阅读说明：本技术 软磁性合金和磁性部件 (Soft magnetic alloy and magnetic component ) 是由 吉留和宏 松元裕之 堀野贤治 天野一 长谷川晓斗 于 2019-06-05 设计创作，主要内容包括：提供熔融金属温度低于以往也可制作且具有良好软磁特性的软磁性合金等。具有(Fe<Sub>(1－(α+β))</Sub>X1<Sub>α</Sub>X2<Sub>β</Sub>)<Sub>(1－(a+b+c+d+e+f+g))</Sub>M<Sub>a</Sub>Ti<Sub>b</Sub>B<Sub>c</Sub>P<Sub>d</Sub>Si<Sub>e</Sub>S<Sub>f</Sub>C<Sub>g</Sub>所示组成。X1为选自Co和Ni的1种以上,X2为选自Al、Mn、Ag、Zn、Sn、As、Sb、Cu、Cr、Bi、N、O和稀土元素的1种以上,M为选自Nb、Hf、Zr、Ta、Mo、W和V的1种以上。0.020≤a+b≤0.140、0.001≤b≤0.140、0.020＜c≤0.200、0.010≤d≤0.150、0≤e≤0.060、a≥0、f≥0、g≥0、a+b+c+d+e+f+g＜1、α≥0、β≥0、0≤α+β≤0.50。具有纳米异质结构或Fe基纳米结晶构成的结构。(Provided are a soft magnetic alloy and the like which can be produced even at a lower molten metal temperature than in the past and which have good soft magnetic characteristics. Has (Fe) (1－(α+β)) X1 α X2 β ) (1－(a+b+c+d+e+f+g)) M a Ti b B c P d Si e S f C g The composition is shown. X1 is more than 1 selected from Co and Ni, X2 is more than 1 selected from Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements, and M is more than 1 selected from Nb, Hf, Zr, Ta, Mo, W and V. A + b is more than or equal to 0.020 and less than or equal to 0.140, b is more than or equal to 0.001 and less than or equal to 0.140, c is more than or equal to 0.020 and less than or equal to 0.200, d is more than or equal to 0.010 and less than or equal to 0.150, e is more than or equal to 0 and less than or equal to 0.060, a is more than or equal to 0, f is more than or equal to 0, g is more than or equal to 0, a + b + c + d + e +,Alpha and beta are more than or equal to 0 and less than or equal to 0.50. Has a nano-heterostructure or a structure composed of Fe-based nanocrystals.)

1. A soft magnetic alloy characterized by:

has a composition formula of (Fe)_{(1－(α+β))}X1_αX2_β)_{(1－(a+b+c+d+e+f+g))}M_aTi_bB_cP_dSi_eS_fC_gThe composition of the components shown is that,

x1 is at least one member selected from the group consisting of Co and Ni,

x2 is more than 1 selected from Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements,

m is more than 1 selected from Nb, Hf, Zr, Ta, Mo, W and V,

0.020≤a+b≤0.140，

0.001≤b≤0.140，

0.020＜c≤0.200，

0.010≤d≤0.150，

0≤e≤0.060，

a≥0，

f≥0，

g≥0，

a+b+c+d+e+f+g＜1，

α≥0，

β≥0，

0≤α+β≤0.50，

the soft magnetic alloy has a nano-heterostructure in which primary crystallites are present in an amorphous state.

2. The soft magnetic alloy according to claim 1,

the average grain size of the primary crystallites is 0.3 to 10 nm.

3. A soft magnetic alloy characterized by:

has a composition formula of (Fe)_{(1－(α+β))}X1_αX2_β)_{(1－(a+b+c+d+e+f+g))}M_aTi_bB_cP_dSi_eS_fC_gThe composition of the components shown is that,

x1 is at least one member selected from the group consisting of Co and Ni,

x2 is more than 1 selected from Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements,

m is more than 1 selected from Nb, Hf, Zr, Ta, Mo, W and V,

0.020≤a+b≤0.140，

0.001≤b≤0.140，

0.020＜c≤0.200，

0.010≤d≤0.150，

0≤e≤0.060，

a≥0，

f≥0，

g≥0，

a+b+c+d+e+f+g＜1，

α≥0，

β≥0，

0≤α+β≤0.50，

the soft magnetic alloy has a structure composed of Fe-based nanocrystals.

4. The soft magnetic alloy of claim 3, wherein,

the average grain diameter of the Fe-based nanocrystal is 5-30 nm.

5. The soft magnetic alloy according to claim 3 or 4,

0.010≤b/(a+b)≤0.500。

6. the soft magnetic alloy according to claim 3 or 4,

0≤f≤0.020、0≤g≤0.050。

7. the soft magnetic alloy according to claim 3 or 4,

0.730≤1－(a+b+c+d+e+f+g)≤0.950。

8. the soft magnetic alloy according to claim 3 or 4,

the soft magnetic alloy is in the shape of a thin strip.

9. The soft magnetic alloy according to claim 3 or 4,

the soft magnetic alloy is in the form of a powder.

10. A magnetic part comprising the soft magnetic alloy according to any one of claims 1 to 9.

Technical Field

The present invention relates to a soft magnetic alloy and a magnetic component.

Background

In recent years, electronic, information, communication devices, and the like are required to have low power consumption and high efficiency. In order to achieve low power consumption and high efficiency, a soft magnetic alloy having good soft magnetic properties (low coercive force and high saturation magnetic flux density) is required.

In general, a molten metal obtained by melting a raw material metal is used for producing a soft magnetic alloy. By lowering the temperature of the molten metal at this time, the manufacturing cost can be reduced. This is because the life of a material such as a refractory used in the production process is increased, and a more inexpensive material can be used for the refractory itself.

Patent document 1 describes an invention of an iron-based amorphous alloy containing Fe, Si, B, C, and P.

Disclosure of Invention

Technical problem to be solved by the invention

The invention aims to: provided is a soft magnetic alloy or the like which can be produced even when the temperature of molten metal is lower than that of the conventional one and has good soft magnetic characteristics.

Technical solution for solving technical problem

In order to achieve the above object, a soft magnetic alloy according to a first aspect of the present invention is characterized in that:

has a composition formula of (Fe)_{(1－(α+β))}X1_αX2_β)_{(1－(a+b+c+d+e+f+g))}M_aTi_bB_cP_dSi_eS_fC_gThe composition of the components shown is that,

x1 is at least one member selected from the group consisting of Co and Ni,

x2 is more than 1 selected from Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements,

m is more than 1 selected from Nb, Hf, Zr, Ta, Mo, W and V,

0.020≤a+b≤0.140，

0.001≤b≤0.140，

0.020＜c≤0.200，

0.010≤d≤0.150，

0≤e≤0.060，

a≥0，

f≥0，

g≥0，

a+b+c+d+e+f+g＜1，

α≥0，

β≥0，

0≤α+β≤0.50，

has a nano-heterostructure with primary crystallites present in the amorphous state.

The soft magnetic alloy according to the first aspect of the present invention can be produced even when the temperature of the molten metal is lower than that of the conventional one. In addition, a soft magnetic alloy having both a low coercive force and a high saturation magnetic flux density can be easily produced by heat treatment.

The average particle diameter of the initial crystallites may be 0.3 to 10 nm.

A soft magnetic alloy according to a second aspect of the present invention is characterized in that:

has a composition formula of (Fe)_{(1－(α+β))}X1_αX2_β)_{(1－(a+b+c+d+e+f+g))}M_aTi_bB_cP_dSi_eS_fC_gThe composition of the components shown is that,

x1 is at least one member selected from the group consisting of Co and Ni,

x2 is more than 1 selected from Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements,

m is more than 1 selected from Nb, Hf, Zr, Ta, Mo, W and V,

0.020≤a+b≤0.140，

0.001≤b≤0.140，

0.020＜c≤0.200，

0.010≤d≤0.150，

0≤e≤0.060，

a≥0，

f≥0，

g≥0，

a+b+c+d+e+f+g＜1，

α≥0，

β≥0，

0≤α+β≤0.50，

has a structure composed of Fe-based nanocrystals.

The soft magnetic alloy according to the second aspect of the present invention can be produced even when the temperature of the molten metal is lower than that of the conventional one. In addition, the coercive force and the saturation magnetic flux density are both low.

The average particle size of the Fe-based nanocrystal may be 5 to 30 nm.

The soft magnetic alloy according to the first aspect and the soft magnetic alloy according to the second aspect of the present invention may be 0.010. ltoreq. b/(a + b). ltoreq.0.500.

The soft magnetic alloy of the first aspect and the soft magnetic alloy of the second aspect of the present invention may be 0. ltoreq. f.ltoreq.0.020 and 0. ltoreq. g.ltoreq.0.050.

The soft magnetic alloy according to the first aspect and the soft magnetic alloy according to the second aspect of the present invention may be 0.730. ltoreq.1- (a + b + c + d + e + f + g). ltoreq.0.950.

The soft magnetic alloy of the first aspect and the soft magnetic alloy of the second aspect of the present invention may be 0. ltoreq. alpha { 1- (a + b + c + d + e + f + g) } 0.40.

The soft magnetic alloy according to the first aspect and the soft magnetic alloy according to the second aspect of the present invention may have α ═ 0.

The soft magnetic alloy of the first aspect and the soft magnetic alloy of the second aspect of the present invention may be 0. ltoreq. beta { 1- (a + b + c + d + e + f + g) } 0.030.

The soft magnetic alloy according to the first aspect and the soft magnetic alloy according to the second aspect of the present invention may be β ═ 0.

The soft magnetic alloy according to the first aspect and the soft magnetic alloy according to the second aspect of the present invention may be α ═ β ═ 0.

The soft magnetic alloy according to the first aspect and the soft magnetic alloy according to the second aspect of the present invention may have a thin strip shape.

The soft magnetic alloy of the first aspect and the soft magnetic alloy of the second aspect of the present invention may be in the form of powder.

The magnetic member of the present invention includes the soft magnetic alloy described above.

Detailed Description

(first embodiment)

The soft magnetic alloy according to the first embodiment of the present invention has a composition formula (Fe)_{(1－(α+β))}X1_αX2_β)_{(1－(a+b+c+d+e+f+g))}M_aTi_bB_cP_dSi_eS_fC_gA soft magnetic alloy of the composition shown is,

x1 is at least one member selected from the group consisting of Co and Ni,

x2 is more than 1 selected from Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements,

m is more than 1 selected from Nb, Hf, Zr, Ta, Mo, W and V,

0.020≤a+b≤0.140，

0.001≤b≤0.140，

0.020＜c≤0.200，

0.010≤d≤0.150，

0≤e≤0.060，

a≥0，

f≥0，

g≥0，

a+b+c+d+e+f+g＜1，

α≥0，

β≥0，

0≤α+β≤0.50，

has a nano-heterostructure with primary crystallites present in the amorphous state.

The soft magnetic alloy having the composition represented by the above atomic ratio contains an amorphous phase, and is easily produced as a soft magnetic alloy not containing a crystal phase composed of crystals having a particle diameter of more than 30 nm. The soft magnetic alloy of the first embodiment has a nano-heterostructure in which primary crystallites are present in an amorphous state. The initial crystallites mean crystallites having a particle size of 15nm or less (preferably 0.3 to 10 nm). The nano-heterostructure is a structure in which the initial crystallites are present in the amorphous phase.

The soft magnetic alloy of the present embodiment has a nano-heterostructure, and therefore, Fe-based nanocrystals are likely to precipitate during heat treatment described later. In addition, a soft magnetic alloy containing Fe-based nanocrystals (a soft magnetic alloy according to the second embodiment described later) tends to have good magnetic properties.

In other words, the soft magnetic alloy having the above composition is likely to be a starting material for a soft magnetic alloy (a soft magnetic alloy according to the second embodiment described later) in which Fe-based nanocrystals are precipitated.

Hereinafter, each component of the soft magnetic alloy of the present embodiment will be described in detail. The coercive force and the saturation magnetic flux density described below refer to the coercive force and the saturation magnetic flux density of the soft magnetic alloy of the second embodiment in the case where a soft magnetic alloy containing Fe-based nanocrystals (the soft magnetic alloy of the second embodiment) is obtained by a heat treatment described later.

M is more than 1 selected from Nb, Hf, Zr, Ta, Mo, W and V. From the viewpoint of increasing the saturation magnetic flux density, the content ratio of Nb to the whole M is preferably 50 at% or more. From the viewpoint of increasing the saturation magnetic flux density, the content of M to the total of M and Ti is preferably more than 50%.

The content (a) of M is substantially arbitrary, and a is not less than 0. Alternatively, a may be 0, i.e., M may not be included. However, the ratio of a + b is 0.020. ltoreq. a + 0.140 in relation to the Ti content (b) described later. Since a + b is not less than 0.020 and not more than 0.140, the saturation magnetic flux density is easily increased and the coercive force is easily lowered. When a + b is too small, the coercive force tends to be high. When a + b is too large, the coercive force tends to be high, and the saturation magnetic flux density tends to be low.

The content (b) of Ti is more than or equal to 0.001 and less than or equal to 0.140. Preferably 0.020. ltoreq. b.ltoreq.0.100. Ti can reduce the viscosity of the molten metal described later in particular. When b is too small, the viscosity of the molten metal described later increases. Further, the production of a soft magnetic alloy at low temperature is likely to be difficult. When b is too large, the saturation magnetic flux density is likely to decrease.

Preferably, the content of Ti with respect to the total of M and Ti is 1% to 50%. Namely, it is preferably 0.010. ltoreq. b/(a + b). ltoreq.0.500. More preferably 0.014. ltoreq. b/(a + b). ltoreq.0.500, still more preferably 0.071. ltoreq. b/(a + b) 0.500. When b/(a + b) is within the above range, the coercive force is likely to be lowered, and the saturation magnetic flux density is likely to be increased.

The content (c) of B is more than 0.020 and less than or equal to 0.200. Preferably 0.025. ltoreq. c.ltoreq.0.200, more preferably 0.025. ltoreq. c.ltoreq.0.080. If c is too small, a crystal phase consisting of crystals having a particle size of more than 30nm tends to be formed in the soft magnetic alloy before heat treatment described later, and if a crystal phase is formed, Fe-based nanocrystals cannot be precipitated by the heat treatment, and the coercive force tends to be high. When c is too large, the saturation magnetic flux density tends to decrease.

The content (d) of P satisfies that d is more than or equal to 0.010 and less than or equal to 0.150. Preferably 0.010. ltoreq. d.ltoreq.0.030. P can particularly lower the melting point of the molten metal described later. If d is too small, the melting point of the molten metal described later is increased. Further, the production of a soft magnetic alloy at low temperature is likely to be difficult. If d is too large, the saturation magnetic flux density tends to decrease.

The content (e) of Si satisfies 0. ltoreq. e.ltoreq.0.060. It may be such that e ═ 0, i.e., Si is not contained. When e is too large, the saturation magnetic flux density tends to decrease.

The S content (f) and the C content (g) are substantially arbitrary, and f is not less than 0 and g is not less than 0. F may be 0, i.e., S may not be contained. G may be 0, i.e., C may not be contained.

When S and/or C are contained, the viscosity of the molten metal described later can be further reduced, and the temperature of the molten metal can be further reduced, as compared with the case where S and C are not contained, whereby a soft magnetic alloy can be produced. By further lowering the temperature of the molten metal, the coercive force can be further lowered.

As for the content (f) of S, it is preferably 0.005. ltoreq. f.ltoreq.0.020, more preferably 0.005. ltoreq. f.ltoreq.0.010. The content (g) of C is preferably 0.010. ltoreq. g.ltoreq.0.050, and more preferably 0.010. ltoreq. g.ltoreq.0.030.

The content of Fe (1- (a + b + c + d + e + f + g)) can be set to any value. Further, it is preferably 0.730. ltoreq.1- (a + b + c + d + e + f + g). ltoreq.0.950.

In the soft magnetic alloy of the present embodiment, a part of Fe may be replaced with X1 and/or X2.

X1 is at least 1 selected from Co and Ni. The content of X1 may be α ═ 0. That is, X1 may not be contained. When the number of atoms in the entire composition is 100 at%, the number of atoms of X1 is preferably 40 at% or less. That is, it is preferable to satisfy 0. ltoreq. α { 1- (a + b + c + d + e + f + g) } 0.400.

X2 is more than 1 selected from Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements. The content of X2 may be β ═ 0. That is, X2 may not be contained. When the number of atoms in the entire composition is 100 at%, the number of atoms of X2 is preferably 3.0 at% or less. That is, it is preferable to satisfy 0. ltoreq. beta { 1- (a + b + c + d + e + f + g) } 0.030.

The range of the amount of substitution of X1 and/or X2 for Fe is equal to or less than half of Fe based on the number of atoms. I.e., 0. ltoreq. alpha. + β. ltoreq.0.50. In the case where α + β > 0.50, it is difficult to produce an Fe-based nanocrystalline alloy by heat treatment.

The soft magnetic alloy according to the present embodiment may contain elements other than those described above as inevitable impurities. For example, the content may be 0.1 wt% or less with respect to 100 wt% of the soft magnetic alloy.

The method for producing the soft magnetic alloy according to the first embodiment will be described below.

The method for producing the soft magnetic alloy according to the first embodiment is not particularly limited. For example, there is a method of manufacturing a thin strip of the soft magnetic alloy of the first embodiment by a single-roll method. Further, the ribbon may be a continuous ribbon.

In the single-roll method, first, pure metals of the respective metal elements contained in the finally obtained soft magnetic alloy are prepared and weighed so as to have the same composition as the finally obtained soft magnetic alloy. Then, a master alloy is prepared by melting and mixing pure metals of the respective metal elements. The method of melting the pure metal is not particularly limited, and for example, a method of melting the pure metal by high-frequency heating after evacuating the chamber may be used. The master alloy and the soft magnetic alloy including the primary crystallites (the soft magnetic alloy according to the first embodiment) are generally the same composition. The composition of the soft magnetic alloy containing initial crystallites (the soft magnetic alloy according to the first embodiment) and the composition of the soft magnetic alloy containing Fe-based nanocrystals obtained by heat-treating the soft magnetic alloy containing initial crystallites (the soft magnetic alloy according to the second embodiment described later) are generally the same.

Next, the produced master alloy is heated and melted to obtain molten metal (molten metal). In the case of producing the soft magnetic alloy of the present embodiment, the temperature of the molten metal can be made lower than in the conventional case. For example, 1100 ℃ or higher and less than 1200 ℃ may be set. Preferably 1150 ℃ to 1175 ℃. From the viewpoint of ease of production of the soft magnetic alloy of the present embodiment, the higher the temperature of the molten metal, the better. From the viewpoint of reducing the manufacturing cost and the coercive force, the lower the temperature of the molten metal, the better.

In the single roll method, the thickness of the obtained thin strip can be adjusted mainly by adjusting the rotation speed of the roll, but the thickness of the obtained thin strip can also be adjusted by adjusting, for example, the interval between the nozzle and the roll, the temperature of the molten metal, or the like. The thickness of the thin strip is arbitrary, and in the case of manufacturing the soft magnetic alloy of the present embodiment, the thickness of the thin strip may be thicker than that of the conventional one. The thickness of the ribbon may be, for example, 20 to 60 μm, and preferably 50 to 55 μm. Since the thickness of the thin strip is larger than that of the conventional one, the packing density can be increased when the ring-shaped core around which the thin strip is wound is manufactured, and thus the dc superimposition characteristics are good. The soft magnetic alloy of the present embodiment has higher amorphousness than conventional soft magnetic alloys. Therefore, even if the thickness of the ribbon is increased, it is difficult to form crystals having a particle size of more than 30nm at the stage before the heat treatment. In addition, it is easy to produce a soft magnetic alloy containing Fe-based nanocrystals at the stage after heat treatment.

The soft magnetic alloy of the first embodiment is amorphous containing no crystal having a particle size of more than 30 nm. The amorphous alloy is subjected to a heat treatment described later, whereby an Fe-based nanocrystalline alloy according to a second embodiment described later can be obtained.

Further, the method for confirming whether or not crystals having a particle size of more than 30nm are contained in the thin strip of the soft magnetic alloy is not particularly limited. For example, the presence or absence of crystals having a particle size of more than 30nm can be confirmed by ordinary X-ray diffraction measurement.

The soft magnetic alloy according to the first embodiment is a nano-heterostructure composed of an amorphous phase and the initial crystallites present in the amorphous phase. Further, the particle size of the initial crystallites is not particularly limited, but is preferably in the range of 0.3 to 10nm in average particle size.

The presence or absence of the initial crystallites and the method of observing the average particle size are not particularly limited, and for example, the presence or absence and the method can be confirmed by obtaining a limited-field diffraction image, a nanobeam diffraction image, a bright-field image, or a high-resolution image using a transmission electron microscope with respect to a sample that is flaked by ion milling. In the case of using a limited field diffraction image or a nanobeam diffraction image, annular diffraction is formed in the case of being amorphous in the diffraction pattern, whereas diffraction spots due to the crystalline structure are formed in the case of not being amorphous. In addition, when a bright field image or a high resolution image is used, the magnification is 1.00 × 10⁵～3.00×10⁵The presence or absence of the initial crystallites and the average particle size were observed visually.

There is no particular limitation on the temperature, rotation speed of the roller and atmosphere inside the chamber. The temperature of the roller is preferably 4 to 30 ℃ because of amorphization. The faster the rotation speed of the roll, the thinner the thickness of the formed thin strip. The atmosphere inside the chamber is preferably made to be an atmosphere if considering an inert atmosphere (argon, nitrogen, or the like) or considering cost.

In addition, as a method for obtaining the soft magnetic alloy of the first embodiment, in addition to the above-described single roll method, there is a method for obtaining a powder of the soft magnetic alloy of the first embodiment by, for example, a water atomization method or an air atomization method. Hereinafter, the gas atomization method will be described.

In the gas atomization method, a molten alloy at 1100 ℃ or higher and less than 1200 ℃ is obtained in the same manner as in the single-roll method described above. And then spraying the molten alloy in the cavity to prepare powder.

In this case, the nano-heterostructure of the present embodiment can be easily obtained by setting the gas ejection temperature to 50 to 90 ℃ and the vapor pressure in the chamber to 4hPa or less.

(second embodiment)

Hereinafter, a second embodiment of the present invention will be described, but the description of the parts overlapping with the first embodiment will be omitted as appropriate.

The soft magnetic alloy according to the second embodiment of the present invention has the composition formula (Fe)_{(1－(α+β))}X1_αX2_β)_{(1－(a+b+c+d+e+f+g))}M_aTi_bB_cP_dSi_eS_fC_gA soft magnetic alloy of the composition shown is,

x1 is at least one member selected from the group consisting of Co and Ni,

x2 is more than 1 selected from Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements,

m is more than 1 selected from Nb, Hf, Zr, Ta, Mo, W and V,

0.020≤a+b≤0.140，

0.001≤b≤0.140，

0.020＜c≤0.200，

0.010≤d≤0.150，

0≤e≤0.060，

a≥0，

f≥0，

g≥0，

a+b+c+d+e+f+g＜1，

α≥0，

β≥0，

0≤α+β≤0.50，

the soft magnetic alloy has a structure composed of Fe-based nanocrystals.

The above-described composition is the same as that of the soft magnetic alloy of the first embodiment. However, the soft magnetic alloy of the second embodiment has a structure composed of Fe-based nanocrystals, unlike the soft magnetic alloy of the first embodiment.

The Fe-based nanocrystal is a crystal having a particle diameter of nanometer order and a crystal structure of Fe bcc (body-centered cubic lattice structure). In the present embodiment, it is preferable to precipitate Fe-based nanocrystals having an average particle size of 5 to 30 nm. The saturation magnetic flux density of the soft magnetic alloy in which such Fe-based nanocrystals are precipitated is likely to increase, and the coercive force is likely to decrease.

A method for producing a soft magnetic alloy according to a second embodiment will be described below.

The method for producing the soft magnetic alloy according to the second embodiment is arbitrary. For example, it can be produced by heat-treating the soft magnetic alloy having a nano-heterostructure of the first embodiment. However, it can also be produced by heat-treating a soft magnetic alloy containing no nano-heterostructure and no crystal observed in the initial crystallite.

The heat treatment conditions for producing the Fe-based nanocrystalline alloy are not particularly limited. The preferable heat treatment conditions vary depending on the composition of the soft magnetic alloy, the presence or absence of a nano-heterostructure of the soft magnetic alloy before heat treatment, etc., and the preferable heat treatment temperature is approximately 500 to 650 ℃, and the preferable heat treatment time is approximately 0.1 to 3 hours. However, depending on the composition, shape, and the like, there may be cases where the heat treatment temperature and heat treatment time are preferable unless the ranges are outside the above ranges. For example, in the case where the soft magnetic alloy having the nano-heterostructure (the soft magnetic alloy of the first embodiment) is heat-treated, the preferable heat treatment temperature tends to be lower than in the case where the soft magnetic alloy having no nano-heterostructure is heat-treated. The atmosphere during the heat treatment is preferably an inert atmosphere such as Ar gas.

The method for calculating the average particle diameter of the Fe-based nanocrystalline alloy obtained is not particularly limited. For example, it can be calculated by observation using a transmission electron microscope. Further, a method for confirming that the crystal structure is bcc (body-centered cubic lattice structure) is also not particularly limited. For example, the confirmation can be performed by using X-ray diffraction measurement.

While one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment.

The shape of the soft magnetic alloy of the first embodiment and the second embodiment is not particularly limited. As described above, the shape of a thin strip or the shape of a powder is exemplified, but in addition to this, a block shape or the like is also considered.

The use of the soft magnetic alloy (Fe-based nanocrystalline alloy) of the second embodiment is not particularly limited. For example, a magnetic member may be mentioned, and among them, a magnetic core may be particularly mentioned. Can be preferably used as a magnetic core for inductors, particularly for high-strength inductors. The soft magnetic alloy according to the second embodiment can be applied to a thin film inductor and a magnetic head in addition to a magnetic core.

Hereinafter, a method of obtaining a magnetic component, particularly a core and an inductor, from the soft magnetic alloy of the second embodiment will be described, but the method of obtaining a core and an inductor from the soft magnetic alloy of the second embodiment is not limited to the following method. Further, applications of the magnetic core include a transformer, a motor, and the like, in addition to an inductor.

Examples of a method for obtaining a magnetic core from a soft magnetic alloy in a thin strip shape include a method of winding a soft magnetic alloy in a thin strip shape and a method of laminating the soft magnetic alloy. When the soft magnetic alloy in the form of a thin strip is laminated via an insulator, a magnetic core having further improved characteristics can be obtained.

As a method for obtaining a magnetic core from a powder-shaped soft magnetic alloy, for example, a method of appropriately mixing with a binder and then molding with a mold is cited. Further, by applying an oxidation treatment or coating with an insulating film or the like to the powder surface before mixing with the binder, the specific resistance is improved, and the magnetic core is more suitable for a high frequency band.

The molding method is not particularly limited, and molding using a mold, molding, or the like can be exemplified. The type of the binder is not particularly limited, and a silicone resin can be exemplified. The mixing ratio of the soft magnetic alloy powder and the binder is also not particularly limited. For example, 1 to 10 mass% of a binder is mixed with 100 mass% of the soft magnetic alloy powder.

For example, the occupancy rate can be obtained by mixing 1 to 5 mass% of a binder with 100 mass% of the soft magnetic alloy powder and compression molding the mixture using a mold(powder filling rate) is 70% or more, and 1.6X 10⁴A magnetic core having a magnetic flux density of 0.45T or more and a specific resistance of 1. omega. cm or more in an A/m magnetic field. The above characteristics are equal to or more than those of a general ferrite core.

For example, by mixing 1 to 3 mass% of a binder with 100 mass% of the soft magnetic alloy powder and compression molding the mixture with a mold under a temperature condition of the softening point of the binder or higher, the occupied area ratio can be 80% or more and 1.6 × 10 is applied⁴A powder magnetic core having a magnetic flux density of 0.9T or more and a specific resistance of 0.1. omega. cm or more in an A/m magnetic field. The above characteristics are more excellent than those of a general dust core.

In addition, when the molded body forming the magnetic core is subjected to heat treatment after molding as a strain-removing heat treatment, the core loss is further reduced, and the usefulness is improved. In addition, the loss of the magnetic core is reduced by reducing the coercive force of the magnetic material constituting the magnetic core.

In addition, an inductance component can be obtained by winding the magnetic core. The method of implementing the winding and the method of manufacturing the inductance component are not particularly limited. For example, a method of winding at least 1 turn of a wire around the magnetic core manufactured by the above-described method is exemplified.

In the case of using soft magnetic alloy particles, there is a method of manufacturing an inductance component by integrating by press molding in a state where a coil is incorporated in a magnetic body. In this case, an inductance component corresponding to a high frequency and a large current can be easily obtained.

In the case of using soft magnetic alloy particles, an inductance component can be obtained by alternately printing and laminating a soft magnetic alloy paste prepared by adding a binder and a solvent to the soft magnetic alloy particles and a conductor paste prepared by adding a binder and a solvent to a conductor metal for a coil, and then heating and baking the layers. Alternatively, a soft magnetic alloy sheet is formed using a soft magnetic alloy paste, a conductor paste is printed on the surface of the soft magnetic alloy sheet, and the soft magnetic alloy sheet and the conductor paste are laminated and fired to obtain an inductance component in which a coil is incorporated in a magnetic body.

Here, in the case of manufacturing an inductance component using soft magnetic alloy particles, it is preferable to use a center particle diameter (D) having a maximum particle diameter of 45 μm or less in terms of the mesh diameter in order to obtain excellent Q characteristics₅₀) The soft magnetic alloy powder is 30 μm or less. In order to set the maximum particle diameter to 45 μm or less in terms of the mesh diameter, a sieve having a mesh size of 45 μm may be used, and only the soft magnetic alloy powder passing through the sieve may be used.

The use of a soft magnetic alloy powder having a larger maximum particle size tends to lower the Q value in the high frequency region, and particularly, in the case of using a soft magnetic alloy powder having a maximum particle size exceeding 45 μm in terms of the mesh size, the Q value in the high frequency region may be greatly lowered. However, when the Q value in the high frequency region is not regarded as important, soft magnetic alloy powder having large variations can be used. Since the soft magnetic alloy powder with large variation can be produced at relatively low cost, the cost can be reduced when the soft magnetic alloy powder with large variation is used.