a lamination direction of the laminated body to a second temperature range equal to or more than the crystallization starting temperature after the heating the laminated body. An ambient temperature is held after heating the laminated body such that the laminated body is maintained within a temperature range in which the laminated body can be crystallized by heating the end portion to the second temperature range.