Amorphous Alloy Ribbon Cu Segregation Workability
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Solution Overview
Problem
Amorphous alloy ribbons used for nanocrystalline soft magnetic alloys are prone to embrittlement, making them difficult to work with in manufacturing, and their magnetic properties are influenced by thermal history and element concentration distribution, which is challenging for mass production and achieving high magnetic performance.
Innovation Solution
Control the Cu concentration distribution in the amorphous alloy ribbon by controlling the manufacturing conditions, such as cooling rate and atmosphere, to create a Cu-segregated portion with a maximum concentration of 4 at.% or less, enhancing workability and magnetic properties by forming a nanocrystalline layer with improved insulation and high-frequency performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If amorphous alloy ribbon is manufactured by rapid quenching method, then excellent soft magnetic properties are achieved, but the ribbon becomes embrittled and difficult to work with
Solution Approach 1:
The invention creates a Cu-segregated portion localized at the surface layer (depth of 2-20 nm) with controlled Cu concentration (maximum 4 at.% or less), while the inner portion maintains the original amorphous alloy composition. This local differentiation allows the surface to have improved toughness for workability while the bulk retains excellent soft magnetic properties.
Solution Approach 2:
The invention changes the Cu concentration parameter in the surface layer by controlling manufacturing conditions (cooling rate, atmosphere) to create a Cu-segregated portion with maximum Cu concentration of 4 at.% or less. This parameter change in the surface region improves toughness without compromising the magnetic properties of the bulk material.
2Ease of manufacture
If Cu concentration is increased to improve workability, then toughness is enhanced, but magnetic properties deteriorate
Solution Approach 1:
The invention confines the Cu-segregated portion to the surface layer with depth of 2-20 nm, creating a local region with enhanced toughness. The bulk material (500 nm depth and beyond) maintains Cu concentration at levels that preserve excellent soft magnetic properties, thus resolving the contradiction between workability and magnetic performance.
Solution Approach 2:
The invention applies a limited amount of Cu segregation (maximum 4 at.% in the surface layer) rather than uniform distribution throughout the material. This partial action provides sufficient toughness improvement for workability while avoiding excessive Cu content that would deteriorate magnetic properties in the bulk material.
3Productivity
If element concentration distribution is not controlled, then manufacturing is simpler, but magnetic properties show variation and instability
Solution Approach 1:
The invention changes the manufacturing parameters (cooling rate, atmosphere composition) to naturally produce a Cu-segregated portion with controlled Cu concentration (maximum 4 at.% or less) in the surface layer. This parameter control ensures stable and reproducible magnetic properties while maintaining mass production efficiency.
Solution Approach 2:
The invention establishes a feedback mechanism where the manufacturing conditions (cooling rate, atmosphere) are controlled to produce the desired Cu concentration distribution. By monitoring and adjusting these parameters, the process ensures consistent Cu segregation patterns that yield stable magnetic properties across mass production.
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
The controlled Cu concentration distribution results in an amorphous alloy ribbon with improved toughness and magnetic properties, facilitating easier processing and achieving stable, high-performance nanocrystalline soft magnetic alloys with reduced iron loss and variation in characteristics.
Implementation Method 1
amorphous alloys are generally manufactured by quenching raw materials from a liquid phase or a gas phase
Implementation Method 2
These Fe-based nanocrystalline alloys are fabricated by annealing amorphous alloys prepared by rapid quenching technique from a melt or gas phase to microcrystallize them
Implementation Method 3
a Cu-segregated portion is present where Cu is segregated in a higher concentration in the surface side of the amorphous alloy ribbon than in the outermost surface
Data Source
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AI summary
Disclosed are a thin strip of an amorphous alloy having excellent workability, a nanocrystalline soft magnetic alloy which can stably provide good magnetic properties, and a magnetic core using the nanocrystalline soft magnetic alloy. The thin strip of an amorphous alloy is characterized in that the thin strip is formed of an alloy having a composition represented by Fe100-a-b-c-dMaSibBcCud (atomic%), wherein 0 ≦ a ≦ 10, 0 ≦ b ≦ 20, 4 ≦ c ≦ 20, 0.1 ≦ d ≦ 3, and 9 ≦ a + b + c ≦ 35, and containing unavoidable impurities, and, in the composition, M represents at least one element selected from Ti, V, Zr, Nb, Mo, Hf, Ta, and W, a Cu segregated part is present, on the surface side of the thin strip of the amorphous alloy, in which Cu is segregated at a higher concentration than the Cu concentration in the outermost surface part of the thin strip of the amorphous alloy, and the highest Cu concentration in the Cu segregated part is not more than 4 atomic%.