R-Fe-B Magnetic Composition for High-Temperature Magnetization Retention
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Solution Overview
Problem
Nd—Fe—B-based magnetic materials experience a significant decrease in coercive force and saturation magnetization at high temperatures, which is problematic for high-output and miniaturized motor applications, especially when Nd is substituted with light rare earth elements like La or Ce.
Innovation Solution
The development of an R—Fe—B-based magnetic material with a main phase having an R2T14B type crystal structure, where Nd is partially substituted with La and Fe is substituted with Co or Ni, maintaining stability and improving high-temperature saturation magnetization within practical limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a part or all of Nd is substituted with light rare earth elements (La, Ce) to reduce Nd usage, then cost is reduced and resource sustainability is improved, but saturation magnetization at high temperature significantly decreases
Solution Approach 1:
The patent changes the compositional parameters by introducing Co substitution for Fe in specific ratios (0.05≤z≤0.40) while controlling La substitution (0.25≤x≤1.00). This parameter optimization resolves the contradiction by finding the right balance between reducing Nd content and maintaining high-temperature saturation magnetization through the synergistic effect of Co addition.
Solution Approach 2:
The patent creates a composite magnetic material system ((Nd,Pr)(1-x-y)LaxR1y))2((Fe(1-z-w)(Co, Ni)zMw))14B that combines multiple rare earth elements and transition metals. This composite approach allows the material to benefit from the cost and resource advantages of light rare earth substitution while compensating for the saturation magnetization loss through Co/Ni addition, thus resolving the technical contradiction.
2Quantity of substance
If a part or all of Nd is substituted with light rare earth elements to reduce Nd usage, then resource sustainability is improved, but coercive force at high temperature significantly decreases
Solution Approach 1:
The patent optimizes compositional parameters by controlling the substitution ratios of La (x) and Co (z) within specific ranges. This parameter adjustment resolves the contradiction by maintaining coercive force at high temperature through Co substitution while achieving Nd reduction, as Co addition compensates for the coercive force loss caused by light rare earth substitution.
3Reliability
If Fe is substituted with Co to improve saturation magnetization at high temperature, then magnetic performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the compositional parameters by optimizing the Co substitution ratio (0.05≤z≤0.40) to achieve the minimum effective amount needed to improve high-temperature saturation magnetization. This resolves the contradiction by finding the cost-effective balance point where sufficient magnetic performance improvement is achieved without excessive Co addition that would unnecessarily increase manufacturing cost.
Data Source
AI summary
A magnetic material according to the present disclosure includes a main phase having an R2T14B type crystal structure (R is a rare earth element and T is a transition metal element). The main phase has a composition represented by ((Nd, Pr)(1-x-y)LaxR1y))2((Fe(1-z-w)(Co, Ni)zMw))14B (where, R1 is a rare earth element other than Nd, Pr, and La, M is an element other than Fe, Co, Ni, and a rare earth element, and the like, and 0.25≤x≤1.00, 0≤y≤0.10, 0.15≤z≤0.40, and 0≤w≤0.1 are satisfied). A manufacturing method of the magnetic material according to the present disclosure includes melting a raw material containing the elements constituting the main phase and solidifying the melted raw material.