阅读说明：本技术 R-t-b系永久磁铁 (R-T-B permanent magnet ) 是由 岩崎信 原田明洋 于 2020-03-18 设计创作，主要内容包括：本发明提供一种剩余磁通密度Br、矫顽力HcJ及耐腐蚀性良好的R-T-B系永久磁铁。一种R-T-B系永久磁铁,其中,R为一种以上的稀土元素,T为Fe及Co,B为硼。所述磁铁含有M、C及N。M为选自Cu、Ga、Mn、Zr及Al中的两种以上,并且至少含有Cu及Ga。R的合计含量为29.0质量％以上且33.5质量％以下,Co的含量为0.10质量％以上且0.49质量％以下,B的含量为0.80质量％以上且0.96质量％以下,M的合计含量为0.63质量％以上且4.00质量％以下,Cu的含量为0.51质量％以上且0.97质量％以下,Ga的含量为0.12质量％以上且1.07质量％以下,C的含量为0.065质量％以上且0.200质量％以下,N的含量为0.023质量％以上且0.323质量％以下,Fe为实际的剩余部分。(The invention provides an R-T-B permanent magnet with excellent residual magnetic flux density Br, coercive force HcJ and corrosion resistance. An R-T-B permanent magnet, wherein R is at least one rare earth element, T is Fe and Co, and B is boron. The magnet contains M, C and N. M is two or more selected from Cu, Ga, Mn, Zr and Al, and at least Cu and Ga are contained. The total content of R is 29.0 to 33.5 mass%, the content of Co is 0.10 to 0.49 mass%, the content of B is 0.80 to 0.96 mass%, the total content of M is 0.63 to 4.00 mass%, the content of Cu is 0.51 to 0.97 mass%, the content of Ga is 0.12 to 1.07 mass%, the content of C is 0.065 to 0.200 mass%, the content of N is 0.023 to 0.323 mass%, and Fe is the actual remainder.)

1. An R-T-B permanent magnet, wherein,

r is more than one rare earth element, T is Fe and Co, B is boron,

the R-T-B permanent magnet contains M, C and N,

m is two or more selected from Cu, Ga, Mn, Zr and Al, and contains at least Cu and Ga,

the total mass of the R-T-B permanent magnet is 100%,

the total content of R is 29.0-33.5% by mass,

the content of Co is 0.10-0.49 mass%,

the content of B is 0.80 to 0.96 mass%,

the total content of M is 0.63-4.00 mass%,

the Cu content is 0.51-0.97 mass%,

the Ga content is 0.12-1.07 mass%,

the content of C is 0.065-0.200 mass%,

the content of N is 0.023 mass% or more and 0.323 mass% or less,

fe is the actual remainder.

2. The R-T-B permanent magnet according to claim 1,

the Mn content is 0.02 mass% or more and 0.08 mass% or less.

3. The R-T-B series permanent magnet according to claim 1 or 2,

the Zr content is 0.15-0.42 mass%.

4. The R-T-B series permanent magnet according to claim 1 or 2,

the content of Al is 0.08 to 0.41 mass%.

5. The R-T-B series permanent magnet according to claim 1 or 2,

the total content of Co, Cu and Al is 1.00 mass% or more and 2.00 mass% or less.

6. The R-T-B series permanent magnet according to claim 1 or 2,

the total content of Co and Mn is 0.40 to 1.00 mass%.

Technical Field

The present invention relates to an R-T-B permanent magnet.

Background

Patent document 1 discloses a compound having R₂T₁₄An R-T-B sintered magnet having B crystal grains. Discloses that more than 2 adjacent R₂T₁₄The grain boundary formed by the B crystal grains has the concentration of R, Ga, Co, Cu and N which are all higher than that of R₂T₁₄And a R-Ga-Co-Cu-N concentration part in the B crystal grains. Further, it is disclosed that the corrosion resistance and the magnetic properties are excellent in combination due to the above characteristics.

Disclosure of Invention

Technical problem to be solved by the invention

Currently, there is a demand for R-T-B permanent magnets having excellent magnetic properties and corrosion resistance.

The invention aims to provide an R-T-B permanent magnet with excellent residual magnetic flux density Br, coercive force HcJ and corrosion resistance.

Technical solution for solving technical problem

In order to achieve the above object, the present invention provides an R-T-B permanent magnet, wherein R is at least one rare earth element, T is Fe and Co, and B is boron, wherein the R-T-B permanent magnet contains M, C and N,

m is two or more selected from Cu, Ga, Mn, Zr and Al, and contains at least Cu and Ga,

the total mass of the R-T-B permanent magnet is 100%,

the total content of R is 29.0-33.5% by mass,

the content of Co is 0.10-0.49 mass%,

the content of B is 0.80 to 0.96 mass%,

the total content of M is 0.63-4.00 mass%,

the Cu content is 0.51-0.97 mass%,

the Ga content is 0.12-1.07 mass%,

the content of C is 0.065-0.200 mass%,

the content of N is 0.023 mass% or more and 0.323 mass% or less,

fe is the actual remainder.

The R-T-B permanent magnet of the present invention has the above-mentioned characteristics, and thus has good Br, HcJ and corrosion resistance.

The Mn content may be 0.02 mass% or more and 0.08 mass% or less.

The Zr content may be 0.15 mass% or more and 0.42 mass% or less.

The content of Al may be 0.08 mass% or more and 0.41 mass% or less.

The total content of Co, Cu, and Al may be 1.00 mass% or more and 2.00 mass% or less.

The total content of Co and Mn may be 0.40 mass% or more and 1.00 mass% or less.

Detailed Description

The present invention will be described below based on embodiments.

< R-T-B series permanent magnet >

The R-T-B permanent magnet of the present embodiment will be explained. The R-T-B permanent magnet of the present embodiment comprises a magnet having R₂T₁₄Main phase particles composed of crystal grains of type B crystal structure. The R-T-B permanent magnet of the present embodiment has a grain boundary formed by two or more adjacent main phase grains. The R-T-B permanent magnet of the present embodiment may have a concentrated portion of R-Ga-Co-Cu-N in which the concentrations of R, Ga, Co, Cu, and Nd are higher than those of the main phase grains in the grain boundary.

The average particle diameter of the main phase particles is usually about 1 μm to 30 μm.

The grain boundaries include two-particle grain boundaries formed by two adjacent main phase particles and multi-particle grain boundaries formed by three or more adjacent main phase particles. The R-Ga-Co-Cu-N concentrated portion is a region which exists in the grain boundary and in which the concentrations of R, Ga, Co, Cu, and N are higher than those in the main phase grains. The R-Ga-Co-Cu-N concentrated portion may contain any other components as long as R, Ga, Co, Cu and N are contained as main components.

The grain boundary of the R-T-B permanent magnet of the present embodiment includes at least the above-described R-Ga-Co-Cu-N concentrated portion. The concentration ratio R of R may be contained in addition to the concentration portion R-Ga-Co-Cu-N₂T₁₄R-rich phase with high B crystal grains or concentration ratio R of boron (B)₂T₁₄B-rich phase with high B grains.

The R-T-B permanent magnet of the present embodiment may be a sintered body formed using an R-T-B alloy.

R represents at least one of rare earth elements. The rare earth elements refer to Sc, Y and lanthanoid elements belonging to group 3 of the long period periodic Table of elements. The lanthanoid element includes, for example, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, etc. The rare earth elements can be classified into light rare earth elements and heavy rare earth elements, the heavy rare earth elements refer to Gd, Tb, Dy, Ho, Er, Tm, Yb, and Lu, and the light rare earth elements are rare earth elements other than the heavy rare earth elements. In the present embodiment, Nd and/or Pr may be contained as R from the viewpoint of appropriately controlling the manufacturing cost and the magnetic properties. In addition, from the viewpoint of improving HcJ in particular, both the light rare earth element and the heavy rare earth element may be contained. The content of the heavy rare earth element is not particularly limited, and the heavy rare earth element may not be contained. The content of the heavy rare earth element is, for example, 5 mass% or less (including 0 mass%).

In the present embodiment, T is Fe and Co. In addition, B is boron.

The total content of R in the R-T-B permanent magnet of the present embodiment is 29.0 mass% to 33.5 mass%. When the total content of R is too small, the formation of main phase particles of the R-T-B permanent magnet is insufficient. Therefore, α -Fe and the like having soft magnetism are precipitated, and HcJ is lowered. When the total content of R is too large, the volume ratio of the main phase grains of the R-T-B permanent magnet decreases, and Br decreases.

The content of B in the R-T-B permanent magnet of the present embodiment is 0.80 mass% to 0.96 mass%. The content may be 0.80 mass% or more and 0.90 mass% or less. If the content of B is too small, HcJ decreases. Further, the sinterability is reduced. If the content of B is too large, abnormal grain growth is likely to occur. Further, Br and corrosion resistance are reduced.

T is Fe and Co. The content of Co in the R-T-B permanent magnet of the present embodiment is 0.10 mass% to 0.49 mass%. The content may be 0.10 mass% or more and 0.44 mass% or less. The content may be 0.20 mass% or more and 0.42 mass% or less. The content may be 0.20 mass% or more and 0.39 mass% or less. When the Co content is too small, the R-Ga-Co-Cu-N concentrated portion is difficult to form, and the corrosion resistance is lowered. When the content of Co is too large, Br and HcJ decrease. The R-T-B permanent magnet of the present embodiment tends to be expensive.

The R-T-B permanent magnet of the present embodiment further includes M. M is two or more selected from Cu, Ga, Mn, Zr and Al, and contains at least Cu and Ga. The total content of M is not particularly limited, and is, for example, 0.63 mass% or more and 4.00 mass% or less.

The content of Cu in the R-T-B permanent magnet of the present embodiment is 0.51 mass% or more and 0.97 mass% or less. The content may be 0.53 mass% or more and 0.97 mass% or less. The content may be 0.55 mass% or more and 0.80 mass% or less. By sufficiently containing Cu, the R-Ga-Co-Cu-N concentrated portion can be sufficiently formed even if the Co content is 0.49 mass% or less. When the Cu content is too small, the R-Ga-Co-Cu-N concentrated portion is difficult to form, and the corrosion resistance is lowered. When the Cu content is too large, Br decreases.

The content of Ga in the R-T-B permanent magnet of the present embodiment is 0.12 to 1.07 mass%. The content may be 0.13 mass% or more and 1.06 mass% or less. The content may be 0.55 mass% or more and 0.82 mass% or less. By sufficiently containing Ga, the R-Ga-Co-Cu-N concentrated portion is sufficiently formed even if the Co content is 0.49 mass% or less. When the content of Ga is too small, the R-Ga-Co-Cu-N concentrated portion is difficult to form, and the corrosion resistance is lowered. When the Ga content is too large, Br decreases.

The R-T-B permanent magnet of the present embodiment may contain Al as needed. By containing Al, the R-Ga-Co-Cu-N concentrated portion can be easily formed sufficiently even if the Co content is 0.49 mass% or less. The content of Al is not particularly limited, and Al may not be contained. The content of Al is, for example, 0.08 mass% or more and 0.41 mass% or less. The content may be 0.10 mass% or more and 0.19 mass% or less. The smaller the content of Al, the more likely HcJ and corrosion resistance are reduced. The larger the Al content, the more likely the Br is decreased.

The R-T-B permanent magnet of the present embodiment may contain Zr as necessary. By containing Zr, a ZrB phase is easily formed in the grain boundary. The formation of the ZrB phase improves the corrosion resistance and the stability of the characteristics at the sintering temperature. The content of Zr is not particularly limited, and Zr may not be contained. The Zr content is, for example, 0.15 mass% or more and 0.42 mass% or less. The content may be 0.22 mass% or more and 0.31 mass% or less. The smaller the Zr content is, the more likely the corrosion resistance and sinterability are reduced. The more Zr content, the more easily Br is decreased.

The R-T-B permanent magnet of the present embodiment may contain Mn as needed. By containing Mn, the R-Ga-Co-Cu-N concentrated portion can be easily formed sufficiently even if the Co content is 0.49 mass% or less. The content of Mn is not particularly limited, and Mn may not be contained. The content of Mn is, for example, 0.02 mass% or more and 0.08 mass% or less. The content may be 0.03 mass% or more and 0.05 mass% or less. The smaller the Mn content, the more likely the corrosion resistance is decreased. The larger the Mn content is, the more easily Br and HcJ decrease.

The total content of Co, Cu, and Al in the R-T-B permanent magnet of the present embodiment may be 1.00 mass% or more. By setting the total content of Co, Cu, and Al to 1.00 mass% or more, the corrosion resistance is easily improved. The total content of Co, Cu and Al is not limited to an upper limit, and is, for example, 2.00 mass% or less.

The total content of Co and Mn in the R-T-B permanent magnet of the present embodiment may be 0.40 mass% or more. By setting the total content of Co and Mn to 0.40 mass% or more, the corrosion resistance is easily improved. The total content of Co and Mn is not limited to an upper limit, and is, for example, 1.00 mass% or less.

The R-T-B permanent magnet of the present embodiment includes C and N.

In the R-T-B permanent magnet of the present embodiment, the carbon content is 0.065 to 0.200 mass%. The content may be 0.073 to 0.202 mass%, or may be 0.076 to 0.105 mass%. When the amount of carbon is within the above range, an appropriate amount of Fe-rich phase is easily formed in the grain boundary. The Fe-rich phase is Fe with a higher concentration than in the main phase grains and has La₆Co₁₁Ga₃A phase of crystalline structure of form (la). When the amount of carbon is too small, the mixture is burnedThe caking property is lowered, and HcJ and corrosion resistance are lowered. If the amount of carbon is too large, HcJ and corrosion resistance are reduced.

In the R-T-B permanent magnet of the present embodiment, the nitrogen content is 0.023 mass% to 0.323 mass%. The content of the polymer may be 0.035 to 0.096% by mass. When the nitrogen content is in the above range, the R-Ga-Co-Cu-N concentrated portion is easily formed in the grain boundary. When the amount of nitrogen is too small, it becomes difficult to form a concentrated portion of R-Ga-Co-Cu-N, and the corrosion resistance is lowered. In the case of an excessive amount of nitrogen, HcJ decreases. The method of adding nitrogen to the R-T-B permanent magnet is not particularly limited, and for example, as described later, nitrogen can be introduced by heat-treating the raw material alloy in a nitrogen atmosphere having a predetermined concentration. Alternatively, nitrogen may be introduced as a grinding aid by using, for example, an aid containing nitrogen such as urea. Further, nitrogen may be introduced into the grain boundaries in the R-T-B permanent magnet by using a compound containing nitrogen as a treating agent for the raw material alloy.

The amount of carbon and the amount of nitrogen in the R-T-B permanent magnet can be measured by a conventionally known method. The amount of carbon is measured by, for example, a combustion-infrared absorption method in an oxygen stream, and the amount of nitrogen is measured by, for example, an inert gas melting-thermal conductivity method.

The Fe content in the R-T-B permanent magnet of the present embodiment is the actual remainder of the constituent elements of the R-T-B permanent magnet. Specifically, the content of Fe as the actual remainder means that the total content of the above elements, i.e., elements other than R, T, B, M, C, N, is 1 mass% or less.

In the R-T-B permanent magnet of the present embodiment, the R-Ga-Co-Cu-N concentrated portion may be formed in the grain boundary. In an R-T-B permanent magnet in which a R-Ga-Co-Cu-N concentrated portion is not formed, it is difficult to sufficiently suppress adsorption of hydrogen generated in a corrosion reaction by water such as water vapor in a use environment to grain boundaries, and corrosion resistance of the R-T-B permanent magnet is likely to be lowered.

In the present embodiment, by forming the R-Ga-Co-Cu-N concentrated portion in the grain boundary, it is possible to effectively suppress the intrusion of water such as water vapor in the use environment into the R-T-B-based permanent magnet and the adsorption of hydrogen generated by the reaction with R in the R-T-B-based permanent magnet to the entire grain boundary. Therefore, the R-Ga-Co-Cu-N concentrated portion is formed in the grain boundary, whereby the progress of corrosion of the R-T-B permanent magnet into the inside can be suppressed, and the R-Ga-Co-Cu-N concentrated portion can have excellent magnetic characteristics.

The corrosion of the R-T-B permanent magnet is performed by adsorption of hydrogen generated by a corrosion reaction between water formed by water vapor or the like in the use environment and R in the R-T-B permanent magnet, to an R-rich phase present in the grain boundary of the R-T-B permanent magnet. As a result of the adsorption of hydrogen by the R-rich phase, the corrosion of the R-T-B-based permanent magnet is accelerated toward the inside of the R-T-B-based permanent magnet.

That is, it is considered that the corrosion of the R-T-B permanent magnet proceeds in the following manner. First, since the R-rich phase present in the grain boundary is easily oxidized, R of the R-rich phase present in the grain boundary is oxidized by water formed by water vapor or the like in the use environment, and R is corroded to change into hydroxide, and hydrogen is generated in the process.

2R+6H₂O→2R(OH)₃+3H₂…(I)

This generated hydrogen is then adsorbed by the non-corroding R-rich phase.

2R+xH₂→2RH_x…(Ⅱ)

Then, the R-rich phase is more easily corroded by hydrogen absorption, and hydrogen is generated in an amount equal to or more than the amount adsorbed by the R-rich phase by a corrosion reaction that occurs between the R-rich phase that absorbs hydrogen and water.

2RH_x+6H₂O→2R(OH)₃+(3+x)H₂…(Ⅲ)

Due to the chain reaction of the above-mentioned (I) to (III), corrosion of the R-T-B-based permanent magnet proceeds toward the inside of the R-T-B-based permanent magnet, and the R-rich phase is converted into R hydroxide and R hydride. The main phase grains of the R-T-B permanent magnet are exfoliated by the accumulated stress due to the volume expansion accompanying the change. Further, the main phase particles are detached to form a new surface of the R-T-B permanent magnet, and the R-T-B permanent magnet is further corroded inside the R-T-B permanent magnet.

Therefore, the R-T-B permanent magnet of the present embodiment tends to have a concentrated R-Ga-Co-Cu-N portion at grain boundaries, particularly at polycrystal grain boundaries. Since the R-Ga-Co-Cu-N concentrated portion hardly adsorbs hydrogen, hydrogen generated by the corrosion reaction can be prevented from adsorbing to the R-rich phase inside, and the progress of the corrosion in the above-described process to the inside can be suppressed. Further, the R-Ga-Co-Cu-N concentrated portion is less likely to be oxidized than the R-rich portion, and therefore hydrogen itself generated by corrosion can be suppressed. Therefore, according to the R-T-B permanent magnet of the present embodiment, the corrosion resistance of the R-T-B permanent magnet can be greatly improved. In addition, in the present embodiment, the R-rich phase may also be present in the grain boundary. Even if the R-rich phase exists in the grain boundary, the R-rich phase having the R-Ga-Co-Cu-N concentration portion can effectively prevent hydrogen from being adsorbed to the inside, and therefore, the corrosion resistance can be sufficiently improved.

In the R-T-B permanent magnet of the present embodiment, the number of N atoms in the R-Ga-Co-Cu-N concentrated portion may be 1 to 13% of the total number of R, Fe, Ga, Co, Cu, and N atoms in the R-Ga-Co-Cu-N concentrated portion in the grain boundary. By having the N-containing R-Ga-Co-Cu-N concentrated portion at such a ratio, it is possible to effectively suppress the R-rich phase in which hydrogen generated by the corrosion reaction of water and R in the R-T-B-based permanent magnet is adsorbed, and to suppress the progress of corrosion of the R-T-B-based permanent magnet into the inside. The R-T-B permanent magnet according to the present embodiment can have good magnetic properties.

The number of atoms of Ga in the R-Ga-Co-Cu-N concentrated portion may be 7 to 16% based on the total number of atoms of R, Fe, Ga, Co, Cu and N, the number of atoms of Co may be 1 to 9% based on the total number of atoms of R, Fe, Ga, Co, Cu and N, and the number of atoms of Cu may be 4 to 8% based on the total number of atoms of R, Fe, Ga, Co, Cu and N. By providing the R-Ga-Co-Cu-N concentrated portion containing the respective elements at such a ratio, the R-rich phase in which hydrogen generated by the corrosion reaction of water and R in the R-T-B-based permanent magnet is adsorbed inside can be effectively suppressed. The progress of corrosion of the R-T-B permanent magnet into the interior can be suppressed, and the R-T-B permanent magnet of the present embodiment tends to have more favorable magnetic characteristics.

The R-T-B permanent magnet of the present embodiment is generally processed into an arbitrary shape and used. The shape of the R-T-B-based permanent magnet of the present embodiment is not particularly limited, and may be any shape such as a rectangular parallelepiped, a hexahedron, a flat plate, a columnar shape such as a quadrangular prism, or a cylindrical shape in which the cross-sectional shape of the R-T-B-based permanent magnet is a C-shape. The quadrangular prism may be, for example, a rectangular quadrangular prism having a rectangular bottom surface or a square bottom surface.

The R-T-B permanent magnet according to the present embodiment includes both a magnet product magnetized by processing the magnet and a magnet product not magnetized by processing the magnet.

Method for manufacturing < R-T-B series permanent magnet

An example of a method for manufacturing the R-T-B permanent magnet of the present embodiment having the above-described configuration will be described. The method for producing the R-T-B-based permanent magnet (R-T-B-based sintered magnet) according to the present embodiment includes the following steps.

(a) Alloy preparation step for preparing raw alloy

(b) Crushing step for crushing raw alloy

(c) Molding step of molding the obtained alloy powder

(d) Sintering step for obtaining R-T-B permanent magnet by sintering molded body

(e) Aging treatment process for aging treatment of R-T-B permanent magnet

(f) Cooling step for cooling R-T-B permanent magnet

(g) Process for producing R-T-B permanent magnet

(h) Grain boundary diffusion step for diffusing heavy rare earth element into grain boundary of R-T-B permanent magnet

(i) Surface treatment process for surface treatment of R-T-B permanent magnet

[ alloy preparation Process ]

A raw material alloy having a composition that is a raw material of the R-T-B permanent magnet according to the present embodiment is prepared (alloy preparation step). In the alloy preparation step, the raw material metal corresponding to the composition of the R-T-B-based permanent magnet of the present embodiment is melted in a vacuum or an inert gas atmosphere such as Ar gas. Then, the molten raw material metal is cast to produce a raw material alloy having a desired composition. In the present embodiment, a single alloy method is described, but a two-alloy method may be used in which two alloys, i.e., a first alloy and a second alloy, are mixed to prepare a raw material powder.

Examples of the raw material metal include rare earth metals, rare earth alloys, pure iron, ferroboron, alloys and compounds thereof. Examples of the casting method for casting the raw metal include an ingot casting method, a strip casting method, a book molding method (book molding method), and a centrifugal casting method. When the obtained raw material alloy has solidification segregation, homogenization treatment is performed as necessary. The homogenization treatment of the raw material alloy is performed by holding the raw material alloy at a temperature of 700 ℃ to 1500 ℃ for 1 hour or more in a vacuum or an inert gas atmosphere. Thereby, the raw material alloy is melted and homogenized.

[ grinding Process ]

After the raw material alloy is produced, the raw material alloy is pulverized (pulverization step). The pulverization step includes a coarse pulverization step of pulverizing the mixture to a particle size of several hundred micrometers to several mm and a fine pulverization step of pulverizing the mixture to a particle size of several micrometers or so.

(coarse grinding step)

The raw material alloy is coarsely pulverized to a particle size of several hundred μm to several mm (coarse pulverization step). This gave a coarsely pulverized powder of the raw material alloy. The rough pulverization can be performed, for example, by causing hydrogen to be desorbed from the raw material alloy based on the difference in hydrogen adsorption amount between the different phases, and then dehydrogenating the hydrogen to cause self-collapsing pulverization (hydrogen adsorption pulverization).

The amount of nitrogen added required for forming the R-Ga-Co-Cu-N concentration section can be controlled by adjusting the nitrogen concentration in the atmosphere during the dehydrogenation treatment in the hydrogen adsorption/pulverization. The optimum nitrogen concentration varies depending on the composition of the raw material alloy, etc., but may be 300ppm or more.

In addition, the rough grinding step may be performed by using a rough grinder such as a masher, a jaw crusher, or a brown grinder in an inert gas atmosphere, in addition to the hydrogen adsorption grinding as described above.

In order to obtain high magnetic properties, the atmosphere in each step from the pulverization step to the sintering step described later may be a low oxygen concentration. The oxygen concentration is adjusted by controlling the atmosphere in each production process. When the oxygen concentration in each production step is high, the rare earth element in the alloy powder obtained by crushing the raw material alloy is oxidized to produce an R oxide. The R oxide is not reduced during sintering, and precipitates directly at the grain boundaries in the form of the R oxide. As a result, Br of the obtained R-T-B permanent magnet is reduced. Therefore, for example, the oxygen concentration in each step may be set to 100ppm or less.

(Fine grinding Process)

After the raw material alloy is coarsely pulverized, the obtained coarsely pulverized powder of the raw material alloy is finely pulverized until the average particle diameter becomes about several μm (fine pulverization step). Thus, a fine powder of the raw material alloy was obtained. By further finely pulverizing the coarsely pulverized powder, it is possible to obtain a finely pulverized powder having particles of, for example, 1 μm or more and 10 μm or less, or 3 μm or more and 5 μm or less.

The fine grinding is carried out by further grinding the coarsely ground powder using a fine grinder such as a jet mill, a ball mill, a vibration mill, or a wet grinder while appropriately adjusting conditions such as grinding time. Jet mills release high pressure inert gas (e.g., N) from a narrow nozzle₂Gas) to accelerate the coarsely pulverized powder of the raw material alloy by the high-speed gas flow and to collide the coarsely pulverized powder of the raw material alloy with each other or with the object or the container wall to perform pulverization.

When coarsely pulverized powder of the raw material alloy is finely pulverized, a finely pulverized powder having high orientation during molding can be obtained by adding a pulverization aid such as zinc stearate, urea, or oleamide. Further, by controlling the amount of the grinding aid added, the content of C, the content of N, and the like in the finally obtained R-T-B permanent magnet can be controlled.

[ Molding Process ]

The finely pulverized powder is molded into a desired shape (molding step). In the molding step, the finely pulverized powder is filled in a mold surrounded by an electromagnet and pressurized, thereby molding the finely pulverized powder into an arbitrary shape. At this time, the molding is performed while applying a magnetic field, and the fine powder is molded in the magnetic field in a state where the crystal axes are oriented by applying the magnetic field to generate a predetermined orientation. Thus, a molded article was obtained. Since the molded article obtained is oriented in a specific direction, an R-T-B permanent magnet having a stronger magnetic anisotropy can be obtained.

The pressing during molding may be performed at 30MPa to 300 MPa. The applied magnetic field may also be between 950kA/m and 1600 kA/m. The applied magnetic field is not limited to the static magnetic field, and may be a pulse magnetic field. In addition, a static magnetic field and a pulsed magnetic field can be used in combination.

As the molding method, in addition to dry molding in which the fine powder is directly molded as described above, wet molding in which slurry obtained by dispersing the fine powder in a solvent such as oil is molded can be applied.

The shape of the molded article obtained by molding the fine powder is not particularly limited, and may be any shape depending on the desired shape of the R-T-B-based permanent magnet, such as a rectangular parallelepiped, a flat plate, a columnar shape, or a ring shape.

[ sintering Process ]

A molded body molded in a magnetic field and molded into a desired shape is sintered in a vacuum or an inert gas atmosphere to obtain an R-T-B permanent magnet (sintering step). The sintering temperature needs to be adjusted according to various conditions such as composition, pulverization method, particle size and difference in particle size distribution. The molded body is sintered by heating at 1000 ℃ to 1200 ℃ for 1 hour to 48 hours, for example, in vacuum or in the presence of an inert gas. As a result, the finely pulverized powder is subjected to liquid phase sintering, and an R-T-B permanent magnet (sintered body of R-T-B magnet) having an improved volume ratio of main phase particles is obtained. After the molded body is sintered to obtain a sintered body, the sintered body may be quenched from the viewpoint of improving the production efficiency.

[ aging treatment Process ]

After the molded body is sintered, the R-T-B permanent magnet is subjected to aging treatment (aging treatment step). After sintering, the obtained R-T-B permanent magnet is held at a temperature lower than that at the time of sintering, and the R-T-B permanent magnet is subjected to aging treatment. The aging treatment is, for example, 2-stage heating in which the steel sheet is heated at a temperature of 700 ℃ to 1000 ℃ for 10 minutes to 6 hours, and further heated at a temperature of 500 ℃ to 700 ℃ for 10 minutes to 6 hours; or 1-stage heating at a temperature of about 600 ℃ for 10 minutes to 6 hours, and the treatment conditions are appropriately adjusted according to the number of times of aging treatment. The magnetic properties of the R-T-B permanent magnet can be improved by the aging treatment. The aging treatment step may be performed after the processing step described later.

[ Cooling Process ]

After the R-T-B permanent magnet is subjected to aging treatment, the R-T-B permanent magnet is quenched in an Ar gas atmosphere (cooling step). Thus, the R-T-B permanent magnet of the present embodiment can be obtained. The cooling rate is not particularly limited, and may be 30 ℃/min or more.

[ working procedure ]

The obtained R-T-B permanent magnet may be processed into a desired shape as needed (processing step). Examples of the processing method include shape processing such as cutting and polishing, and chamfering such as barrel polishing.

[ procedure of grain boundary diffusion ]

The heavy rare earth element may be further diffused into the grain boundaries of the R-T-B permanent magnet after the machining (grain boundary diffusion step). The method of grain boundary diffusion is not particularly limited. For example, the method can be carried out by attaching a compound containing a heavy rare earth element to the surface of an R-T-B permanent magnet by coating, vapor deposition, or the like, and then performing heat treatment. The heat treatment may be performed by subjecting the R-T-B permanent magnet to a heat treatment in an atmosphere containing a vapor of a heavy rare earth element. The HcJ of the R-T-B permanent magnet can be further improved by grain boundary diffusion.

[ surface treatment Process ]

The R-T-B permanent magnet obtained by the above steps may be subjected to surface treatment (surface treatment step) such as plating, resin coating, oxidation treatment, or chemical synthesis treatment. This can further improve the corrosion resistance.

In the present embodiment, the machining step, the grain boundary diffusion step, and the surface treatment step are performed, but these steps are not necessarily performed.

The R-T-B permanent magnet of the present embodiment obtained as described above has excellent corrosion resistance and also has good magnetic properties.

The R-T-B-based permanent magnet of the present embodiment thus obtained can be used for a long period of time and can provide a highly reliable R-T-B-based permanent magnet because of its high corrosion resistance when used as a magnet for a rotating electrical machine such as an electric motor. The R-T-B-based Permanent Magnet according to the present embodiment is suitably used as a Magnet such as a Surface Magnet (SPM) Motor in which a Magnet is attached to a rotor Surface, an Interior Magnet embedded (IPM) Motor such as an inner rotor type brushless Motor, or a PRM (Permanent Magnet reluctance Motor). Specifically, the R-T-B permanent magnet according to the present embodiment is suitably used for applications such as a spindle motor or a voice coil motor for driving a hard disk in a hard disk drive, a motor for an electric car or a hybrid car, a motor for an electric power steering in an automobile, a servo motor for a machine tool, a motor for a vibrator of a mobile phone, a motor for a printer, and a motor for a generator.

The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the present invention.

The method for producing the R-T-B permanent magnet is not limited to the above-described method, and may be modified as appropriate. For example, the R-T-B permanent magnet of the present embodiment can be manufactured by hot working. A method for manufacturing an R-T-B permanent magnet by hot working comprises the following steps.

(a) A melting and quenching step of melting a raw material metal and quenching the obtained melt to obtain a thin strip;

(b) a pulverization step of pulverizing a thin strip to obtain a flake-shaped raw material powder;

(c) a cold forming step of cold forming the pulverized raw material powder;

(d) a preheating step of preheating the cold-formed body;

(e) a thermoforming step of thermoforming the preheated cold-formed body;

(f) a thermoplastic processing step of plastically deforming the thermally formed body into a predetermined shape;

(g) and an aging treatment step of aging the R-T-B permanent magnet.