IRON-BASED AMORPHOUS ALLOY POWDER, PREPARATION METHOD THEREFOR AND APPLICATION THEREOF

Abstract

The present application provides an iron-based amorphous alloy powder, a preparation method therefor and an application thereof. The iron-based amorphous alloy powder comprises a Cu element, and the particle shape of the iron-based amorphous alloy powder is spherical. The preparation method comprises the following steps: (1) smelting a master alloy to obtain iron-based amorphous alloy molten iron, the master alloy comprising a Cu element; and (2) treating the iron-based amorphous alloy molten iron obtained in step (1) by means of water-gas combined atomization to obtain the iron-based amorphous alloy powder.

Claims

1. An iron-based amorphous alloy powder, comprising a Cu element; the iron-based amorphous alloy powder has a spherical particle shape.

2. The iron-based amorphous alloy powder according to claim 1, wherein the iron-based amorphous alloy powder further comprises a metalloid element and a main transition metal element.

3. The iron-based amorphous alloy powder according to claim 2, wherein the metalloid element comprises any one or a combination of at least two of B, P, Si or C.

4. The iron-based amorphous alloy powder according to claim 2, wherein the main transition metal element comprises Ni and/or Cr; optionally, the iron-based amorphous alloy powder further comprises a trace transition metal element; optionally, the trace transition metal element comprises any one or a combination of at least two of V, Mn or Zn.

5. The iron-based amorphous alloy powder according to claim 1, wherein the iron-based amorphous alloy powder has a chemical formula of aFe-bSi-cB-dP-eC-fNi-gCr-hCu-iV-jMn-kZn; optionally, an atomic percentage of each element in the chemical formula is 64.8%≤a≤80.2%, 0%≤Sb≤2%, 5%≤c≤10%, 3%≤d≤6.2%, 1.2%≤e≤5.5%, 0.5%≤f≤4%, 1%≤g≤5%, 0.1%≤h≤1.5%, 0%≤i≤0.2%, 0%≤j≤0.6%, 0%≤k≤0.2%; and optionally 64.8%≤a≤80.2%, 0%≤b≤2%, 5%≤c≤8%, 4%≤d≤6%, 3%≤e≤5%, 1%≤f≤3%, 2%≤g≤4%, 0.5%≤h≤1.2%, 0.02%≤i≤0.12%, 0.1%≤j≤0.4%, 0.1%≤k≤0.15%; optionally, a sum of the atomic percentages of B, P and C in the metalloid element is 14%-18%.

6. The iron-based amorphous alloy powder according to claim 1, wherein the iron-based amorphous alloy powder has a D10 of 2-5 μm; optionally, the iron-based amorphous alloy powder has a D50 of 8-12 μm; optionally, the iron-based amorphous alloy powder has a D90 of 20-30 μm.

7. A preparation method of the iron-based amorphous alloy powder according to claim 1, comprising the following steps: (1) melting a master alloy to obtain an iron-based amorphous alloy iron fluid; the master alloy comprises a Cu element; (2) treating the iron-based amorphous alloy iron fluid in step (1) by a water-gas combined atomization to obtain the iron-based amorphous alloy powder.

8. The preparation method of the iron-based amorphous alloy powder according to claim 7, wherein the melting in step (1) has a temperature of 1300-1500° C.; optionally, the melting in step (1) has a time of 80-150 min; optionally, the water-gas combined atomization treatment in step (2) comprises feeding the iron-based amorphous alloy iron fluid in step (1) into an atomization tower, then breaking the iron-based amorphous alloy iron fluid in step (1) into fine metal droplets by applying water and gas atomization media to the iron-based amorphous alloy iron fluid in step (1) in the atomization tower, and then cooling the fine metal droplets to obtain the iron-based amorphous alloy powder treated by the water-gas combined atomization; optionally, the water has a pressure of 100-150 MPa; optionally, the gas has a pressure of 0.5-1.0 MPa; optionally, the gas is a protective gas; optionally, the protective gas comprises N.sub.2 and Ar.sub.2; optionally, the iron-based amorphous alloy powder treated by the water-gas combined atomization is further baked and gas-flow graded.

9. The preparation method of the iron-based amorphous alloy powder according to claim 7, wherein the preparation method comprises the following steps: (1) melting a master alloy at 1300-1500° C. for 80-150 min to obtain an iron-based amorphous alloy iron fluid; the master alloy comprises a Cu element; (2) feeding the iron-based amorphous alloy iron fluid in step (1) into an atomization tower, then breaking the iron-based amorphous alloy iron fluid in step (1) into fine metal droplets by applying water and N.sub.2 atomization media, which have pressures of 100-150 MPa and 0.5-1.0 MPa, respectively, to the iron-based amorphous alloy iron fluid in step (1) in the atomization tower, then cooling the fine metal droplets, and then performing baking and gas-flow grading to obtain the iron-based amorphous alloy powder.

10. A magnetic powder core, comprising the iron-based amorphous alloy powder according to claim 1, a first inorganic layer coated on the surface of the iron-based amorphous alloy powder, a second inorganic layer coated on the surface of the first inorganic layer, and an organic layer coated on the surface of the second inorganic layer.

11. The magnetic powder core according to claim 10, wherein the first inorganic layer comprises phosphate; optionally, the second inorganic layer comprises any one or a combination of at least two of sodium silicate, potassium silicate, a silane coupling agent, magnesium silicate, or nano SiO.sub.2; optionally, the organic layer comprises a resin; optionally, the resin comprises any one or a combination of at least two of polyvinyl butyral, an epoxy resin, a silicone resin or a phenolic resin.

12. A method for preparing the magnetic powder core according to claim 10, comprising coating the first inorganic layer, the second inorganic layer and the organic layer in sequence on the surface of an iron-based amorphous alloy powder, and then performing sintering; wherein the iron-based amorphous alloy powder comprises a Cu element; the iron-based amorphous alloy powder has a spherical particle shape; optionally, the sintering has a temperature of 340-440° C., optionally 360-400° C.; optionally, the sintering has a time of 0.5-4 h, optionally 1.5-2.5 h.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0064] FIG. 1 is an SEM image of an iron-based amorphous alloy powder provided in Example 1.

[0065] FIG. 2 is a loss diagram of iron-based amorphous alloy powders with different Cu element contents provided in Examples 1-9 and Comparative Example 1.

DETAILED DESCRIPTION

[0066] The technical solutions of the present application are further described below through embodiment. It should be apparent to those skilled in the art that the embodiments are only used for a better understanding of the present application and should not be regard as a specific limitation of the present application.

Example 1

[0067] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.77.1Si.sub.1B.sub.6P.sub.5.5C.sub.4.5 Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0068] A preparation method is as follows: [0069] according to the chemical formula of the amorphous component, raw materials were fed into a medium frequency high temperature melting furnace, the master alloy was melted to 1400° C., the molten iron liquid was fed into an atomization tower, and the iron liquid was broken into fine metal droplets by applying high-pressure water and low-pressure gas atomization media to the alloy liquid, and the fine metal droplets were cooled to obtain the amorphous powder, in which the high-pressure water had a pressure of 120 MPa, and the gas had a pressure of 0.8 MPa; the Fe.sub.77.1Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.3V.sub.0.1Mn.sub.0.2Zn.sub.0.1 amorphous alloy powder was prepared by the water-gas combined atomization; [0070] the amorphous powder obtained from the water-gas combined atomization was passivated with 0.2 wt % phosphoric acid, then coated with 0.2 wt % potassium silicate, and then coated with a 0.6 wt % epoxy resin for prilling; the 180 mesh powder was sieved and pressed into a magnetic ring with a magnetic powder core of 14 mm*8 mm*3 mm at a press of 1600 MPa, and then sintered at 360° C. under nitrogen atmosphere for 2 h; the molded magnetic ring was subjected to heat treatment and then wound 30 round for characteristic tests; the inductance was tested at 1 MHz&0.25 V, the superimposed current was 20 A, and the loss was tested at 1 MHz&20 mT.

[0071] As can be seen from FIG. 1, the iron-based amorphous alloy powder provided in this example is obviously spherical particle.

Example 2

[0072] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.77.3Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.2V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0073] This example differs from Example 1 in that an atomic percentage of the Cu element is 0.2% in the powder of this example.

[0074] Other preparation methods and test conditions were the same as in Example 1.

Example 3

[0075] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.77.4 Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.1V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0076] This example differs from Example 1 in that an atomic percentage of the Cu element is 0.1% in the powder of this example.

[0077] Other preparation methods and test conditions were the same as in Example 1.

Example 4

[0078] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.76.8Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.8V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0079] This example differs from Example 1 in that an atomic percentage of the Cu element is 0.8% in the powder of this example.

[0080] Other preparation methods and test conditions were the same as in Example 1.

Example 5

[0081] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.76.6Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.1.0V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0082] This example differs from Example 1 in that an atomic percentage of the Cu element is 1% in the powder of this example.

[0083] Other preparation methods and test conditions were the same as in Example 1.

Example 6

[0084] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.76.4Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.1.2V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0085] This example differs from Example 1 in that an atomic percentage of the Cu element is 1.2% in the powder of this example.

[0086] Other preparation methods and test conditions were the same as in Example 1.

Example 7

[0087] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.76.1Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.1.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0088] This example differs from Example 1 in that an atomic percentage of the Cu element is 1.5% in the powder of this example.

[0089] Other preparation methods and test conditions were the same as in Example 1.

Example 8

[0090] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.75.8Si.sub.1B.sub.6P.sub.5.5C.sub.4.5 Ni.sub.2Cr.sub.3Cu.sub.1.8V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0091] This example differs from Example 1 in that an atomic percentage of the Cu element is 1.8% in the powder of this example.

[0092] Other preparation methods and test conditions were the same as in Example 1.

Example 9

[0093] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.75.6Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.2.0V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0094] This example differs from Example 1 in that an atomic percentage of the Cu element is 2% in the powder of this example.

[0095] Other preparation methods and test conditions were the same as in Example 1.

Comparative Example 1

[0096] This comparative example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.77.6Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0097] Other preparation methods and test conditions were the same as in Example 1.

[0098] It can be clearly seen from FIG. 2 that the atomic percentage of the Cu element in the present application significantly influences the loss value of the iron-based amorphous alloy powder. Too much or too little Cu element will have a negative effect on the iron-based amorphous alloy powder. In the case where the iron-based amorphous alloy powder contains no Cu element, the loss value is much higher than that of the iron-based amorphous alloy powder provided in Example 1, because Cu atoms can provide nucleating points for nanocrystallization; the Cu element content is too high in Examples 8 and 9, and the loss is high. As in Example 9, the high proportion of Cu element will lead to an increased probability of the nanocrystalline nucleating points close to each other to merge and grow, resulting in larger nanocrystalline grain size and increased loss value of the iron-based amorphous alloy powder.

[0099] Table 1 shows the properties of the iron-based amorphous alloy powders obtained from Examples 1-9 and Comparative Example 1.

TABLE-US-00001 TABLE 1 Glass Nano αFe Loss Transition Precipitation Chemical Magnetic Superposition (1 MHz & Temperature Temperature Formula Permeability Ratio (20 A) 20 mT) (° C.) (° C.) Example 1 Fe.sub.77.1Si.sub.1B.sub.6 52.3 65.5% 243.1 320° C. 360° C. P.sub.5.5C.sub.4.5Ni.sub.2 Cr.sub.3Cu.sub.0.5V.sub.0.1 Mn.sub.0.2Zn.sub.0.1 Example 2 Fe.sub.77.3Si.sub.1B.sub.6 51.8 65.6% 280.7 330° C. 375° C. P.sub.5.5C.sub.4.5Ni.sub.2 Cr.sub.3Cu.sub.0.2V.sub.0.1 Mn.sub.0.2Zn.sub.0.1 Example 3 Fe.sub.77.4Si.sub.1B.sub.6 51.6 65.6% 295.7 335° C. 380° C. P.sub.5.5C.sub.4.5Ni.sub.2 Cr.sub.3Cu.sub.0.1V.sub.0.1 Mn.sub.0.2Zn.sub.0.1 Example 4 Fe.sub.76.8Si.sub.1B.sub.6 52.2 65.6% 250.4 325° C. 365° C. P.sub.5.5C.sub.4.5Ni.sub.2 Cr.sub.3Cu.sub.0.8V.sub.0.1 Mn.sub.0.2Zn.sub.0.1 Example 5 Fe.sub.76.6Si.sub.1B.sub.6 52.0 65.2% 258.1 325° C. 365° C. P.sub.5.5C.sub.4.5Ni.sub.2 Cr.sub.3Cu.sub.1.0V.sub.0.1 Mn.sub.0.2Zn.sub.0.1 Example 6 Fe.sub.76.4Si.sub.1B.sub.6 51.7 65.2% 265.4 325° C. 365° C. P.sub.5.5C.sub.4.5Ni.sub.2 Cr.sub.3Cu.sub.1.2V.sub.0.1 Mn.sub.0.2Zn.sub.0.1 Example 7 Fe.sub.76.1Si.sub.1B.sub.6 51.3 65.0% 270.6 330° C. 370° C. P.sub.5.5C.sub.4.5Ni.sub.2 Cr.sub.3Cu.sub.1.5V.sub.0.1 Mn.sub.0.2Zn.sub.0.1 Example 8 Fe.sub.75.8Si.sub.1B.sub.6 50.4 64.8% 365.8 335° C. 370° C. P.sub.5.5C.sub.4.5Ni.sub.2 Cr.sub.3Cu.sub.1.8V.sub.0.1 Mn.sub.0.2Zn.sub.0.1 Example 9 Fe.sub.75.6Si.sub.1B.sub.6 49.6 64.8% 405.7 340° C. 380° C. P.sub.5.5C.sub.4.5Ni.sub.2 Cr.sub.3Cu.sub.2.0V.sub.0.1 Mn.sub.0.2Zn.sub.0.1 Comparative Fe.sub.77.6Si.sub.1B.sub.6 51.5 65.8% 350.4 380° C. 450° C. Example 1 P.sub.5.5C.sub.4.5Ni.sub.2 Cr.sub.3V.sub.0.1 Mn.sub.0.2Zn.sub.0.1

[0100] As shown in Table 1, the atomic percentages of the Cu element are different in the iron-based amorphous alloy powders prepared from Examples 1-9. In Examples 1-7, the atomic percentages of the Cu element are all within 0.1-1.5%. Based on the data in the table, it can be concluded that the iron-based amorphous alloys in the above examples have better magnetic permeability and lower loss. However, the Cu element contents are high in Examples 8 and 9, and the loss is high.

[0101] Based on the data from Example 1 and Comparative Example 1, it can be concluded that the loss of the iron-based amorphous alloy powder without Cu element is much higher than that of the iron-based amorphous alloy powder provided in Example 1. The reason is that Cu atoms can provide nucleating points for nanocrystallization; as in Example 9, the high proportion of Cu element will lead to an increased probability of the nanocrystalline nucleating points close to each other to merge and grow, resulting in larger nanocrystalline grain size and increased loss value of the iron-based amorphous alloy powder.

Example 10

[0102] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.77.1Si.sub.1B.sub.5P.sub.5.5C.sub.4Ni.sub.2Cr.sub.3Cu.sub.0.8V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0103] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the B element is 5%, an atomic percentage of the C element is 4%, and a sum of the atomic percentages of the B+P+C metal elements is 14.5%.

[0104] Other preparation methods and test conditions were the same as in Example 1.

Example 11

[0105] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.89.1Si.sub.1B.sub.1P.sub.2C.sub.1Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0106] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the B element is 1%, an atomic percentage of the P element is 2%, an atomic percentage of the C element is 1%, and a sum of the atomic percentages of the B+P+C metal elements is 4%.

[0107] Other preparation methods and test conditions were the same as in Example 1.

Example 12

[0108] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.85.1 Si.sub.1B.sub.3P.sub.3C.sub.2Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0109] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the B element is 3%, an atomic percentage of the P element is 3%, an atomic percentage of the C element is 2%, and a sum of the atomic percentages of the B+P+C metal elements is 8%.

[0110] Other preparation methods and test conditions were the same as in Example 1.

Example 13

[0111] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.81.1Si.sub.1B.sub.3P.sub.5C.sub.4Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0112] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the B element is 3%, an atomic percentage of the P element is 5%, an atomic percentage of the C element is 4%, and a sum of the atomic percentages of the B+P+C metal elements is 12%.

[0113] Other preparation methods and test conditions were the same as in Example 1.

Example 14

[0114] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.80.1Si.sub.1B.sub.6P.sub.5C.sub.2Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0115] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the P element is 5%, an atomic percentage of the C element is 2%, and a sum of the atomic percentages of the B+P+C metal elements is 13%.

[0116] Other preparation methods and test conditions were the same as in Example 1.

Example 15

[0117] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.81.1Si.sub.1B.sub.6P.sub.2C.sub.4Ni.sub.2Cr.sub.3Cu.sub.0.8V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0118] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the P element is 2%, an atomic percentage of the C element is 4%, and a sum of the atomic percentages of the B+P+C metal elements is 12%.

[0119] Other preparation methods and test conditions were the same as in Example 1.

Example 16

[0120] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.68.1Si.sub.1B.sub.8P.sub.10C.sub.7Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0121] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the B element is 8%, an atomic percentage of the P element is 10%, an atomic percentage of the C element is 7%, and a sum of the atomic percentages of the B+P+C metal elements is 25%.

[0122] Other preparation methods and test conditions were the same as in Example 1.

Example 17

[0123] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.72.6Si.sub.1B.sub.6P.sub.10C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.8V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0124] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the P element is 10%, and a sum of the atomic percentages of the B+P+C metal elements is 20.5%.

[0125] Other preparation methods and test conditions were the same as in Example 1.

Example 18

[0126] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.80.6Si.sub.1B.sub.6P.sub.5.5C.sub.1Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0127] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the C element is 1%, and a sum of the atomic percentages of the B+P+C metal elements is 12.5%.

[0128] Other preparation methods and test conditions were the same as in Example 1.

Example 19

[0129] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.73.1Si.sub.1B.sub.1P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0130] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the B element is 100, and a sum of the atomic percentages of the B+P+C metal elements is 11%.

[0131] Other preparation methods and test conditions were the same as in Example 1.

[0132] Table 2 shows the properties of the iron-based amorphous alloy powders obtained in Example 1 and Examples 10-19.

TABLE-US-00002 TABLE 2 Glass Nano αFe Loss Transition Precipitation Chemical Magnetic Superposition (1 MHz & Temperature Temperature Formula Permeability Ratio (20 A) 20 mT) (° C.) (° C.) Example 1 Fe.sub.77.1Si.sub.1B.sub.6 52.3 65.5% 243.1 320° C. 360° C. P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 10 Fe.sub.77.1Si.sub.1B.sub.5 52.5 65.3% 276.2 325° C. 365° C. P.sub.5.5C.sub.4Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 11 Fe.sub.89.1Si.sub.1B.sub.1 26.8 70.2% 1530.2 410° C. 470° C. P.sub.2C.sub.1Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 12 Fe.sub.85.1Si.sub.1B.sub.3 48.6 67.4% 546.7 390° C. 455° C. P.sub.3C.sub.2Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 13 Fe.sub.81.1Si.sub.1B.sub.3 51.3 64.3% 432.2 380° C. 430° C. P.sub.5C.sub.4Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 14 Fe.sub.80.1Si.sub.1B.sub.6 50.7 64.5% 473.1 340° C. 385° C. P.sub.5C.sub.2Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 15 Fe.sub.81.1Si.sub.1B.sub.6 50.4 64.7% 525.4 340° C. 385° C. P.sub.2C.sub.4Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 16 Fe.sub.68.1Si.sub.1B.sub.8 46.3 61.2% 323.5 320° C. 360° C. P.sub.10C.sub.7Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 17 Fe.sub.72.6Si.sub.1B.sub.6 47.5 62.6% 302.7 320° C. 360° C. P.sub.10C.sub.4.5Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 18 Fe.sub.80.6Si.sub.1B.sub.6 48.6 63.2% 321.4 330° C. 370° C. P.sub.5.5C.sub.1Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 19 Fe.sub.73.1Si.sub.1B.sub.1 47.9 62.5% 365.2 330° C. 370° C. P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1

[0133] Based on the data in Table 2, it can be concluded that in the case where the atomic percentages of the B+P+C elements are too high or too low in the iron-based amorphous alloy powder, as shown in the iron-based amorphous alloy powders provided in Examples 11-19, the permeability is not high enough and the loss is very severe and much higher than that of the iron-based amorphous alloy powder provided in Example 1.

Example 20

[0134] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.72.1Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.5Cr.sub.5Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0135] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the Ni element is 5%, and an atomic percentage of the Cr element is 5%. Other preparation methods and test conditions were the same as in Example 1.

Example 21

[0136] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.74.1 Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.5Cr.sub.3Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0137] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the Ni element is 5%.

[0138] Other preparation methods and test conditions were the same as in Example 1.

Example 22

[0139] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.75.1Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.5Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0140] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the Cr element is 5%.

[0141] Other preparation methods and test conditions were the same as in Example 1.

Example 23

[0142] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.80.1Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.1Cr.sub.1Cu.sub.0.5V.sub.0.1Mn.sub.0.2Zn.sub.0.1.

[0143] This example differs from Example 1 in that, in the powder of this example, an atomic percentage of the Ni element is 100, and an atomic percentage of the Cr element is 1%.

[0144] Other preparation methods and test conditions were the same as in Example 1.

[0145] Table 3 shows the properties of the iron-based amorphous alloy powders obtained in Example 1 and Examples 20-23.

TABLE-US-00003 TABLE 3 Rusty Glass Nano αFe Superposition Loss Condition Transition Precipitation Chemical Magnetic Ratio (1 MHz & (in salt mist Temperature Temperature Formula Permeability (20 A) 20 mT) for 48 H) (° C.) (° C.) Example 1 Fe.sub.77.1Si.sub.1B.sub.6 52.3 65.5% 243.1 Unrusted 320° C. 360° C. P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 20 Fe.sub.72.1Si.sub.1B.sub.6 50.8 63.2% 256.1 Unrusted 320° C. 360° C. P.sub.5.5C.sub.4.5Ni.sub.5Cr.sub.5 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 21 Fe.sub.74.1Si.sub.1B.sub.6 50.9 63.1% 266.4 Unrusted 320° C. 360° C. P.sub.5.5C.sub.4.5Ni.sub.5Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 22 Fe.sub.75.1Si.sub.1B.sub.6 50.3 63.5% 263.1 Unrusted 320° C. 360° C. P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.5 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1 Example 23 Fe.sub.80.1Si.sub.1B.sub.6 48.7 66.0% 258.4 Rusty 320° C. 360° C. P.sub.5.5C.sub.4.5Ni.sub.1Cr.sub.1 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Zn.sub.0.1

[0146] Based on the data in Table 3, it can be concluded that in the case where the Ni element content in the iron-based amorphous alloy powder is too low, as shown in Example 23, the iron-based amorphous alloy powder has poor corrosion resistant and is more prone to corrosion and rusting.

Example 24

[0147] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.77.5Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5.

[0148] This example differs from Example 1 in that the powder of this example includes no V, Mn and Zn elements.

[0149] Other preparation methods and test conditions were the same as in Example 1.

Example 25

[0150] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.77.2Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.1Mn.sub.0.2.

[0151] This example differs from Example 1 in that the powder of this example includes no Zn element.

[0152] Other preparation methods and test conditions were the same as in Example 1.

Example 26

[0153] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.77.3Si.sub.1B.sub.6P.sub.5.5C.sub.4.5 Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.1Zn.sub.0.1.

[0154] This example differs from Example 1 in that the powder of this example includes no Mn element.

[0155] Other preparation methods and test conditions were the same as in Example 1.

Example 27

[0156] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.77.2Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5Mn.sub.0.2Zn.sub.0.1.

[0157] This example differs from Example 1 in that the powder of this example includes no V element.

[0158] Other preparation methods and test conditions were the same as in Example 1.

Example 28

[0159] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.77.2Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.8V.sub.0.4Mn.sub.0.2Zn.sub.0.1.

[0160] This example differs from Example 1 in that an automatic percentage of the V element is 0.4% in the powder of this example.

[0161] Other preparation methods and test conditions were the same as in Example 1.

Example 29

[0162] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.76.4Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.2Mn.sub.0.6Zn.sub.0.1.

[0163] This example differs from Example 1 in that, in the powder of this example, an automatic percentage of the V element is 0.2%, and an automatic percentage of the Mn element is 0.6%.

[0164] Other preparation methods and test conditions were the same as in Example 1.

Example 30

[0165] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.76.1Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5V.sub.0.2Mn.sub.0.2Zn.sub.0.4.

[0166] This example differs from Example 1 in that, in the powder of this example, an automatic percentage of the V element is 0.2, and an automatic percentage of the Zn element is 0.4.

[0167] Other preparation methods and test conditions were the same as in Example 1.

[0168] Table 4 shows the properties of the iron-based amorphous alloy powders obtained in Example 1 and Examples 24-30.

TABLE-US-00004 TABLE 4 Glass Nano αFe Superposition Loss Transition Precipitation Chemical Magnetic Ratio (1 MHz & Temperature Temperature Formula Permeability (20 A) 20 mT) (° C.) (° C.) Example 1 Fe.sub.77.1Si.sub.1B.sub.6P.sub.5.5 52.3 65.5% 243.1 320° C. 360° C. C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5 V.sub.0.1Mn.sub.0.2Zn.sub.0.1 Example 24 Fe.sub.77.5Si.sub.1B.sub.6P.sub.5.5 49.5 65.4% 350.2 325° C. 370° C. C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5 Example 25 Fe.sub.77.2Si.sub.1B.sub.6 50.1 65.3% 335.1 330° C. 370° C. P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Mn.sub.0.2 Example 26 Fe.sub.77.3Si.sub.1B.sub.6 50.6 65.1% 330.2 325° C. 365° C. P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3 Cu.sub.0.5V.sub.0.1Zn.sub.0.1 Example 27 Fe.sub.77.2Si.sub.1B.sub.6 50.4 65.2% 330.5 320° C. 360° C. P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3 Cu.sub.0.5Mn.sub.0.2Zn.sub.0.1 Example 28 Fe.sub.77.2Si.sub.1B.sub.6P.sub.5.5 51.6 65.1% 360.7 330° C. 375° C. C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5 V.sub.0.4Mn.sub.0.2Zn.sub.0.1 Example 29 Fe.sub.76.4Si.sub.1B.sub.6P.sub.5.5 51.8 64.9% 371.6 320° C. 360° C. C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5 V.sub.0.2Mn.sub.0.6Zn.sub.0.1 Example 30 Fe.sub.76.1Si.sub.1B.sub.6P.sub.5.5 50.3 64.8% 356.7 340° C. 380° C. C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5 V.sub.0.2Mn.sub.0.2Zn.sub.0.4

[0169] Based on the data from Example 1 and Example 24, it can be seen that the loss of iron-based amorphous alloy powder is significantly higher when no trace transition metal elements are added such as V, Mn and Zn.

[0170] It can be seen from Example 1 and Examples 25-27 that the loss is lower when the three trace transition metal elements, V, Mn and Zn, are added together.

[0171] Based on the data from Example 1 and Examples 28-29, it can be seen that the loss of the iron-based amorphous alloy powder will be higher no matter which one of the three trace transition metal elements, V, Mn and Zn, is added excessively.

Examples 31-38

[0172] The iron-based amorphous alloy powders prepared from Examples 31-38 have the same chemical formula of Fe.sub.77.1Si.sub.1B.sub.6P.sub.5.5C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.8V.sub.0.1Mn.sub.0.2Zn.sub.0.1, and the preparation methods of the examples differ from Example 1 only in sintering conditions. The specific sintering conditions of each example are shown in Table 5.

[0173] Table 5 shows the properties of the iron-based amorphous alloy powders obtained in Example 1 and Examples 31-38.

TABLE-US-00005 TABLE 5 Sintering Magnetic Loss Condition Permeability (1 MHz&20 mT) Example 1 360° C.*2 H 52.3 243.1 Example 31 360° C.*0.5 H 43.7 476.3 Example 32 360° C.*1 H 50.8 347.6 Example 33 360° C.*4 H 53.5 367.1 Example 34 340° C.*2 H 44.2 423.4 Example 35 380° C.*2 H 53.4 278.8 Example 36 400° C.*2 H 53.8 286.4 Example 37 420° C.*2 H 45.2 542.2 Example 38 440° C.*2 H 26.5 1253.2

[0174] The iron-based amorphous alloy powders of Examples 31-38 are the same as Example 1, and accordingly, the glass transition temperature and the nano αFe precipitation temperature are the same as those provided in Example 1.

[0175] Based on the data from Example 1 and Examples 31-33, it can be seen that the loss of the iron-based amorphous alloy powders are increased significantly by being sintered for a too long or too short time.

[0176] Based on the data from Example 1 and Example 34, it can be seen that when the sintering temperature is too low during the sintering process, the magnetic permeability of the iron-based amorphous alloy powder will decrease and the loss will be larger.

[0177] Based on the data from Example 1 and Examples 37-38, it can be seen that when the sintering temperature is too high during the sintering process, by-products will be generated, greatly reducing the magnetic permeability of the iron-based amorphous alloy powder, and severely increasing the loss at the same time.

Comparative Example 2

[0178] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.96.5 Si.sub.3.5. In this comparative example, a sintering temperature is 700° C. and a sintering time is 2h.

[0179] Other preparation methods and test conditions were the same as in Example 1.

Comparative Example 3

[0180] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.92Si.sub.3.5 Cr.sub.4.5. In this comparative example, a sintering temperature is 750° C. and a sintering time is 2 h.

[0181] Other preparation methods and test conditions were the same as in Example 1.

Comparative Example 4

[0182] This example provides an iron-based amorphous alloy powder, the powder has a spherical particle shape, and the iron-based amorphous alloy powder has a chemical formula of Fe.sub.85Si.sub.9.5 Al.sub.5.5. In this comparative example, a sintering temperature is 650° C. and a sintering time is 2 h.

[0183] Other preparation methods and test conditions were the same as in Example 1.

[0184] Table 6 shows the properties of the iron-based amorphous alloy powders obtained in Example 1 and Comparative Examples 2-4.

TABLE-US-00006 TABLE 6 Glass Nano αFe Superposition Loss Transition Precipitation Chemical Magnetic Ratio (1 MHz & Temperature Temperature Formula Permeability (20 A) 20 mT) (° C.) (° C.) Example 1 Fe.sub.77.1Si.sub.1B.sub.6P.sub.5.5 52.3 65.5% 243.1 320° C. 360° C. C.sub.4.5Ni.sub.2Cr.sub.3Cu.sub.0.5 V.sub.0.1Mn.sub.0.2Zn.sub.0.1 Comparative Fe.sub.96.5Si.sub.3.5 51.6 68.2% 785.4 — — Example 2 Comparative Fe.sub.92Si.sub.3.5Cr.sub.4.5 52.5 65.5% 805.3 — — Example 3 Comparative Fe.sub.85Si.sub.9.5Al.sub.5.5 60.2 59.8% 385.7 — — Example 4

[0185] Comparative Examples 2-4 are all crystalline substances, so there is no glass transition temperature and nano αFe precipitation temperature.

[0186] Based on the data from Example 1 and Comparative Examples 2-3, it can be seen that the iron-based amorphous alloy provided by the present application has more excellent characteristics than other alloy powders in terms of magnetic permeability, superimposed current and loss.

[0187] The applicant declares that although the embodiments of the present application are described above, the protection scope of the present application is not limited to the embodiments. The protection scope of the present application is defined by the claims.