FE-BASED AMORPHOUS ALLOY POWDER, DUST CORE USING THE SAME, AND COIL-EMBEDDED DUST CORE

• US 20130300531A1
• Filed: 07/15/2013
• Published: 11/14/2013
• Est. Priority Date: 01/17/2011
• Status: Active Grant

• Current Assignee: Alps Alpine Co., Ltd.
• Original Assignee: Alps Green Devices Co., Ltd. (Alps Alpine Co., Ltd.)
• Inventors: TSUCHIYA, Keiko, OKAMOTO, Jun, KOSHIBA, Hisato
• Granted Patent: US 8,854,173 B2
• Time in Patent Office: Days
• US Class Current: 336/221
• CPC Class Codes: B22F 1/08 Metallic powder characterised by particles having an amorphous microstructure
• CPC Class Codes: C22C 33/0257 characterised by the range of the alloying elements
• CPC Class Codes: C22C 38/00 Ferrous alloys, e.g. steel alloys cast-iron alloys C22C37/00
• CPC Class Codes: C22C 45/02 with iron as the major constituent
• CPC Class Codes: H01F 1/15308 based on Fe/Ni H01F1/15325 takes precedence
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• CPC Class Codes: H01F 41/0246 Manufacturing of magnetic circuits by moulding or by pressing powder magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36

Abstract

An Fe-based amorphous alloy powder of the present invention has a composition represented by (Fe_{100-a-b-c-x-y-z-t}Ni_aSn_bCr_cP_xC_yB_zSi_t)_100-αM_α. In this composition, 0 at %≦a≦10 at %, 0 at %≦b≦3 at %, 0 at %≦c≦6 at %, 6.8 at %≦x≦10.8 at %, 2.2 at %≦y≦9.8 at %, 0 at %≦z≦4.2 at %, and 0 at %≦t≦3.9 at % hold, a metal element M is at least one selected from the group consisting of Ti, Al, Mn, Zr, Hf, V, Nb, Ta, Mo, and W, and the addition amount α of the metal element M satisfies 0.04 wt %≦α≦0.6 wt %. Accordingly, besides a decrease of a glass transition temperature (Tg), an excellent corrosion resistance and high magnetic characteristics can be obtained.

Claims

1. An Fe-based amorphous alloy powder having a composition represented by (Fe_{100-a-b-c-x-y-z-t}Ni_aSn_bCr_cP_xC_yB_zSi_t)_100-α

M_α

, wherein 0 at %≦

a≦

10 at %, 0 at %≦

b≦

3 at %, 0 at %≦

c≦

6 at %, 6.8 at %≦

x≦

10.8 at %, 2.2 at %≦

y≦

9.8 at %, 0 at %≦

z≦

4.2 at %, and 0 at %≦

t≦

3.9 at % hold, a metal element M is at least one selected from the group consisting of Ti, Al, Mn, Zr, Hf, V, Nb, Ta, Mo, and W, and the addition amount a of the metal element M satisfies 0.04 wt %≦

α

≦

0.6 wt %.

2. The Fe-based amorphous alloy powder according to claim 1, wherein the addition amount z of B satisfies 0 at %≦

z≦

2 at %, the addition amount t of Si satisfies 0 at %≦

t≦

1 at %, and the sum of the addition amount z of B and the addition amount t of Si satisfies 0 at %≦

z+t≦

2 at %.

3. The Fe-based amorphous alloy powder according to claim 1, wherein the alloy powder includes B and Si, and the addition amount z of B is larger than the addition amount t of Si.

4. The Fe-based amorphous alloy powder according to claim 1, wherein the addition amount α

of the metal element M satisfies 0.1 wt %≦

c≦

0.6 wt %.

5. The Fe-based amorphous alloy powder according to claim 1, wherein the metal element M includes Ti.

6. The Fe-based amorphous alloy powder according to claim 1, wherein the metal element M includes Ti, Al, and Mn.

7. The Fe-based amorphous alloy powder according to claim 1, wherein the alloy powder includes Ni or Sn.

8. The Fe-based amorphous alloy powder according to claim 1, wherein the addition amount a of Ni satisfies 0 at %≦

a≦

6 at %.

9. The Fe-based amorphous alloy powder according to claim 1, wherein the addition amount b of Sn satisfies 0 at %≦

b≦

2 at %.

10. The Fe-based amorphous alloy powder according to claim 1, wherein the addition amount c of Cr satisfies 0 at %≦

c≦

2 at %.

11. The Fe-based amorphous alloy powder according to claim 1, wherein the addition amount x of P satisfies 8.8 at %≦

x≦

10.8 at %.

12. The Fe-based amorphous alloy powder according to claim 1, wherein 0 at %≦

a≦

6 at %, 0 at %≦

b≦

2 at %, 0 at %≦

c≦

2 at %, 8.8 at %≦

x≦

10.8 at %, 2.2 at %≦

y≦

9.8 at %, 0 at %≦

z≦

2 at %, 0 at %≦

t≦

1 at %, 0 at %≦

z+t≦

2 at %, and 0.1 wt %≦

α

≦

0.6 wt % hold.

13. The Fe-based amorphous alloy powder according to claim 1, wherein the alloy powder has an aspect ratio of more than 1 to 1.4.

14. The Fe-based amorphous alloy powder according to claim 13, wherein the alloy powder has an aspect ratio of 1.2 to 1.4.

15. The Fe-based amorphous alloy powder according to claim 1, wherein the concentration of the metal element M is higher in a powder surface layer than that inside the powder.

16. The Fe-based amorphous alloy powder according to claim 15, wherein the alloy powder includes Si as the composition element, and the concentration of the metal element M in the powder surface layer is higher than the concentration of Si.

17. A dust core formed from the Fe-based amorphous alloy powder according to claim 1 by solidification molding using a binding material.

18. A coil-embedded dust core comprising:

a dust core formed from the Fe-based amorphous alloy powder according to claim 1 by solidification molding using a binding material; and

a coil covered with the dust core.

19. The coil-embedded dust core according to claim 18, wherein the coil is an edgewise coil.