阅读说明：本技术 非晶混合粉末、成品粉末、磁粉芯及其制备方法 (Amorphous mixed powder, finished powder, magnetic powder core and preparation method thereof ) 是由 王策 孙海波 陈卫红 于 2019-11-25 设计创作，主要内容包括：本发明提供的一种非晶混合粉末,包括呈片状的第一非晶粉末及呈类球状的第二非晶粉末,所述第一非晶粉末与所述第二非晶粉末均匀混合；所述第一非晶粉末和/或所述第二非晶粉末的合金成分包括有Fe<Sub>(100-x-y-z-a-b)</Sub>Si<Sub>x</Sub>B<Sub>y</Sub>C<Sub>z</Sub>M<Sub>a</Sub>N<Sub>b</Sub>,式中M为Ni、Mo元素中的任意一种,N为Cr、Mn元素中的任意一种；其中6﹤x﹤11,9﹤y﹤16,1﹤z﹤8,0≤a﹤5,0﹤b﹤5；通过该非晶混合粉末可制备有相应的成品粉末及磁粉芯；本发明的非晶混合粉末、成品粉末及磁粉芯通过合金成分的设计优化,具有综合磁性能优异的有益技术效果,满足高性能要求的非晶元件应用需求。(The invention provides amorphous mixed powder, which comprises flaky first amorphous powder and spherical second amorphous powder, wherein the first amorphous powder and the second amorphous powder are uniformly mixed; the alloy component of the first amorphous powder and/or the second amorphous powder comprises Fe (100‑x‑y‑z‑a‑b) Si x B y C z M a N b Wherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5; the amorphous mixed powder can be used for preparing corresponding finished product powder and magnetic powder cores; the amorphous mixed powder, the finished powder and the magnetic powder core are optimized through the design of alloy components, have the beneficial technical effect of excellent comprehensive magnetic performance, and meet the application requirement of amorphous elements with high performance requirements.)

1. The amorphous mixed powder is characterized by comprising a first amorphous powder in a sheet shape and a second amorphous powder in a sphere-like shape, wherein the first amorphous powder and the second amorphous powder are uniformly mixed; the alloy component of the first amorphous powder and/or the second amorphous powder comprises Fe_{(100-x-y-z-a-b)}Si_xB_yC_zM_aN_bWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5.

2. The amorphous mixed powder according to claim 1, wherein the composition of the amorphous mixed powder comprises Fe₇₆Si_7.5B₇C₄Ni_1.5Cr₃Or Fe₇₅Si₈B₇C₄Mo₁Cr₅Or Fe₇₈Si₆B₈C₃Ni₃Mn₂Or Fe₇₆Si₉B₇C₅Cr₃Or Fe₇₈Si₆B₉C₄Cr₃。

3. The amorphous mixed powder according to claim 1, wherein the powder ratio of the first amorphous powder is: 10-30% of-100 meshes to +150 meshes, 20-50% of-150 meshes to +200 meshes, and 10-30% of-200 meshes to +270 meshes; the proportion of the second amorphous powder is 10-40%.

4. Amorphous finished powder, comprising the amorphous mixed powder as claimed in any one of claims 1 to 3, wherein the surface of the amorphous mixed powder is coated with an insulating coating layer.

5. An amorphous magnetic powder core comprising the amorphous final powder according to claim 4.

6. The method for preparing amorphous mixed powder as claimed in any one of claims 1 to 3, comprising the steps of:

s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe_{(100-x-y-z-a-b)}Si_xB_yC_zM_aN_bWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;

s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;

and S3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain the amorphous mixed powder.

7. The method for preparing amorphous finished powder according to claim 4, comprising the steps of:

s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe_{(100-x-y-z-a-b)}Si_xB_yC_zM_aN_bWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;

s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;

s3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain amorphous mixed powder;

s4, carrying out insulation coating treatment on the amorphous mixed powder to obtain amorphous coated powder;

and S5, adding a lubricant into the amorphous coated powder, and stirring and mixing to obtain amorphous finished powder.

8. The method for preparing amorphous magnetic powder core according to claim 5, comprising the steps of:

s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe_{(100-x-y-z-a-b)}Si_xB_yC_zM_aN_bWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;

s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;

s3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain amorphous mixed powder;

s4, carrying out insulation coating treatment on the amorphous mixed powder to obtain amorphous coated powder;

s5, adding a lubricant into the amorphous coated powder, and stirring and mixing to obtain amorphous finished powder;

s6, performing pressing treatment, sintering treatment, annealing treatment and curing treatment on the amorphous finished product powder to obtain a magnetic powder core base block;

and S7, performing surface coating treatment on the magnetic powder core base block to obtain the amorphous magnetic powder core.

9. The manufacturing method according to claim 7 or 8, wherein in step S4, a first insulation coating method, a second insulation coating method, or a third insulation coating method is applied to perform insulation coating treatment on the amorphous mixed powder;

the first insulation cladding method comprises the following steps:

s4-01, mixing and attaching inorganic powder to the amorphous mixed powder by ultrasonic waves to obtain amorphous attached powder;

and S4-02, mixing and fully reacting the alkali solution with the amorphous adhesive powder, drying and fixing by using a binder to fix the surface of the amorphous adhesive powder to form an insulating coating layer, thus obtaining the amorphous coated powder.

The second insulation covering method comprises the following steps:

s4-11, preheating and heating a rotary furnace to 240-450 ℃, and adding the amorphous mixed powder into the rotary furnace;

and S4-12, continuously introducing oxygen-containing air into the rotary furnace, turning the amorphous mixed powder in the rotary furnace, and fully reacting the surface of the amorphous mixed powder with the oxygen-containing air to form an insulating coating layer on the surface of the amorphous mixed powder, so as to obtain the amorphous coated powder.

The third insulation covering method includes the steps of:

and S4-21, adding the amorphous mixed powder by using a cohesive inorganic substance, and uniformly mixing to fix the surface of the amorphous mixed powder to form an insulating coating layer so as to obtain the amorphous coated powder.

10. The method of claim 8, wherein step S7 includes the steps of:

s7-1, performing surface pretreatment on the magnetic powder core base block to form a pretreatment insulating layer on the surface of the magnetic powder core base block;

s7-2, carrying out preheating treatment on the magnetic powder core base block after surface pretreatment, wherein the preheating treatment temperature is 180-240 ℃; then, performing roller coating treatment by using a second insulating material; and adsorbing and melting the second insulating material by self heat of the preheated magnetic powder core base block so as to form a roll coating on the pretreated insulating layer.

Technical Field

The invention relates to the technical field of soft magnetic alloy metallurgy, in particular to amorphous mixed powder, finished powder, a magnetic powder core and a preparation method thereof.

Background

The amorphous material has high saturation magnetic induction, high magnetic conductivity, low coercive force, low high-frequency loss, good strong hardness, wear resistance, corrosion resistance, good temperature and environmental stability and the like, has excellent comprehensive performance, replaces permalloy, silicon steel and ferrite, is applied to power electronic technology, shows the characteristics of small volume, high efficiency, energy conservation and the like, and has the optimal cost performance ratio in all metal soft magnetic materials.

Disclosure of Invention

The invention provides iron-based amorphous mixed powder, finished powder, a magnetic powder core and a preparation method thereof to overcome the defects of the prior art.

The amorphous mixed powder comprises flaky first amorphous powder and spherical second amorphous powder, and the first amorphous powder and the second amorphous powder are uniformly mixed; the alloy component of the first amorphous powder and/or the second amorphous powder comprises Fe_{(100-x-y-z-a-b)}Si_xB_yC_zM_aN_bWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5.

Further, the amorphous mixed powder contains Fe₇₆Si_7.5B₇C₄Ni_1.5Cr₃Or Fe₇₅Si₈B₇C₄Mo₁Cr₅Or Fe₇₈Si₆B₈C₃Ni₃Mn₂Or Fe₇₆Si₉B₇C₅Cr₃Or Fe₇₈Si₆B₉C₄Cr₃。

Further, the powder ratio of the first amorphous powder is as follows: 10-30% of-100 meshes to +150 meshes, 20-50% of-150 meshes to +200 meshes, and 10-30% of-200 meshes to +270 meshes; the proportion of the second amorphous powder is 10-40%.

The amorphous finished product powder comprises the amorphous mixed powder, and the surface of the amorphous mixed powder is coated with an insulating coating layer.

The amorphous magnetic powder core contains the amorphous finished product powder.

The preparation method of the amorphous mixed powder comprises the following steps:

s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe_{(100-x-y-z-a-b)}Si_xB_yC_zM_aN_bWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;

s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;

and S3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain the amorphous mixed powder.

The preparation method of the amorphous finished product powder comprises the following steps:

s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe_{(100-x-y-z-a-b)}Si_xB_yC_zM_aN_bWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;

s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;

s3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain amorphous mixed powder;

s4, carrying out insulation coating treatment on the amorphous mixed powder to obtain amorphous coated powder;

and S5, adding a lubricant into the amorphous coated powder, and stirring and mixing to obtain amorphous finished powder.

The preparation method of the amorphous magnetic powder core comprises the following steps:

s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe_{(100-x-y-z-a-b)}Si_xB_yC_zM_aN_bWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;

s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;

s3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain amorphous mixed powder;

s4, carrying out insulation coating treatment on the amorphous mixed powder to obtain amorphous coated powder;

s5, adding a lubricant into the amorphous coated powder, and stirring and mixing to obtain amorphous finished powder;

s6, performing pressing treatment, sintering treatment, annealing treatment and curing treatment on the amorphous finished product powder to obtain a magnetic powder core base block;

and S7, performing surface coating treatment on the magnetic powder core base block to obtain the amorphous magnetic powder core.

Further, a first insulation coating method, a second insulation coating method or a third insulation coating method is applied to perform insulation coating treatment on the amorphous mixed powder;

the first insulation cladding method comprises the following steps:

s4-01, mixing and attaching inorganic powder to the amorphous mixed powder by ultrasonic waves to obtain amorphous attached powder;

and S4-02, mixing and fully reacting the alkali solution with the amorphous adhesive powder, drying and fixing by using a binder to fix the surface of the amorphous adhesive powder to form an insulating coating layer, thus obtaining the amorphous coated powder.

The second insulation covering method comprises the following steps:

s4-11, preheating and heating a rotary furnace to 240-450 ℃, and adding the amorphous mixed powder into the rotary furnace;

and S4-12, continuously introducing oxygen-containing air into the rotary furnace, turning the amorphous mixed powder in the rotary furnace, and fully reacting the surface of the amorphous mixed powder with the oxygen-containing air to form an insulating coating layer on the surface of the amorphous mixed powder, so as to obtain the amorphous coated powder.

The third insulation covering method includes the steps of:

and S4-21, adding the amorphous mixed powder by using a cohesive inorganic substance, and uniformly mixing to fix the surface of the amorphous mixed powder to form an insulating coating layer so as to obtain the amorphous coated powder.

Further, in step S7, the method includes the following steps:

s7-1, performing surface pretreatment on the magnetic powder core base block to form a pretreatment insulating layer on the surface of the magnetic powder core base block;

s7-2, carrying out preheating treatment on the magnetic powder core base block after surface pretreatment, wherein the preheating treatment temperature is 180-240 ℃; then, performing roller coating treatment by using a second insulating material; and adsorbing and melting the second insulating material by self heat of the preheated magnetic powder core base block so as to form a roll coating on the pretreated insulating layer.

Further, in step S7-1, the method includes the following steps:

s7-1-01, heating the magnetic powder core base block to a temperature of 150-250 ℃;

s7-1-02, performing electrostatic spraying treatment on the magnetic powder core base block heated and heated by the first insulating powder to form the pre-treatment insulating layer on the surface of the magnetic powder core base block; the first insulating powder is acetal insulating powder, phenolic insulating powder or epoxy insulating powder.

Further, in step S7-1, the method includes the following steps:

s7-1-11, performing spraying treatment on the magnetic powder core base block by using first insulating paint; the first insulating paint is acetal insulating paint or phenolic insulating paint or epoxy insulating paint;

s7-1-21, baking and heating the magnetic powder core base block after spraying treatment, wherein the baking and heating temperature is 100-150 ℃; so that the surface of the magnetic powder core base block is formed with the pretreatment insulating layer.

The invention has the beneficial effects that:

the amorphous mixed powder, the finished powder and the magnetic powder core are optimized through the design of alloy components, have the beneficial technical effect of excellent comprehensive magnetic performance, and meet the application requirement of amorphous elements with high performance requirements.

Detailed Description

In order to make the technical solution, objects and advantages of the present invention more apparent, the following examples further illustrate the present invention.

The invention relates to a preparation method of an amorphous magnetic powder core, which specifically comprises the following steps:

s1, smelting the alloy raw materials in a smelting furnace to prepare a master alloy;

s2, preparing corresponding amorphous powder from the master alloy;

s3, mixing the amorphous powder according to a ratio to obtain amorphous mixed powder;

s4, carrying out insulation coating treatment on the amorphous mixed powder to obtain amorphous coated powder;

s5, adding a lubricant into the amorphous coated powder, and stirring and mixing to obtain amorphous finished powder;

s6, performing pressing treatment, sintering treatment, annealing treatment and curing treatment on the amorphous finished product powder to obtain a magnetic powder core base block;

and S7, performing surface coating treatment on the magnetic powder core base block to obtain the amorphous magnetic powder core.

In step S1, the present invention provides a mother alloy for Fe-based amorphous alloy, which comprisesThe composition expression is Fe_{(100-x-y-z-a-b)}Si_xB_yC_zM_aN_bWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5.

The mother alloy for the iron-based amorphous alloy may be based on Fe₇₈Si₉B₁₃The preparation is carried out by adding elements to change the internal atomic arrangement of the amorphous alloy.

Specifically, the Fe is added to the mixture according to the preparation requirement₇₈Si₉B₁₃On the basis of the components of the alloy, the alloy is designed by adding and replacing elements such as C, Ni, Mo, Cr, Mn and the like; calculating the weight ratio of each required element according to the designed component atomic ratio, and further calculating the weight of each raw material required by each element added; and calculating the weight of each required raw material and smelting to prepare the master alloy for the iron-based amorphous alloy.