Amorphous Soft Magnetic Powder Heat Treatment for Low Coercive Force
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Solution Overview
Problem
Existing methods for producing soft magnetic powders struggle to reliably reduce coercive force without compromising production efficiency.
Innovation Solution
A method involving the production of an amorphous alloy powder with a specific composition and particle size, followed by a heat treatment at controlled temperatures to produce a soft magnetic powder with low coercive force, and then pressing this powder at a specific pressure to achieve a green compact with desired volume resistivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the amorphous alloy powder has a specific composition and particle size, then the magnetic properties are improved, but the production process becomes more complex
Solution Approach 1:
The invention specifies precise parameter ranges for composition (Fea(Si1-xBx)bCc with defined atomic ratios) and particle size (3.0-40.0 μm average diameter) to ensure consistent magnetic properties. By establishing clear parameter boundaries, the invention transforms a complex production challenge into a manageable process with defined specifications, resolving the contradiction between property consistency and production complexity.
2Loss of energy
If the green compact has a volume resistivity of 3.7×10−2 Ω·cm or less, then the eddy current loss is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The invention sets a specific volume resistivity threshold (3.7×10−2 Ω·cm or less) for the green compact to minimize eddy current losses. This parameter specification allows manufacturers to balance energy efficiency requirements with achievable manufacturing precision, resolving the contradiction by providing a clear target value that optimizes the trade-off between energy loss reduction and production feasibility.
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 method effectively reduces coercive force variation and enhances the stability and quality of the soft magnetic powder, leading to improved magnetic properties and reduced iron loss in magnetic elements.
Implementation Method 1
a heat treatment step of subjecting the amorphous alloy powder to a heat treatment at a temperature of 370° C. or higher and 460° C. or lower
Implementation Method 2
By performing the heat treatment, it is possible to reduce various defects and anisotropy (stress-induced anisotropy) that are introduced during the production of the soft magnetic powder
Implementation Method 3
when the amorphous alloy soft magnetic powder is pressurized at a pressure of 63.7 MPa to produce a green compact having a mass of 7.0 g, volume resistivity of the green compact is 3.7×10−2 [Ω·cm] or less
Data Source
AI summary
A method for producing an amorphous alloy soft magnetic powder, includes: producing an amorphous alloy powder that has an average particle diameter of 3.0 μm or more and 40.0 μm or less and that is formed of impurities and a composition represented by Fea(Si1-xBx)bCc, where 76.0≤a≤81.0, 16.0≤b≤22.0, 0<c≤3.0, and 0.5≤x≤0.9; and performing a heat treatment of heating at 370° C. or higher and 460° C. or lower. When the amorphous alloy soft magnetic powder is pressurized at a pressure of 63.7 MPa to produce a green compact having a mass of 7.0 g, volume resistivity is 3.7×10−2 [Ω·cm] or less.