Fe-Based Amorphous Alloy Heat Treatment Wrapper
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Solution Overview
Problem
The production of soft magnetic materials with high saturation magnetization is hindered by the formation of an oxide layer when Fe-based amorphous alloys are heat-treated in an atmosphere, leading to a decrease in magnetic properties, and requires controlled atmosphere conditions and large-scale equipment.
Innovation Solution
Heat-treating Fe-based amorphous alloys wrapped with sheets of substances having a negative standard Gibbs energy of oxide formation greater than Fe, such as Ti, Si, or Al, to suppress oxide layer formation, allowing for high saturation magnetization production even in uncontrolled oxygen-rich atmospheres.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heat treatment is performed in an atmosphere without controlling the oxygen concentration, then the process is simpler and does not require large-scale equipment, but an oxide layer forms on the surface of the soft magnetic material, causing a decrease in saturation magnetization and deterioration of magnetic properties
Solution Approach 1:
A wrapper containing Fe-based amorphous alloy is introduced as an intermediary substance during heat treatment. The wrapper acts as a mediator between the alloy and the atmosphere, preventing direct oxidation of the alloy surface while allowing heat treatment to proceed in air without requiring controlled atmosphere conditions
Solution Approach 2:
The invention converts the harmful effect of oxygen in the atmosphere into a beneficial outcome by using the wrapper to selectively interact with oxygen. The wrapper material is designed to form an oxide layer that protects the underlying alloy, effectively using oxidation as a protective mechanism rather than a harmful one
2Reliability
If heat treatment is performed in a controlled atmosphere to prevent oxide layer formation, then magnetic properties are maintained, but the process requires atmosphere control steps and large-scale equipment
Solution Approach 1:
The wrapper serves as a portable, self-contained atmosphere control mechanism. Instead of requiring large-scale equipment to control the overall heat treatment atmosphere, the wrapper creates a localized protective environment directly on the alloy surface, dramatically simplifying the required equipment
Solution Approach 2:
Atmosphere control is applied locally at the surface of the alloy through the wrapper, rather than requiring global control of the entire heat treatment chamber. This localized approach maintains magnetic properties without the need for complex system-wide atmosphere control
3Productivity
If heat treatment is performed in air without atmosphere control, then equipment requirements are reduced, but saturation magnetization decreases due to oxide layer formation
Solution Approach 1:
The alloy is pre-wrapped before heat treatment, establishing protective coverage in advance. This preliminary action ensures that when heat treatment occurs in air, the alloy surface is already protected from oxidation, maintaining high saturation magnetization without requiring post-treatment correction steps
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 method effectively prevents oxide layer formation, maintaining high saturation magnetization and magnetic properties without the need for atmosphere control, enabling efficient production of soft magnetic materials with improved magnetic properties.
Implementation Method 1
the alloy is wrapped with a sheet comprising one or more substances having a standard Gibbs energy of formation of an oxide thereof that is larger in a negative direction than Fe
Implementation Method 2
a Fe-based nanocrystalline soft magnetic material can be produced by performing a heat treatment, in which a Fe-based amorphous alloy comprising Fe as a main component is heated to a crystal formation temperature range and is then cooled
Data Source
AI summary
It is an object of the present disclosure to produce a soft magnetic material having high saturation magnetization by heat-treating a Fe-based amorphous alloy, without needing the control of the atmosphere. The present disclosure provides a method for producing a soft magnetic material, including heat treating a Fe-based amorphous alloy in a state in which the alloy is wrapped with a sheet comprising one or more substances having a standard Gibbs energy of formation of an oxide thereof that is larger in a negative direction than Fe, to form a crystal phase.