Method for Producing Sintered Magnet and Sintered Magnet

Abstract

A sintered magnet and a method for producing the same are provided. The method includes producing an R—Fe—B-based magnet powder by a reduction-diffusion method, adding a R—Al—Cu powder as a sintering agent to the R—Fe—B-based magnet powder to form a mixed powder, wherein the R—Al—Cu powder is an alloy of R, Al and Cu, and R is Nd, Pr, Dy, Tb or Ce, and sintering the mixed powder to form a sintered magnet.

Claims

1. A method for producing a sintered magnet, comprising: producing an R—Fe—B-based magnet powder by a reduction-diffusion method, adding a R—Al—Cu powder as a sintering agent to the R—Fe—B-based magnet powder to form a mixed powder, wherein the R—Al—Cu powder is an alloy of R, Al and Cu, and R is Nd, Pr, Dy, Tb or Ce, and sintering the mixed powder to form a sintered magnet.

2. The method according to claim 1, further comprising forming the R—Al—Cu powder as the sintering agent, wherein the forming the R—Al—Cu powder comprises: mixing RH.sub.2 powder, Al powder, and Cu powder to form a sintered precursor, agglomerating the sintered precursor, raising a temperature of the agglomerated sintered precursor to form a metal alloy, and pulverizing the metal alloy to form the sintering agent.

3. The method according to claim 2, further comprising wrapping the agglomerated sintered precursor in a metal foil when raising the temperature of the agglomerated sintered precursor.

4. The method according to claim 2, wherein the forming the sintered precursor further comprises mixing a liquid Ga.

5. The method according to claim 3, wherein the metal foil is Mo or Ta.

6. The method according to claim 3, wherein when wrapping the agglomerated sintered precursor in the metal foil and raising the temperature, the temperature is raised in an argon gas atmosphere.

7. The method according to claim 2, wherein the forming the metal alloy further comprises: wrapping the agglomerated sintered precursor in the metal foil, raising the temperature up to 900 degrees Celsius to 1050 degrees Celsius, and then performing an additional heat treatment.

8. The method according to claim 2, wherein the agglomerating the sintered precursor uses any one of hydraulic pressing, tapping, or cold isostatic pressing (CIP).

9. The method according to claim 1, further comprising: adding a NdH.sub.2 powder to the R—Al—Cu powder as the sintering agent.

10. A sintered magnet produced by the method according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG. 1 is a view showing a step of producing an R—Al—Cu metal alloy powder in a method of producing a sintered magnet according to an embodiment of the present disclosure.

[0022] FIG. 2 is a BH graph showing the magnetic flux density (Y-axis) according to the coercive force (X-axis) measured in a sintered magnet produced according to Comparative Examples and Examples of the present disclosure.

[0023] FIG. 3 is a BH graph showing the magnetic flux density (Y-axis) according to the coercive force (X-axis) measured in the sintered magnet produced according to Comparative Examples and Examples of the present disclosure, when changing the composition of the magnetic powder before sintering of FIG. 2.

[0024] FIG. 4 is a BH graph showing the magnetic flux density (Y-axis) according to the coercive force (X-axis) measured in a sintered magnet produced by changing the type of rare earth metal contained in the metal alloy, when using the powder of a metal alloy according to an embodiment of the present disclosure as a sintering agent.

[0025] FIGS. 5 and 6 are graphs showing the magnetic flux density (Y-axis) according to the coercive force (X-axis) measured before and after using a quaternary metal alloy powder as the auxiliary agent for infiltrating the sintered magnet.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0026] Hereinafter, various embodiments of the present disclosure will be described in detail so that those skilled in the art can easily implement them. The present disclosure may be modified in various different ways, and is not limited to the embodiments set forth herein.

[0027] Further, throughout the specification, when a portion is referred to as “including” a certain component, it means that it can further include other components, without excluding the other components, unless otherwise stated.

[0028] According to the present embodiment, a magnetic powder can be produced through a reduction-diffusion process using a low-cost rare earth oxide. An oxide film can be formed in the process of removing a reducing agent such as Ca and a reduced by-product used at the time of reduction by such a method. Such an oxide film makes it difficult to sinter the magnetic powder and may impair the properties of the sintered magnet. In order to supplement this, the present embodiment uses the powder of the metal alloy as a sintering agent, thereby being able to prevent the deterioration of the properties of the sintered magnet while lowering the melting temperature.

[0029] When the oxygen content inside the magnet powder during sintering is increased, the magnetic properties are deteriorated, so it is necessary to use a high-purity metal alloy. However, in order to produce such an alloy, it is usually required to subject metal masses to arc melting or induction melting to melt it at high temperature. For example, in the case of the arc melting method, a process in which metal lumps are melted together in a vacuum atmosphere at about 2000 degrees Celsius to 3000 degrees Celsius by the generation of an arc through high pressure and high current, and the molten metal lumps are turned over and re-melted can be repeated. However, due to a space restriction on the arc melting machine, and a restriction on the maximum amount of sample for uniform melting, it can be produced only in small quantities. In addition, it is difficult to accurately control temperature during the arc melting process, and in the case of aluminum, it is vaporized in the process of melting due to the vapor pressure in a vacuum and causes a loss, thereby making it difficult to add an accurate ratio.

[0030] On the other hand, according to the present embodiment, when the melting temperature is lowered during production of a metal alloy used as a sintering agent, the cost can be reduced. Specifically, according to the present embodiment, since the sintering agent is produced below 1050 degrees Celsius by using RH.sub.2 powder and respective metal powders, the economic efficiency can be improved at the process stage. Further, in the case of a metal material such as Ga that is liquid at room temperature, if arc melting is used, it is scattered during arc formation, which is technically difficult to make an alloy, whereas according to the present embodiment, it is possible to add an exact ratio.

[0031] In the present embodiment, the metal alloy as a sintering agent corresponds to 1) a case in which 1) each metal powder corresponding to each element constituting the alloy is included as a sintering agent, or 2) a case in which a material corresponding to each element constituting the alloy is prepared as a precursor before sintering and metal alloy powder is included as a sintering agent.

[0032] FIG. 1 is a view showing a step of producing an R—Al—Cu metal alloy powder in a method of producing a sintered magnet according to an embodiment of the present disclosure.

[0033] According to one embodiment of the present disclosure corresponding to the above case 2), it includes a step of adding a R—Al—Cu metal alloy powder as a sintering agent to the R—Fe—B-based magnet powder to form a mixed powder. Specifically, the step of forming the R—Al—Cu powder includes the steps of: mixing RH.sub.2 powder, Al powder, and Cu powder to form a sintered precursor, agglomerating the sintered precursor, wrapping the agglomerated sintered precursor in a metal foil and raising the temperature to form a metal alloy, and pulverizing the metal alloy to form the sintering agent. The step of forming the sintered precursor may further include a step of mixing a liquid Ga. Further, the metal foil may include Mo or Ta.

[0034] Referring to FIG. 1, a sintered precursor in which RH.sub.2 powder, Al powder, and Cu powder are mixed may be compressed by cold isostatic pressing (CIP) or the like, and the lump may be wrapped in a metal foil of Mo or Ta. The lump 300 wrapped in metal foil is put in an alumina crucible 100 and heated in a tube furnace 200 under an argon (Ar) atmosphere to about 1050 degrees Celsius, thereby obtaining a high-purity alloy. At this time, the tube furnace 200 may be formed of a material such as alumina or SUS (stainless steel).

[0035] According to the present embodiment, it is advantageous to produce a large amount of metal alloys without space restrictions, and materials that are easily vaporized such as aluminum are also vaporized at high temperatures to minimize the lost part, so that an accurate addition ratio can be adjusted in the process progress. Further, since an electric furnace such as a tube furnace that can accurately control temperature and control a gas atmosphere during the process is used, a relatively low-cost device can be used. Further, not only elements such as aluminum that evaporate well, but also metal materials such as Ga that are liquid at room temperature, can be added at an accurate ratio. In addition, it is not necessary to use a vacuum state, and a metal alloy can be produced simply under normal pressure.

[0036] When wrapping the agglomerated sintered precursor in the metal foil and raising the temperature, the temperature may be raised in an argon gas atmosphere.

[0037] The forming of the metal alloy may further include the step of wrapping the agglomerated sintered precursor in the metal foil, raising the temperature up to 900 degrees Celsius to 1050 degrees Celsius, and then performing additional heat treatment. Here, the additional heat treatment is a heat treatment of the already synthesized alloy at a relatively low temperature, and a more uniform phase can be obtained through such annealing.

[0038] The step of agglomerating the sintered precursor may be performed using any one pressing method of hydraulic pressing, tapping and cold isostatic pressing (CIP).

[0039] The step of adding NdH.sub.2 powder to the R—Al—Cu powder as the sintering agent may be further included. Since it is not possible to sinter the magnet powder itself, the NdH.sub.2 powder contained in the sintering agent makes it possible to sinter a magnetic powder by mixing with a small amount of NdH.sub.2 powder.

[0040] Since the composition of Ra.sub.0.7Al.sub.0.2Cu.sub.0.1 generally has the lowest melting point when R (rare earth) and Cu are mixed in a ratio of approximately 7:3, it is preferable to set R to 0.7. According to the present embodiment, from the composition of 100% of Al and 0% of Cu to the composition of 50% of Al and 50% of Cu, they are melted together at less than 800 degrees Celsius to form an alloy, wherein Al can be prepared with a composition larger than that of Cu. If a large amount of Al and Cu are added as a sintering agent, the magnetic flux density may be lowered. Therefore, at the time of sintering, 0.17 wt % of Al and 0.2 wt % of Cu are added, and NdH.sub.2 is further added to set the reference value, followed by sintering.

[0041] Hereinafter, the method of producing a sintered magnet according to one embodiment of the present disclosure will be described in more detail. However, the following examples correspond to examples for explaining the present disclosure, and the scope of the present disclosure are not limited thereto.

Comparative Example 1

[0042] A magnetic powder synthesized with the composition of Nd.sub.2.4Fe.sub.12.8BCu.sub.0.05 and a sintering agent were mixed in a mortar, and the mixture was placed in a molybdenum (Mo) crucible or a carbon (C) crucible as a mold for obtaining a magnet of a desired shape. Thereafter, the temperature was raised to 850 degrees Celsius at a temperature rising rate of 300 degrees Celsius/hour in an ultra-high vacuum state of approximately 10.sup.−6 torr or less, and then maintained for about 30 minutes. The temperature was raised again to 1070 degrees Celsius at the same temperature rising rate, maintained for two hours, and then naturally cooled to room temperature to obtain a sintered body (material after sintering). In the process of sintering, 6 wt % of NdH.sub.2 was added as a sintering agent. All operation was carried out in an argon (Ar) atmosphere.

Example 1

[0043] Sintering was performed under approximately the same conditions as in Comparative Example 1, but in the process of sintering, 6 wt % of NdH.sub.2 powder, 0.17 wt % of Al powder, and 0.2 wt % of Cu powder were added as a sintering agent.

Example 2

[0044] Sintering was performed under approximately the same conditions as in Comparative Example 1, but in the process of sintering, a metal alloy powder of NdH.sub.2 and Nd.sub.0.7Al.sub.0.2Cu.sub.0.1 was added as a sintering agent so that the amount was identical to that of Example 1. In other words, when sintering the mixture of the magnet powder and the sintering agent in Examples 1 and 2, the atomic weight ratio of each added metal element can be identical relative to the mass of the magnet powder.

[0045] In order to prepare a metal alloy powder of NdH.sub.2 and Nd.sub.0.7Al.sub.0.2Cu.sub.0.1, the method for producing a sintering agent as follows was used. NdH.sub.2 powder, Al powder, and Cu powder were mixed, and the mixture was agglomerated by cold isostatic pressing (CIP). Thereafter, the agglomerated mixture was wrapped in Mo metal foil or Ta metal foil, and heated to 300 degrees Celsius per hour in an argon (Ar) gas atmosphere, and further heated at 900 degrees Celsius to 1050 degrees Celsius for an additional hour. The prepared metal alloy was pulverized to obtain a powder form.

Comparative Example 2

[0046] Sintering was performed under approximately the same conditions as in Comparative Example 1, but the magnetic powder synthesized with the composition of Nd.sub.2.4Fe.sub.12Co.sub.0.8BCu.sub.0.05 was used instead of the magnetic powder synthesized with the composition of Nd.sub.2.4Fe.sub.12.8BCu.sub.0.05. In addition, 10 wt % of NdH.sub.2 was added as a sintering agent.

Example 3

[0047] Sintering was performed under approximately the same conditions as in Comparative Example 2, but in the process of sintering, 10 wt % of NdH.sub.2 powder, 0.17 wt % of Al powder, and 0.2 wt % of Cu powder were added as a sintering agent.

Example 4

[0048] Sintering was performed under approximately the same conditions as in Example 3, but in the process of sintering, a metal alloy powder of NdH.sub.2 and Nd.sub.0.7Al.sub.0.2Cu.sub.0.1 was added as a sintering agent so that the amount was identical to that of Example 3. In order to prepare a metal alloy powder of NdH.sub.2 and Nd.sub.0.7Al.sub.0.2Cu.sub.0.1, the method for producing a sintering agent as follows was used. NdH.sub.2 powder, Al powder, and Cu powder were mixed, and the mixture was agglomerated by cold isostatic pressing (CIP). Thereafter, the agglomerated mixture was wrapped in Mo metal foil or Ta metal foil, and heated to 300 degrees Celsius per hour in an argon (Ar) gas atmosphere, and further heated at 900 degrees Celsius to 1050 degrees Celsius for an additional hour. The prepared metal alloy was pulverized to obtain a powder form.

Example 5

[0049] Sintering was performed under approximately the same conditions as in Example 4, but an alloy powder of NdH.sub.2 and Dy.sub.0.7Al.sub.0.2Cu.sub.0.1 was used as a sintering agent instead of the alloy powder of NdH.sub.2 and Nd.sub.0.7Al.sub.0.2Cu.sub.0.1.

Example 6

[0050] Sintering was performed under approximately the same conditions as in Example 4, but an alloy powder of NdH.sub.2 and Pr.sub.0.7Al.sub.0.2Cu.sub.0.1 was used as a sintering agent instead of the alloy powder of NdH.sub.2 and Nd.sub.0.7Al.sub.0.2Cu.sub.0.1.

[0051] FIG. 2 is a BH graph showing the magnetic flux density (Y-axis) according to the coercive force (X-axis) measured in a sintered magnet prepared according to Comparative Examples and Examples of the present disclosure.

[0052] FIG. 2 shows the magnetic flux density (Y-axis) according to the coercive force (X-axis) measured in Comparative Example 1, Example 1, and Example 2, respectively. Referring to FIG. 2, it can be confirmed that the properties of the sintered magnet are improved in Examples 1 and 2 compared to Comparative Example 1. Further, the case of sintering using the powder of a metal alloy as a sintering agent (Example 2) has improved properties of the sintered magnet as compared with the case of mixing and sintering the powder of a material corresponding to each sintering component element (Example 1).

[0053] When the amount of increase in the coercive force of Example 2 is converted into a percentage as compared with Example 1, an improvement of about 10 to 20% can be confirmed. That is, it is possible to obtain a meaningful increase in the coercive force according to the change in the shape of the sintering agent.

[0054] FIG. 3 is a BH graph showing the magnetic flux density (Y-axis) according to the coercive force (X-axis) measured in the sintered magnet produced according to Comparative Examples and Examples of the present disclosure, when changing the composition of the magnetic powder before sintering of FIG. 2.

[0055] FIG. 3 shows the magnetic flux density (Y-axis) according to the coercive force (X-axis) measured in Comparative Example 2, Example 3, and Example 4, respectively. Referring to FIG. 3, it can be confirmed that the properties of the sintered magnet are improved in Examples 3 and 4 compared to Comparative Example 2. Further, the case of sintering using the powder of a metal alloy as a sintering agent (Example 4) has improved properties of the sintered magnet as compared with the case of mixing and sintering the powder of a material corresponding to each sintering component element (Example 3).

[0056] FIG. 4 is a BH graph showing the magnetic flux density (Y-axis) according to the coercive force (X-axis) measured in a sintered magnet produced by changing the type of rare earth metal contained in the metal alloy, when using the powder of a metal alloy according to an embodiment of the present disclosure as a sintering agent.

[0057] FIG. 4 shows the magnetic flux density (Y axis) according to the coercive force (X axis) measured in Comparative Example 2, Example 4, Example 5, and Example 6, respectively. Referring to FIG. 4, it can be confirmed that the properties of the sintered magnet are improved in Examples 4, 5 and 6 compared to Comparative Example 2. Further, when sintering using the powder of the metal alloy as a sintering agent, it can be confirmed that the properties of the sintered magnet are improved even if the type of rare earth metal contained in the metal alloy is changed. In particular, it can be confirmed that the properties of the sintered magnet are most improved when it is Dy among the rare earth metals included in the metal alloy. In addition, in the present embodiment, a sintering agent of a three-phase metal alloy, that is, R—Al—Cu (where R is Nd, Pr, Dy, Tb, or Ce) metal alloy, has been described, but a quaternary metal alloy with the addition of other metals such as Ga is also applicable as a modified example.

[0058] Hereinafter, a case where a quaternary metal alloy is formed in the method of producing a sintered magnet according to one embodiment of the present disclosure will be described. However, the following examples correspond to examples for explaining the present disclosure, and the scope of the present disclosure are not limited thereto.

Example 7

[0059] A sintered magnet was formed by sintering under approximately the same conditions as in Comparative Example 1, and then a metal alloy powder of Pr.sub.0.7Al.sub.0.2Cu.sub.0.1Ga.sub.0.1 was used as an auxiliary agent for infiltration.

[0060] In order to prepare the metal alloy powder of Pr.sub.0.7Al.sub.0.2Cu.sub.0.1Ga.sub.0.1, the method for producing a sintering agent as follows was used. Pr powder, Al powder, Cu powder, and liquid Ga were mixed, and the mixture was agglomerated by a cold isostatic pressing (CIP). Then, the agglomerated mixture was wrapped in Mo metal foil or Ta metal foil, and heated to 300 degrees Celsius per hour in an argon (Ar) gas atmosphere, and further heated at 900 degrees Celsius to 1050 degrees Celsius for an additional hour. The prepared metal alloy was pulverized to obtain a powder form.

Example 8

[0061] Sintering was performed under approximately the same conditions as in Example 7, but an alloy powder of Dy.sub.0.7Al.sub.0.2Cu.sub.0.1Ga.sub.0.1 was used as an auxiliary agent for infiltration instead of the alloy powder of Pr.sub.0.7Al.sub.0.2Cu.sub.0.1Ga.sub.0.1.

[0062] FIGS. 5 and 6 are graphs showing the magnetic flux density (Y-axis) according to the coercive force (X-axis) measured before and after using a quaternary metal alloy powder as the auxiliary agents for infiltrating the sintered magnet. In FIG. 5, in order to confirm the level of the coercive force for the magnet infiltrated using the metal alloy powder of Pr.sub.0.7Al.sub.0.2Cu.sub.0.1Ga.sub.0.1 of Example 7, in a state in which an alloy powder of 2 wt % of Pr.sub.0.7Al.sub.0.2Cu.sub.0.1Ga.sub.0.1 relative to the sintered magnet was attached to the sintered magnet, infiltration was performed at 900 degrees Celsius for about 10 hours under high vacuum, and post-heat treatment was performed at approximately 520 degrees Celsius, and the resulting coercive force before and after is shown. In FIG. 6, the coercive force level of the magnet infiltrated using the metal alloy powder of Dy.sub.0.7Al.sub.0.2Cu.sub.0.1Ga.sub.0.1 of Example 8 is shown.

[0063] Referring to FIGS. 5 and 6, it can be confirmed that the coercive force is improved when the quaternary metal alloy powder is used as an auxiliary agent for infiltration.

[0064] Although the preferred embodiments of the present disclosure have been described in detail above, the scope of the present disclosure is not limited thereto, and various modifications and improvements of those skilled in the art using the basic concepts of the present disclosure defined in the following claims also belong to the scope of rights.

DESCRIPTION OF REFERENCE NUMERALS

[0065] 100: crucible [0066] 200: tube furnace