HIGH-THROUGHPUT PREPARATION METHOD OF (Sm,T)(Fe,M)12 ALLOY BASED ON DIFFUSION MULTIPLE

Abstract

A (Sm,T)(Fe,M).sub.12 alloy is provided, where Sm is samarium element; Fe is iron element; T is selected from the group consisting of Y, Gd, Zr, Nd, Pr, Ce and a combination thereof; and M is selected from the group consisting of Ti, Cr, Mn, Mo, Si, Al, Ga, Co, V and a combination thereof. A high-throughput method of preparing the (Sm,T)(Fe,M).sub.12 alloy based on a diffusion multiple is further provided, in which a can, a cover, and metal strips with desired sizes are prepared, and the metal strips are arranged and loaded in the can. Then the can is subjected to vacuum electron beam welding and hot isostatic pressing to obtain the diffusion multiple, which is cut into slices, and subjected to tube sealing and heat treatment to obtain the desired (Sm,T)(Fe,M).sub.12 alloy.

Claims

1. A method of preparing a (Sm,T)(Fe,M).sub.12 alloy based on a diffusion multiple, comprising: (a) preparing a can and a cover matched with the can; and machining a rectangular groove with a size of 3a2bc in the can, wherein 10 mma3 mm, 10 mmb3 mm, and c10 mm; (b) preparing 6 metal strips each with a size of abc, and grinding and polishing surfaces of the 6 metal strips; wherein the 6 metal strips are made of Fe, Sm, T1, T2, M1, and M2, respectively; T1 and T2 are independently selected from the group consisting of Y, Gd, Zr, Nd, Pr, Ce, and a combination thereof; M1 and M2 are independently selected from the group consisting of Ti, Cr, Mn, Mo, Si, Al, Ga, Co, V, and a combination thereof; and a, b and c represent length, width and height of each of the 6 metal strips, respectively; (c) arranging the 6 metal strips in sequence to form a cuboid structure of 3a2bc, wherein a Sm metal strip is located at a middle of a first row of the cuboid structure, and a Fe metal strip is located at a middle of a second row of the cuboid structure, a M1 metal strip and a M2 metal strip are located at two sides of the Fe metal strip, respectively, and a T1 metal strip and a T2 metal strip are located at two sides of the Sm metal strip, respectively; loading the cuboid structure into the rectangular groove; sealing the can with the cover; and performing vacuum electron beam welding on the can to obtain a welded can; (d) subjecting the welded can to hot isostatic pressing to obtain the diffusion multiple; and (e) cutting the diffusion multiple into a plurality of slices in a height direction followed by tube sealing and diffusion heat treatment to obtain the (Sm,T)(Fe,M).sub.12 alloy.

2. The method of claim 1, wherein in step (a), the can is made of stainless steel, pure iron, or Cr metal; and the cover is made of the same material as the can.

3. The method of claim 1, wherein in step (b), the surfaces of the 6 metal strips are ground with sandpaper and polished by a polishing machine.

4. The method of claim 1, wherein in step (c), a vacuum degree of the vacuum electron beam welding is 510.sup.5-510.sup.4 Pa, and a weld width is 0.5-1.5 mm.

5. The method of claim 1, wherein in step (d), the hot isostatic pressing is performed at 650-950 C. and 50-200 MPa for 2-5 h.

6. The method of claim 1, wherein in step (e), the tube sealing is performed with an argon atmosphere of 0.03-0.06 MPa.

7. The method of claim 1, wherein in step (e), the diffusion heat treatment is performed at 800-1300 C. for 2-30 days; and the method further comprises: cooling a product obtained from the diffusion heat treatment by quenching.

8. The method of claim 1, wherein in the (Sm,T)(Fe,M).sub.12 alloy, Sm is samarium element; Fe is iron element; T is selected from the group consisting of Y, Gd, Zr, Nd, Pr, Ce and a combination thereof; and M is selected from the group consisting of Ti, Cr, Mn, Mo, Si, Al, Ga, Co, V and a combination thereof.

9. A (Sm,T)(Fe,M).sub.12 alloy prepared by the method of claim 1, wherein Sm is samarium element; Fe is iron element; T is selected from the group consisting of Y, Gd, Zr, Nd, Pr, Ce and a combination thereof; and M is selected from the group consisting of Ti, Cr, Mn, Mo, Si, Al, Ga, Co, V and a combination thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 schematically shows an arrangement of a diffusion multiple according to an embodiment of the present disclosure; and

[0024] FIG. 2 is a schematic diagram of a combination of a can and a cover according to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

[0025] The present disclosure is further described below in combination with embodiments. Accordingly, the following detailed description is merely illustrative, and is not intended to limit the scope of the disclosure. The technical features of the various embodiments can be combined without conflict with each other.

[0026] As shown in FIG. 1, 6 metal strips with dimensions of abc are arranged in a runway-shaped can, and a, b and c represents a length, a width and a height of each of the 6 metal strips, respectively. As shown in FIG. 2, cross sections of a can and a cover are runway-shaped. The can has a size of 1mn, and the cover has a size of 1mk. l represents a length of the can and the cover, m represents a width of the can and the cover, n represents a height of the can, and k represents a height of the cover.

Example 1

[0027] (1) A runway-shaped can with dimensions of 301845 mm.sup.3 and a cover with dimensions of 30181 mm.sup.3 were prepared. A rectangular groove of 211440 mm.sup.3 was machined in the can. The can and the cover were each made of 304 stainless steel.

[0028] (2) Sm, Y, Zr, Fe, V and Ti metal strips with dimensions of 7740 mm.sup.3 were prepared. The surfaces of the metal strips were performed with sandpaper grinding and polishing treatment by polishing machine.

[0029] (3) The metal strips were assembled into the rectangular groove followed by covering the cover and carrying out vacuum electron beam welding at 510.sup.4 Pa, and the width of the weld seam was 0.5 mm. The Sm metal strip and the Fe metal strip were respectively located in the middle of the first and second rows of the rectangular groove. The V metal strip and the Ti metal strip were respectively located on the left and right sides of the Fe metal strip. The Y metal strip and the Zr metal strip were respectively located on the left and right sides of the Sm metal strip.

[0030] (4) The welded can was performed with heat isostatic pressing at 750 C. and 100 MPa for 4 h to obtain the diffusion multiple.

[0031] (5) The diffusion multiple was cut into 8 slices parallel to the runway-shaped surface, and the 8 slices were separately sealed into the tubes at 0.04 MPa argon atmosphere followed by carrying out the diffusion heat treatment at 900 C., 1000 C., 1100 C., or 1200 C. for 15 and 30 days, respectively, and quenching cooling to obtain the (Sm,Y,Zr)(Fe,V,Ti).sub.12-phase alloy.

Example 2

[0032] (1) A runway-shaped can with dimensions of 322051 mm.sup.3 and a cover with dimensions of 32201 mm.sup.3 were prepared. A rectangular groove of 241645 mm.sup.3 was machined in the can. The can and the cover were each made of 304 stainless steel.

[0033] (2) Fe, Sm, Nd, Gd, Co and Ti metal strips with dimensions of 8845 mm.sup.3. The surfaces of the metal strips were performed with sandpaper grinding and polishing treatment by polishing machine.

[0034] (3) The metal strips were assembled into the rectangular groove followed by covering the cover and carrying out vacuum electron beam welding at 510.sup.5 Pa, and the width of the weld seam was 1.5 mm. The Sm metal strip and the Fe metal strip were respectively located in the middle of the first and second rows of the rectangular groove. The Co metal strip and the Ti metal strip were respectively located on the left and right sides of the Fe metal strip. The Nd metal strip and the Gd metal strip were respectively located on the left and right sides of the Sm metal strip.

[0035] (4) The welded can was performed with heat isostatic pressing at 650 C. and 50 MPa for 2 h to obtain the diffusion multiple.

[0036] (5) The diffusion multiple was cut into 10 slices parallel to the runway-shaped surface, and the 10 slices were separately sealed into the tubes at 0.06 MPa argon atmosphere followed by carrying out the diffusion heat treatment at 900 C., 950 C., 1000 C., 1050 C., or 1100 C. for 20 and 30 days, respectively, and quenching cooling to obtain the (Sm,Nd,Gd)(Fe,Co,Ti).sub.12-phase alloy.

Example 3

[0037] (1) A runway-shaped can with dimensions of 282051 mm.sup.3 and a cover with dimensions of 28201 mm.sup.3 were prepared. A rectangular groove of 211640 mm.sup.3 was machined in the can. The can and the cover were each made of 304 stainless steel.

[0038] (2) Fe, Sm, V, Gd, Mn and Ce metal strips with dimensions of 7840 mm.sup.3. The surfaces of the metal strips were performed with sandpaper grinding and polishing treatment by polishing machine.

[0039] (3) The metal strips were assembled into the rectangular groove followed by covering the cover and carrying out vacuum electron beam welding at 510.sup.5 Pa, and the width of the weld seam was 1.5 mm. The Sm metal strip and the Fe metal strip were respectively located in the middle of the first and second rows of the rectangular groove. The V metal strip and the Mn metal strip were respectively located on the left and right sides of the Fe metal strip. The Gd metal strip and the Ce metal strip were respectively located on the left and right sides of the Sm metal strip.

[0040] (4) The welded can was performed with heat isostatic pressing at 650 C. and 50 MPa for 2 h to obtain the diffusion multiple.

[0041] (5) The diffusion multiple was cut into 10 slices parallel to the runway-shaped surface, and the 10 slices were separately sealed into the tubes at 0.06 MPa argon atmosphere followed by carrying out the diffusion heat treatment at 900 C., 950 C., 1000 C., 1050 C., or 1100 C. for 20 and 30 days, respectively, and quenching cooling to obtain the (Sm,Ce,Gd)(Fe,Mn,V).sub.12-phase alloy.

Example 4

[0042] (1) A runway-shaped can with dimensions of 322051 mm.sup.3 and a cover with dimensions of 32201 mm.sup.3 were prepared. A rectangular groove of 181245 mm.sup.3 was machined in the can. The can and the cover were each made of 304 stainless steel.

[0043] (2) Fe, Sm, Nd, Y, Cr and Mo metal strips with dimensions of 6645 mm.sup.3. The surfaces of the metal strips were performed with sandpaper grinding and polishing treatment by polishing machine.

[0044] (3) The metal strips were assembled into the rectangular groove followed by covering the cover and carrying out vacuum electron beam welding at 110.sup.5 Pa, and the width of the weld seam was 1.5 mm. The Sm metal strip and the Fe metal strip were respectively located in the middle of the first and second rows of the rectangular groove. The Cr metal strip and the Mo metal strip were respectively located on the left and right sides of the Fe metal strip. The Nd metal strip and the Y metal strip were respectively located on the left and right sides of the Sm metal strip.

[0045] (4) The welded can was performed with heat isostatic pressing at 700 C. and 65 MPa for 5 h to obtain the diffusion multiple.

[0046] (5) The diffusion multiple was cut into 10 slices parallel to the runway-shaped surface, and the 10 slices were separately sealed into the tubes at 0.06 MPa argon atmosphere followed by carrying out the diffusion heat treatment at 950 C., 980 C., 1010 C., 1040 C., or 1070 C. for 15 and 20 days, respectively, and quenching cooling to obtain the (Sm,Nd,Y)(Fe,Cr,Mo).sub.12-phase alloys.

Example 5

[0047] (1) A runway-shaped can with dimensions of 322051 mm.sup.3 and a cover with dimensions of 32201 mm.sup.3 were prepared. A rectangular groove of 241645 mm.sup.3 was machined in the can. The can and the cover were each made of 304 stainless steel.

[0048] (2) Fe, Sm, NdPr (atomic ratio of 8:2), Gd, SiGa (atomic ratio of 2:8) and SiAl (atomic ratio of 1:1) metal strips with dimensions of 8845 mm.sup.3. The surfaces of the metal strips were performed with sandpaper grinding and polishing treatment by polishing machine.

[0049] (3) The metal strips were assembled into the rectangular groove followed by covering the cover and carrying out vacuum electron beam welding at 310.sup.5 Pa, and the width of the weld seam was 1.3 mm. The Sm metal strip and the Fe metal strip were respectively located in the middle of the first and second rows of the rectangular groove. The SiAl metal strip and the SiGa metal strip were respectively located on the left and right sides of the Fe metal strip. The NdPr metal strip and the Gd metal strip were respectively located on the left and right sides of the Sm metal strip.

[0050] (4) The welded can was performed with heat isostatic pressing at 800 C. and 85 MPa for 2 h to obtain the diffusion multiple.

[0051] (5) The diffusion multiple was cut into 9 slices parallel to the runway-shaped surface, and the 9 slices were separately sealed into the tubes at 0.06 MPa argon atmosphere followed by carrying out the diffusion heat treatment at 900 C., 920 C., 940 C., 960 C., or 980 C. for 10 and 20 days, respectively, and quenching cooling to obtain the (Sm,Nd,Pr,Gd)(Fe,Al,Ga,Si).sub.12-phase alloy.

Comparative Example 1

[0052] (1) A runway-shaped can with dimensions of 322051 mm.sup.3 and a cover with dimensions of 32201 mm.sup.3 were prepared. A rectangular groove of 241645 mm.sup.3 was machined in the can. The can and the cover were each made of 304 stainless steel.

[0053] (2) Fe, Sm, Nd, Gd, Co and Ti metal strips with dimensions of 8845 mm.sup.3. The surfaces of the metal strips were performed with sandpaper grinding and polishing treatment by polishing machine.

[0054] (3) The metal strips were assembled into the rectangular groove followed by covering the cover and carrying out vacuum electron beam welding at 510.sup.5 Pa, and the width of the weld seam was 1.5 mm. The Sm metal strip and the Fe metal strip were respectively located in the middle of the first and second rows of the rectangular groove. The Co metal strip and the Ti metal strip were respectively located on the left and right sides of the Sm metal strip. The Nd metal strip and the Gd metal strip were respectively located on the left and right sides of the Fe metal strip.

[0055] (4) The welded can was performed with heat isostatic pressing at 650 C. and 50 MPa for 2 h to obtain the diffusion multiple.

[0056] (5) The diffusion multiple was cut into 10 slices parallel to the runway-shaped surface, and the 10 slices were separately sealed into the tubes at 0.06 MPa argon atmosphere followed by carrying out the diffusion heat treatment at 900 C., 950 C., 1000 C., 1050 C., or 1100 C. for 20 and 30 days, respectively, and quenching cooling. Due to a change in the arrangement positions of the metal strips, Nd and Gd fail to replace the Sm element, Co and Ti fail to replace the Fe element, resulting in a decrease in the formation energy of the SmFe.sub.12-based alloy. The (Sm,T)(Fe,M).sub.12 alloy could not be obtained.

Comparative Example 2

[0057] (1) A runway-shaped can with dimensions of 322051 mm.sup.3 and a cover with dimensions of 32201 mm.sup.3 were prepared. A rectangular groove of 241645 mm.sup.3 was machined in the can. The can and the cover were each made of 304 stainless steel.

[0058] (2) Fe, Sm, Nd, Gd, Co and Ti metal strips with dimensions of 8845 mm.sup.3. The surfaces of the metal strips were performed with sandpaper grinding and polishing treatment by polishing machine.

[0059] (3) The metal strips were assembled into the rectangular groove followed by covering the cover and carrying out vacuum electron beam welding at 510.sup.5 Pa, and the width of the weld seam was 1.5 mm. The Sm metal strip and the Fe metal strip were respectively located in the middle of the first and second rows of the rectangular groove. The Co metal strip and the Ti metal strip were respectively located on the left and right sides of the Fe metal strip. The Nd metal strip and the Gd metal strip were respectively located on the left and right sides of the Sm metal strip.

[0060] (4) The welded can was performed with heat isostatic pressing at 650 C. and 45 MPa for 2 h to obtain the diffusion multiple.

[0061] (5) The diffusion multiple was cut into 10 slices parallel to the runway-shaped surface, and the 10 slices were separately sealed into the tubes at 0.06 MPa argon atmosphere followed by carrying out the diffusion heat treatment at 900 C., 950 C., 1000 C., 1050 C., or 1100 C. for 20 and 30 days, respectively, and quenching cooling. Because the heat isostatic pressure was too low to form a tightly bonded interface, the (Sm,T)(Fe,M).sub.12 alloy could not be obtained.

[0062] Only a very small amount of SmFe.sub.12 phase was formed at the binary interface of Sm and Fe under the delicately controlled conditions, indicating the formation of undoped SmFe.sub.12 phase was difficult. In contrast, a large amount of (Sm, T) (Fe,M) 12 phase was obtained at the interface of Sm, Fe, and M, indicating that M could reduce the formation energy of the 1:12 phase and stabilize the structure. The effect of Ti was the most significant. However, the addition of Ti also significantly reduced the magnetic properties. When M was Co, the saturation magnetization and the Curie temperature of the 1:12 phase increased significantly. Only a small amount of 1:12 phase was formed at the interface of Sm, Fe, and T. In contrast, a large amount of 1:12 phase with different substitution ratios appeared at the quaternary interface of Sm, Fe, M, and T, which ensured the stability of the phase structure while minimizing the loss of magnetic properties.

[0063] Described above are merely some embodiments of the disclosure, which are not intended to limit the disclosure. It should be understood that any modifications and replacements made by those skilled in the art without departing from the spirit of the disclosure should fall within the scope of the disclosure defined by the appended claims.