Magnetostrictive/magnetic material for use in torque sensors

• US 20040142198A1
• Filed: 01/21/2003
• Published: 07/22/2004
• Est. Priority Date: 01/21/2003
• Status: Abandoned Application

• Current Assignee: Delphi Technologies, Inc. (Aptiv PLC)
• Original Assignee: Delphi Technologies, Inc. (Aptiv PLC)
• Inventors: Van Steenkiste, Thomas Hubert
• Application Number:
  US10/348,151
• Publication Number:
  US 20040142198A1
• Time in Patent Office: Days
• US Class Current: 428/553
• CPC Class Codes: C23C 24/04 Impact or kinetic deposition of particles
• CPC Class Codes: C23C 30/00 Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process C23C26/00, C23C28/00 take precedence
• CPC Class Codes: H01F 1/0306 Metals or alloys, e.g. LAVES phase alloys of the MgCu2-type H01F1/0304 takes precedence
• CPC Class Codes: H01F 1/055 and magnetic transition metals, e.g. SmCo5
• CPC Class Codes: H10N 35/101 with mechanical input and electrical output, e.g. generators, sensors
• CPC Class Codes: H10N 35/85 Magnetostrictive active materials
• CPC Class Codes: Y10T 428/12063 Nonparticulate metal component

Abstract

A kinetically sprayed magnetostrictive/magnetic material, comprising: magnetostriction particles; magnetic particles with coercivity; a ductile matrix for bonding the magnetostriction particles and magnetic particles with coercivity together; wherein an applied magnetic field will align the magnetic particles with coercivity and subsequently the magnetostriction particles such that the magnetostrictive material will produce a detectable change in the magnetostrictive/magnetic material when placed under an applied stress. A method of forming a composite coating of magnetostrictive/magnetic material on a substrate, comprising: spraying a powder mixture of magnetostriction particles, magnetic particles with coercivity and a ductile matrix in a spray gas stream flowing at supersonic velocity against the substrate to form a composite coating wherein an applied magnetic field will align the magnetic particles with coercivity and subsequently the magnetostriction particles such that the magnetostrictive material will produce a detectable change in the magnetostrictive/magnetic material when placed under an applied stress.

Claims

1. A kinetically sprayed magnetostrictive/magnetic material, comprising:

magnetostrictive particles;

magnetic particles with coercivity;

a ductile matrix for bonding the magnetostriction particles and magnetic particles with coercivity together;

wherein an applied magnetic field will align the magnetic particles with coercivity and subsequently the magnetostrictive particles such that the magnetostrictive material will produce a detectable change in the magnetostrictive/magnetic material when placed under an applied stress.

2. The kinetically sprayed magnetostrictive/magnetic material as in claim 1, wherein said detectable change is an external magnetic flux.

3. The kinetically sprayed magnetostrictive/magnetic material as in claim 1, wherein either the magnetostriction particles or the magnetic particles with coercivity provides said ductile matrix.

4. The kinetically sprayed magnetostrictive/magnetic material as in claim 3, wherein the magnetostriction particles are one of the following:

iron, iron alloys, ingot rare earth composites, nickel, terfenol and the magnetic particles with coercivity are AlNiCo₅ magnets or melt spun terfenol.

5. The kinetically sprayed magnetostrictive/magnetic material as in claim 1, wherein the magnetostriction particles are one of the following:

iron, iron alloys, ingot rare earth composites, terfenol and the magnetic particles with coercivity are AlNiCo₅ magnets or melt spun terfenol.

6. The kinetically sprayed magnetostrictive/magnetic material as in claim 5, wherein the ductile matrix comprises Ni.

7. The kinetically sprayed magnetostrictive/magnetic material as in claim 1, wherein the magnetostriction particles are one of the following:

iron, iron alloys, ingot rare earth composites, nickel, terfenol and the magnetic particles with coercivity are AlNiCo₅ magnets or melt spun terfenol, and the ductile matrix is nickel (Ni) each comprising approximately 33 percent of the sprayed material.

8. The kinetically sprayed magnetostrictive/magnetic material as in claim 7, wherein the ductile matrix is copper and the material is disposed on a nitronic steel shaft.

9. The kinetically sprayed magnetostrictive/magnetic material as in claim 7, wherein the material is disposed on a nitronic steel shaft.

10. The kinetically sprayed magnetostrictive/magnetic material as in claim 1, wherein the magnetostriction particles are one of the following:

iron, iron alloys, ingot rare earth composites, nickel, terfenol and the magnetic particles with coercivity are AlNiCo₅ magnets or melt spun terfenol and the ductile matrix is nickel (Ni) each comprising approximately 10 percent magnetic particles with coercivity, 80 percent nickel and 40 percent magnetostriction particles.

11. The kinetically sprayed magnetostrictive/magnetic material as in claim 1, wherein the magnetostriction particles are one of the following:

iron, iron alloys, ingot rare earth composites, nickel, terfenol and the magnetic particles with coercivity are AlNiCo₅ magnets or melt spun terfenol and the ductile matrix is nickel (Ni) and the amount of nickel is in a range of 10-90 percent by volume of the sprayed material.

12. A method of forming a composite coating of magnetostrictive/magnetic material on a substrate, comprising:

spraying a powder mixture of magnetostriction particles, magnetic particles with coercivity and a ductile matrix in a spray gas stream flowing at supersonic velocity against the substrate to form a composite coating wherein an applied magnetic field will align the magnetostriction particles such that the magnetostrictive material will produce a detectable change in the magnetostrictive/magnetic material when placed under an applied stress.

13. The method as in claim 12, wherein either the magnetostriction particles or the magnetic particles with coercivity provides said ductile matrix.

14. The method as in claim 12, wherein the magnetostriction particles are one of the following:

iron, iron alloys, ingot rare earth composites, terfenol and the magnetic particles with coercivity are AlNiCo₅ magnets or melt spun terfenol.

15. A kinetically sprayed magnetostrictive/magnetic material adapted for use in a torque sensor, comprising:

magnetostrictive particles;

magnetic particles with coercivity;

a ductile matrix for bonding the magnetostriction particles and magnetic particles with coercivity together;

wherein the magnetostrictive/magnetic material is kinetically sprayed to a shaft and an applied magnetic field will align the magnetic particles with coercivity and subsequently the magnetostrictive particles such that the magnetostrictive material will produce a detectable change in the magnetostrictive/magnetic material when a torque is applied to the shaft.

16. The kinetically sprayed magnetostrictive/magnetic material as in claim 15, wherein said detectable change is an external magnetic flux.

17. The kinetically sprayed magnetostrictive/magnetic material as in claim 15, wherein either the magnetostriction particles or the magnetic particles with coercivity provides said ductile matrix.

18. The kinetically sprayed magnetostrictive/magnetic material as in claim 15, wherein the magnetostriction particles are one of the following:

iron, iron alloys, ingot rare earth composites, nickel, terfenol and the magnetic particles with coercivity are AlNiCo₅ magnets or melt spun terfenol.

19. The kinetically sprayed magnetostrictive/magnetic material as in claim 18, wherein the ductile matrix comprises Ni.

20. The kinetically sprayed magnetostrictive/magnetic material as in claim 15, wherein the shaft is a nitronic steel shaft.

21. The kinetically sprayed magnetostrictive/magnetic material as in claim 20, wherein the magnetostriction particles are one of the following:

iron, iron alloys, ingot rare earth composites, nickel, terfenol and the magnetic particles with coercivity are AlNiCo₅ magnets or melt spun terfenol and the ductile matrix is nickel (Ni) each comprising approximately 10 percent magnetic particles with coercivity, 80 percent nickel and 10 percent magnetostriction particles.