PRODUCTION OF Fe16N2 COMPOUND AS A PERMANENT MAGNET

Abstract

A production method of a Fe.sub.16N.sub.2 based permanent magnet includes the following steps: 1) obtaining a Fe.sub.16N.sub.2 compound in a form of micro flakes by applying a nitriding process to α′-Fe powders of micro or nano sizes; 2) forming a structure by combining a polymer material with the Fe.sub.16N.sub.2 compound and utilizing a 3D printer; and 3) applying a magnetization process to the structure obtained in step 2 to obtain a magnetized structure and carrying out a heat treatment process to the magnetized structure to obtain the Fe.sub.16N.sub.2 based permanent magnet. The production method is continuous, less difficult, and less costly compared to the production of previous permanent magnets.

Claims

1. A production method of a Fe.sub.16N.sub.2 based permanent magnet, comprising: 1 obtaining a Fe.sub.16N.sub.2 compound in a form of micro flakes by applying a nitriding process to α′-Fe powders of micro or nano sizes, 2) forming a structure by combining a polymer material with the Fe.sub.16N.sub.2 compound and utilizing a 3D printer, 3) applying a magnetization process to the structure obtained in step 2 to obtain a magnetized structure and carrying out a heat treatment process to the magnetized structure to obtain the Fe.sub.16N.sub.2 based permanent magnet.

2. The production method according to claim 1, wherein the α′-Fe powders in step 1 have a thickness between 50 nm and 150 nm.

3. The production method according to claim 1, wherein the α′-Fe powders in step 1 have a diameter between 5 and 15 μm.

4. The production method according to claim 1, wherein step 1 comprises performing a flaking process with auxiliary surfactants and/or solvents to the α′-Fe powders.

5. The production method according to claim 4, wherein the flaking process is carried out in a ball mill device for a period of 10 to 14 hours.

6. The production method according to claim 1, wherein the nitriding process in step 1 is performed at a temperature range of 150 to 190° C.

7. The production method according to claim 1, wherein the nitriding process in step 1 is performed between 24 to 160 hours.

8. The production method according to claim 1, wherein the nitriding process in step 1 is performed with ammonia gas.

9. The production method according to claim 1, wherein the polymer material in step 2 is at least one polymer selected from the group consisting of SU8, PETA, LAP, PVP, polyurethane, and PVDF.

10. The production method according to claim 9, wherein the polymer material is SU8.

11. The production method according to claim 1, wherein in step 2, when combining the polymer material with the Fe.sub.16N.sub.2 compound, the polymer material has a weight percentage of 10-40% in a combination of the polymer material and the Fe.sub.16N.sub.2 compound.

12. The production method according to claim 1, wherein step 2 further comprises applying an annealing process to the structure printed with the 3D printer, wherein the annealing process is applied under vacuum at a temperature between 100 and 200° C.

13. The production method according to claim 12, wherein the annealing process is carried out for 3 to 7 hours.

14. The production method according to claim 1, wherein in step 3, the magnetization process is performed with an electromagnet with a magnetic field of 1 to 2 Tesla.

15. The production method according to claim 14, wherein the magnetization process is carried out between 1 minute and 2 minutes.

Description

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0034] In this detailed description of the invention, a permanent magnet whose continuous production can be provided, which is less difficult and costly compared to the production routes of permanent magnets, thereof is described only for clarifying the subject matter and in a manner such that no limiting effect is created.

[0035] So as to produce the permanent magnet mentioned in the invention, a permanent magnet is obtained by applying nitriding processes to α′-Fe powders and by applying magnetization processes to the Fe.sub.16N.sub.2 compound obtained after nitriding process. The following process steps are applied so as to obtain permanent magnet with required properties and structures: [0036] i. Obtaining the chemical compound Fe.sub.16N.sub.2 in the form of micro flakes by applying nitriding process to the materials that contain micron or nano-sized α′-Fe powders, [0037] ii. Forming a structure by 3D printing a polymer material with Fe.sub.16N.sub.2 compound, [0038] iii. Applying the magnetization process to the chemical compound obtained in step (ii) and carrying out heat treatment processes.

[0039] Before applying step (i), α′-Fe powders are turned into micron-sized flakes by means of the ball milling technique containing surfactant. Said ball milling process is continued for 10 to 14 hours. Anisotropic material is obtained in magnet production by flaking α′-Fe powders. Moreover, when the surface area of α′-Fe powders increases, the nitriding process will be more efficient. Subsequently, process of cleaning α′-Fe powders from foreign materials on the surface is carried out. Said surface cleaning processes are performed at 300 to 500° C. for 1 to 4 hours.

[0040] The nitriding process stated in step (i) is performed under powder ammonia gas. The nitriding processes of the α′-Fe powders exposed to surface cleaning processes are performed at a temperature range between of 150 to 190° C. for 24 to 160 hours.

[0041] A prototype material in the dimensions and form required by the end user can be produced with the process of 3D printer shaping stated in step (ii). Polymer material with a value of 10 to 40% by weight is added to the Fe.sub.16N.sub.2 compound to be subjected to step (ii).

[0042] The polymer material stated in step (ii) is one of the chemical compounds SU8, PETA, LAP, PVP, polyurethane and PVDF or mixtures thereof in certain weight ratios.

[0043] UV curable SU8 chemical compound is selected as the polymer material.

[0044] In step (ii), a vacuum annealing process is applied at a temperature between 100 and 200° C. in order to ensure that the Fe.sub.16N.sub.2 compound obtained in the desired structures with the 3D printer can solidify and maintain its volume. Said annealing process is carried out for 3 to 7 hours.

[0045] The magnetization processes stated in step (iii) are performed with an electromagnet with a magnetic field of 1 to 2 Tesla. The magnetization process is carried out between 1 minute and 2 minutes.

[0046] In step (iii), heat treatment is applied to obtain the Fe.sub.16N.sub.2 magnet after magnetization permanent. Said heat treatments are carried out at a temperature between 100 and 200° C. and are applied for 3 to 7 hours.

[0047] The protection scope of the invention is specified in the appended claims and cannot be limited to the description made for illustrative purposes in this detailed description.

[0048] Likewise, it is clear that a person skilled in the art can present similar embodiments in the light of the above descriptions without departing from the main theme of the invention.