PROCESS FOR PRODUCING PERMANENT MAGNETS

Abstract: This process for producing improved permanent magnets comprises the following steps (1) a permanent magnet alloy is pulverised. The alloy is represented by the fomula R(T,M)z where R is a rare earth metal or a mixture of more than one rare earth metal, T is a mixture of transition metals composed mainly of Fe and Co. M is a mixture of metalloid elements the main component of which is B, and z=4-9. (2) the pulverised product is oriented-compression-moulded in a magnetic field or compression-moulded in a non-magnetic field, and then (3) sintered at 900 to 1200 deg.C, (4) the product is then ground and polished into a suitable shape (5) following by solution heat treatment at 900 to 1200 deg.C at a pressure of 10 power (01) -1 Torr oxygen and/or nitrogen; (6) and then aged at 300 to 900 deg.C. Process (4) and (5) can be exchanged. As a result of these processes an oxide and/or nitride film of thickness 0.001-0.1 microns is formed on the surface of the magnet.

Description: The present invention relates to a process for producing permanent magnets from a permanent magnet alloy powder comprising compression forming of a green body from said powder in a magnetic or non-magnetic field, sintering and heat treating said body. More specifically, the invention is concerned with a heat treatment method for rare-earth type permanent magnets, principally those of the Nd-Fe-B variety. Since the discovery that there would be theoretically very high magnetic properties [(BH)max ≈4.0 x 10⁵ J/m³ (50 MGOe)] when rare-earth metals and transition metals are combined into metal compounds in a ratio of 2:17 to form a rare-earth transition metal alloy, there have been a number of attempts to obtain practical permanent magnet applications using these types of compounds. One example is the Sm-Co-Cu-Fe metal compound where (BH)max has reached ≈2.4 x 10⁵ J/m³ (30MGOe). Further, with Nd-Fe metal compounds, high magnetic properties of (BH)max ≈3.2 x 10⁵ J/m³ (40MGOe) have been reached. These alloy formulations are crushed into powder, and then aligned and compression formed in a magnetic field, or formed in a non-magnetic field, sintered, solution treated and aged to form a mass, and then cut and polished into permanent magnets of the shape required according to the most usual methods of their preparation. Since the rare-earth and ferrous type permanent magnets, particularly the R-Fe-M permanent magnets (where R represents one or more types of rare-earth metals, and M represents B or other metalloid element), are easily oxidized when exposed to air, when they are used in precision applications, such as in miniature electronic parts for magnetic circuits using permanent magnets, there are many instances where oxidation caused by exposure of the magnet to air leads to a degradation of the magnetic properties and fluctuations in their permanence due to changes in the magnetic space. Because of this, the prior art has used Cr or Ni plating to cover the surface to prevent this oxidation. When wet type plating means are used, however, the surface of the permanent magnet itself can be corroded by the degreasing and oxidation removal processes, which makes plating difficult. In addition, following the plating operation, gaps sometimes exist between the permanent magnet surface and the plating. Peeling of the plating is likely in these areas. Also, pinhole defects are common. Overall magnetic properties are additionally likely to be affected by the numerous processing steps involved, sintering, solution treating, aging, machining (cutting, grinding and polishing) to obtain the desired magnetic properties and shape, etc., which are apt to lead to surface defects. Figure 1A shows a graph of the resulting demagnetization curve where the effects of the above types of defects can be seen. These phenomena are especially dramatic in permanent magnets which have a relatively small volume but a relatively large surface area. Such defects result in lower production yields. Japanese Patent Abstract of JP-A-61-87310 discloses a process for producing permanet magnets from a permanent magnet alloy powder comprising compression forming of a green body from said powder in a magnetic or non-magnetic field, sintering and heat treating said body wherein an alloy powder of the composition Sm (Co 0.65 Fe 0.23 Cu 0.11 Zr 0.01 )₇₂ is pressed in a magnetic field, placed on a plate for sintering, then a vacuum is fully made to a temperature of 800° C, held for one hour at 1200° C in Ar 100 Torr, whereafter 0.5 Torr O₂ is introduced, held for 10 minutes, and rapidly cooled, resulting in the formation of an oxide film of 100 µm or less on the sintered material whereby welding of the plate for sintering can be prevented. It is an object of the present invention to provide a process for producing permanent magnets of the type as described above wherein any strain caused by machining is eliminated, any rust formation of the surface of the sintered body is prevented, and any degradation of magnetic properties is avoided. This object is accomplished by each of the processes as recited in the present independent claims 1 to 3 while preferred embodiments of these processes are recited in claims 4 to 7, respectively. The invention is indicated in the independent method claims 1-3. According to the invention, said permanent magnet alloy has the general formula R(T,B) z , wherein R represents at least one selected from the group consisting of Nd, Pr, La and Dy, T is Fe or Fe with Co being partially substituted for said Fe, B is boron, and z is 4 to 9. The alloy is crushed and compressed in a magnetic or non-magnetic field to form the green body. Then first, for permanent magnets having a small surface area/volume ratio, they are sintered at a temperature of 900 to 1200°C, then machined into appropriate shapes, and then solution treated at 900 to 1200°C in a 1.33 x 10⁻⁶ to 1.33 x 10² Pa (10⁻⁸ to 1 Torr) gas atmosphere, after which they are aged at 300 to 900°C. Secondly, for permanent magnets having a large surface area/volume ratio, they are sintered at 900 to 1200°C, solution treated at 900 to 1200°C, machined into appropriate shapes, and then aged in a gas atmosphere of 1.33 x 10⁻⁶ to 1.33 x 10² Pa (10⁻⁸ to 1 Torr) at 300 to 900°C. Thirdly, they can be sintered at 1000 to 1200°C, machined into usable shapes, re-sintered in a 1.33 x 10⁻⁶ to 1.33 x 10² Pa (10⁻⁸ to 1 Torr) gas atmosphere at 1000 to 1200°C, in order to manufacture these permanent magnets. The gas environment used for these various processes may be oxygen, nitrogen or a mixture; it is desirable that the surface layer be 10 µm or less in thickness. When heating, if the amount of oxygen and/or nitrogen in the atmosphere is less than 1.33 x 10⁻⁶ Pa (10⁻⁸ Torr), then a surface layer will not be formed, or, if there is more than 1.33 x 10² Pa (l Torr), then the oxide and/or the nitride layer will become skin-like and cause degradation of the magnetic properties of the permanent magnets themselves. Also, if heated to a temperature of under 300°C, formation of the surface layer will not take place. If a temperature of l200°c is exceeded, then oxygen and/or nitrogen will disperse into the interior of the permanent magnet and magnetic properties will be drastically reduced. Accordingly, under these conditions, it is not desirable for a surface layer thickness of l0µm to be exceeded. The reason for the limitation placed on the temperature is to eliminate strain layers from machining in the final product and to promote the maintenance of magnetic force. In other words, with the sintering, solution treating and aging processes, the appropriate temperature ranges are: 900 to l200°C, 900 to l200°c and 300 to 900°C, respectively. If any of those ranges are not observed, the result will be a degradation of magnetic properties, or strain layers resulting from machining which adversely affect the magnets. In this invention, the oxygen causes the formation of black-colored rust layer on the surface of the permanent magnet which prevents further oxidation and allows it to be stable in the air. When nitrogen is used, a similar effect is observed, and one of the objectives of this invention, preventing rust, is thereby realized. At the same time, by accomplishing the heat treatment according to this invention, following any machining procedures after the sintering has taken place, any machining strain that was induced can be eliminated during the aging process. In the appending drawings, Figure l shows a demagnetization curve for permanent magnets. A: for the production method of the prior art involving sintering, solution treating, aging and machining for the permanent magnets. B: for the production method of this invention where there is sintering, machining, solution treating and aging for the permanent magnets. Figure 2 shows an Auger spectral analysis of a magnet prepared according to this invention. It indicates the concentration distribution in the direction of the layer thickness. Below, examples of some of the best means of implementing this invention will be described. EXAMPLE l: A formulation of Nd(Fe 0.9 B 0.l )₅ alloy was placed in solution, roughly crushed, and finely crushed to prepare the green body for the magnet. It was sintered at a temperature of l080°C to obtain a 9mm square sintered block. Next this sintered block was machined to dimensions of 8mm square, after which it was solution treated in a 1.33x10⁻⁴ Pa (10⁻⁶ Torr) oxygen partial pressure atmosphere at l050°C for 30min, and then it was cooled to room temperature. Next, it was aged for 60 min. at 600°C; this was called sample A. On the other hand, the same type of sintered block was aged prior to machining it. This, sample B, was then machined to an 8mm block. Table l shows the physical properties of sample A and B. A B Br(x 10³ T) 1.16 1.16 iHc(x 10⁵ A/m) 8.36 8.28 (BH)max (x 10⁵ J/m³) 2.52 2.43 Sample A and B were left in a 95% humidity, 65°C environment and were checked for corrosion. On the processed surface of sample B, a red-colored rust appeared, but only a small amount of red-colored rust was observed around the perimeter edges of sample A; there was no change at all to the surface areas. EXAMPLE 2: A Nd-Fe-B alloy was melted and cast into an ingot. A vibrating mill was then used to crush it into 5 to 20µm powder. This was then compressed in a magnetic field and then formed into blocks which were sintered for an hour in a vacuum at ll20°C. The resulting blocks were divided into samples A and B. The sample A was then processed according to methods of the prior art: solution treatment for l hour at ll00°C followed by aging for an hour at 600°C and machining to the proper dimensions to form the permanent magnet. Sample B was then processed according to this invention. It was machined to the same dimensions and shape, and then solution treated at ll00°C for l hour, and then aged at 600°C for an additional hour. The demagnetization curves of the respective magnets were measured. As shown in Figure l, Sample A had a wavy curve, while B showed a good curve with a sharp shoulder. EXAMPLE 3: Nd 0.8 Pr 0.l La 0.05 Dy 0.05 (Fe 0.92 B 0.08 )₆ alloy was used to make the green body as in EXAMPLE l. Sintering then took place at temperatures of l050, ll00 and l200°C respectively to obtain sintered blocks 9mm square. These machined to 8mm square blocks, and then they were solution treated in an atmosphere mixed oxygen and nitrogen in a 1:4 ratio at 1.33x10⁻¹ Pa (10⁻³ Torr) for 30 minutes at temperature of l050, l000 and 900°C respectively. Then, they were aged in this same atmosphere for 60 minutes at 600°C to prepare sample (samples No. l through 9). Then these, along with samples made according to the prior art method (samples l0 through l2) were measured for their magnetic properties [maximum energy products: (BH)max(x 10⁵ J/m³)] after having been left to stand at 60°C in 90% humidity for 100 hours. Table 2 shows the results. EXAMPLE 4: Sintered blocks were prepared as in EXAMPLE 3, and after solution treating, the samples were machined into 8mm blocks prior to aging them. The magnetic properties were measured for these samples [maximum energy products: (BH)max (x 10⁵ J/m³)] before and after leaving in a 60°C 90% humidity environment for 100 hours. The appearance of any rust was also observed. Those results appear in TABLE 3. EXAMPLE 5: An alloy composed of Nd 0.9 Dy 0.l (Fe 0.8l Co 0.l B 0.09 ) 5.8 was sintered as in EXAMPLE l and machined into 8mm square blocks. Next, the blocks were solution treated in a mixed gas atmosphere of oxygen : nitrogen = l:4 under various partial pressures, and then they were aged. These samples were then tested for magnetic properties [maximum energy products: (BH)max(x10⁵ J/m³)] and the appearance of rust after letting them stand at 60°C and 90% humidity for 100 hours. The results appear in TABLE 4. As is clear from TABLE 4, when the gas partial pressure is low, there is an undesirable weakness rust protective layer on the surface. Also, if the gas pressure is too high, oxygen and nitrogen permeate to the inside of the magnet, not just the surface, causing the original magnetic properties to decline. EXAMPLE 6: An alloy formulation of Nd 0.9 Dy 0.l (Fe 0.92 B 0.08 ) 5.8 was sintered, machined, solution treated and aged as in EXAMPLE l. Auger spectrography was used to assess the surface condition. Figure 2 shows the concentration distribution of O₂ and N₂ in the thickness direction of the surface layer. As can be seen from Figure 2, nitrogen and oxygen are captured to a depth of l0² to l0³ nm from the surface of the magnets. When these samples were left to stand for l00 hours at 60°C and 90% humidity, almost no rust was noted. As described above, by using the surface treatment method of this invention in permanent magnets, superior corrosion protection is realized and there is a strong bond between the protective layer and the magnet. Also, since it is very easy to control the coating layer, this process is appropriate for precision parts applications in miniature electronic circuits. This process provides both mechanical and cost advantages over those processes used in the prior art.,and the aging process in this invention also works to relieve any machining strain in the surface layer from machining, so that magnetic retention is improved and machining strain is eliminated through the heating in the aging process. This helps damaged surface layers to return to their normal structure.

Claims: A process for producing permanent magnets from a permanent magnet alloy powder comprising compression forming of a green body from said powder in a magnetic or non-magnetic field, sintering and heat treating said body, characterized in that said powder is formed from an alloy having the general formula R(T,B) z , wherein R is at least one selected from the group consisting of Nd, Pr, La, and Dy; T is Fe or Fe with Co being partially substituted for said Fe; B is boron; and z is 4 to 9, and by the steps, in this sequence, of sintering said green body at 900 to 1200° C; machining said sintered body into a utilizable shape; solution treating said machined body at a temperature of 900 to 1200° C in a gas atmosphere of 1.33 x 10⁻⁶ to 1.33 x 10² Pa (10⁻⁸ to 1 Torr); and aging said solution treated body at 300 to 900° C. A process for producing permanent magnets from a permanent magnet alloy powder comprising compression forming of a green body from said powder in a magnetic or non-magnetic field, sintering and heat treating said body, characterized in that said powder is formed from an alloy having the general formula R(T,B) z , wherein R is at least one selected from the group consisting of Nd, Pr, La, and Dy; T is Fe or Fe with Co being partially substituted for said Fe; B is boron; and z is 4 to 9, and by the steps, in this sequence, of sintering said green body at 900 to 1200° C; solution treating said sintered body at a temperature of 900 to 1200° C; machining said solution treated body into a utilizable shape; and aging said machined body at 300 to 900° C in a gas atmosphere of 1.33 x 10⁻⁶ to 1.33 x 10² Pa (10⁻⁸ to 1 Torr). A process for producing permanent magnets from a permanent magnet alloy powder comprising compression forming of a green body from said powder in a magnetic or non-magnetic field, sintering and heat treating said body, characterized in that said powder is formed from an alloy having the general formula R(T,B) z , wherein R is at least one selected from the group consisting of Nd, Pr, La, and Dy; T is Fe or Fe with Co being partially substituted for said Fe; B is boron; and z is 4 to 9, and by the steps, in this sequence, of sintering said green body at 900 to 1200° C; machining said sintered body into a utilizable shape; and re-sintering said machined body at a temperature of 900 to 1200° C in a gas atmosphere of 1.33 x 10⁻⁶ to 1.33 x 10² Pa (10⁻⁸ to 1 Torr). The process of any one of claims 1 to 3 wherein the gas atmosphere is a mixture of oxygen and nitrogen. The process of any one of claims 1 to 3 wherein the gas atmosphere is oxygen. The process of any one of claims 1 to 3 wherein the gas atmosphere is nitrogen. The process of any one of claims 1 to 3 wherein an oxide or nitride layer is formed which is 0.001 to 10 µm thick.

Inventors: IMAIZUMI, NOBUO
Applicants: NAMIKI PRECISION JEWEL CO., LTD.
Application year: 1986
Main classification: H01F1
IPC codes: H01F41, C22C1, H01F1, B22F3