Fe-Based Magnetic Sintered Compact with BN for Sputtering Targets
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Solution Overview
Problem
The existing sintered compacts used for magnetic recording media face issues with machinability due to the formation of brittle iron oxide, leading to cracks and chipping, which deteriorates the yield and quality of the sputtering targets, especially when materials like C or BN are present.
Innovation Solution
An Fe-based magnetic material sintered compact with reduced oxygen content, containing BN, Pt, C, and optional additives like B, Ru, Ag, Au, Cu, and inorganic materials, is produced using a method that minimizes powder pulverization and oxidation, resulting in improved machinability and reduced oxygen levels below 4000 wtppm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sintered compact containing C or BN is used to improve magnetic recording medium performance, then the magnetic properties and corrosion resistance are improved, but the machinability deteriorates due to formation of brittle iron oxide causing cracks and chipping
Solution Approach 1:
The patent applies parameter changes by controlling the oxygen content in the sintered compact to 1000 ppm or less (a specific quantitative parameter). This parameter control prevents the formation of brittle iron oxide while maintaining the beneficial properties of C or BN additives, thereby resolving the contradiction between corrosion resistance and machinability
Solution Approach 2:
The patent uses composite materials by combining Fe-based magnetic material with C or BN additives in a controlled composition. The composite structure provides both the desired magnetic properties and corrosion resistance while the controlled oxygen content ensures good machinability by preventing iron oxide formation
2Ease of manufacture
If oxygen content is reduced to below 1000 wtppm to improve machinability, then cracks and chipping are suppressed, but the production process complexity increases
Solution Approach 1:
The patent applies preliminary action by performing powder mixing and sintering under controlled atmospheric conditions (inert or reducing atmosphere) before the iron oxide can form during machining. This preliminary control of oxygen content during manufacturing prevents the formation of brittle phases that would cause machining problems, thereby achieving good machinability without requiring complex post-processing
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 approach effectively suppresses crack and chipping generation during processing, enhancing the yield and quality of sputtering targets, allowing for the deposition of high-quality magnetic thin films with minimal abnormal discharge and particles.
Implementation Method 1
when the sintered compact is processed into a sputtering target
Implementation Method 2
a magnetic thin film having a granular structure in which the FePt magnetic grains having an L10 structure are isolated through the interposition of nonmagnetic materials
Data Source
AI summary
An Fe-based magnetic material sintered compact containing BN, wherein the Fe-based magnetic material sintered compact has an oxygen content of 4000 wtppm or less. The present invention provides a sintered compact which enables the formation of a magnetic thin film in a thermally assisted magnetic recording media, and in which the generation of cracks and chipping is suppressed when the sintered compact is processed into a sputtering target or the like.