Hexagonal Ferrite Magnet with Pr, Nd, La Substitution
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Solution Overview
Problem
Conventional M-type ferrite sintered magnets face challenges in achieving high coercive force and residual magnetic flux density while maintaining cost-effectiveness, as they require high Co content, which increases material costs.
Innovation Solution
Incorporating Pr and/or Nd into a hexagonal M-type ferrite with substituted La and Co, with specific atomic percentage ratios, to enhance magnetic properties without increasing Co content, and optionally adding Si and Ca for improved sinterability and grain control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Co content is increased to improve coercive force and residual magnetic flux density, then magnetic properties are improved, but material cost increases
Solution Approach 1:
The invention changes the compositional parameters by introducing Pr and/or Nd elements alongside La and Co substitution, creating a multi-element substitution system that achieves high coercive force without relying solely on increased Co content. The specific compositional ranges (La: 0.003-10 atomic%, R: 0-10 atomic%, Co: 0.05-5 atomic%) represent optimized parameter changes that balance magnetic properties with cost considerations.
Solution Approach 2:
The invention creates a composite ferrite material system combining multiple rare earth elements (La, Pr, Nd) with transition metal substitution (Co, Fe) to achieve synergistic effects. This composite approach allows the material to exhibit enhanced coercive force and residual magnetic flux density while controlling the expensive Co content within specific ranges rather than using high Co alone.
2Reliability
If Co content is increased to improve residual magnetic flux density, then magnetic performance is enhanced, but manufacturing cost increases
Solution Approach 1:
The invention optimizes the compositional parameters by establishing specific ranges for multiple elements working together: La (0.003-10 atomic%), R (0-10 atomic%), Co (0.05-5 atomic%), and Fe (80-95 atomic%). This multi-parameter optimization achieves high residual magnetic flux density while controlling Co content, avoiding the need for expensive high-Co formulations.
Solution Approach 2:
The invention introduces Pr and/or Nd as intermediary elements that mediate between La substitution and Co addition. These intermediary rare earth elements help achieve the desired magnetic properties through cooperative effects, allowing reduced Co content while maintaining or enhancing residual magnetic flux density compared to conventional approaches.
3Quantity of substance
If La and Co substitution is performed to reduce material cost, then cost decreases, but coercive force and saturation magnetization are insufficient
Solution Approach 1:
The invention applies parameter changes by establishing a multi-element substitution system with optimized compositional ranges. The coordinated substitution of La (0.003-10 atomic%), R (0-10 atomic%), Co (0.05-5 atomic%), and Fe (80-95 atomic%) creates a balanced composition that achieves both cost reduction and sufficient coercive force, overcoming the limitations of simple La-Co substitution.
Solution Approach 2:
The invention develops a composite ferrite material incorporating multiple rare earth elements (La, Pr, Nd) with transition metals (Co, Fe) in specific proportions. This composite structure provides synergistic effects where the combination of elements delivers adequate coercive force and saturation magnetization at lower overall cost compared to conventional high-Co formulations.
4Quantity of substance
If La and Co substitution is performed to reduce material cost, then manufacturing cost decreases, but saturation magnetization is insufficient
Solution Approach 1:
The invention optimizes compositional parameters with Fe content set at 80-95 atomic%, ensuring sufficient saturation magnetization is maintained. The coordinated substitution strategy with La (0.003-10 atomic%), R (0-10 atomic%), and Co (0.05-5 atomic%) allows cost reduction while preserving adequate saturation magnetization through balanced element ratios.
Solution Approach 2:
The composite ferrite material combines multiple elements (La, Pr, Nd, Co, Fe) in optimized proportions to achieve a balance between cost and performance. The high Fe content (80-95 atomic%) in the composite structure ensures sufficient saturation magnetization is maintained even with La and Co substitution, overcoming the limitation of simple substitution approaches.
Data Source
AI summary
The present invention provides a ferrite magnet material comprising, as a main phase, a ferrite having a hexagonal structure, the main phase containing A, La, R, Fe and Co, wherein A is at least one element selected from Sr, Ba and Pb, R is Pr and/or Nd, and the proportions of the total metal elements A, La, R, Fe and Co in the main phase are respectively A: 1 to 13 atomic %, La: 0.003 to 10 atomic %, R: 0 to 10 atomic % (excluding 0) Fe: 80 to 95 atomic % and Co: 0.05 to 5 atomic % based on the total amounts of metal elements. The residual magnetic flux density Br and coercive force HcJ can be improved without increasing the content of Co by incorporating Pr and/or Nd along with La and Co in the ferrite magnet material.