JP2005286176A - R-t-b-based sintered magnet and its manufacturing method - Google Patents

R-t-b-based sintered magnet and its manufacturing method Download PDF

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JP2005286176A
JP2005286176A JP2004099450A JP2004099450A JP2005286176A JP 2005286176 A JP2005286176 A JP 2005286176A JP 2004099450 A JP2004099450 A JP 2004099450A JP 2004099450 A JP2004099450 A JP 2004099450A JP 2005286176 A JP2005286176 A JP 2005286176A
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sintered magnet
alloy
rtb
based sintered
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Hideki Nakamura
英樹 中村
Tomomi Yamamoto
智実 山本
Tetsuya Hidaka
徹也 日▲高▼
Eiji Kato
英治 加藤
Makoto Nakane
誠 中根
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TDK Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide an R-T-B-based sintered magnet that can obtain a high coercive force even when the oxygen content of the sintered body of the magnet is low and, at the same time, has a wide sintering temperature range. <P>SOLUTION: The R-T-B-based sintered magnet is composed of a sintered body which is provided with main-phase crystal grains composed of an R<SB>2</SB>T<SB>14</SB>B phase (wherein, R is one, two, or more kinds of elements selected from among rare-earth elements and T is one, two, or more kinds of elements selected from among transition metal elements including Fe or Fe and Co), and a crystal boundary phase containing more R than the main-phase crystal grains do and contains Ta in the crystal boundary phase. It is desirable that the Ta exists in the crystal boundary phase as a Ta-Fe compound. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、R(Rは希土類元素から選択される1種又は2種以上の元素)、T(TはFe又はFe及びCoを含む遷移金属元素から選択される1種又は2種以上の元素)及びB(ホウ素)を主成分とするR−T−B系焼結磁石に関する。   The present invention relates to R (R is one or more elements selected from rare earth elements), T (T is one or more elements selected from transition metal elements including Fe or Fe and Co) ) And B (boron) as main components.

焼結磁石の中でもR−T−B系焼結磁石は、磁気特性に優れていること、主成分であるNdが資源的に豊富で比較的安価であることから、種々の用途に使用されている。
R−T−B系焼結磁石の磁気特性を向上するための研究開発も精力的に行われている。例えば、特開平1−219143号公報(特許文献1)では、R−T−B系焼結磁石に0.02〜0.5at%のCuを添加することにより、磁気特性が向上し、熱処理条件も改善されることが報告されている。しかしながら、特許文献1に記載の方法は、高性能磁石に要求されるような高磁気特性、具体的には高い保磁力(Hcj)及び残留磁束密度(Br)を得るには不十分であった。
ここで、焼結で得られるR−T−B系焼結磁石の磁気特性は焼結温度に依存するところがある。その一方、工業的生産規模においては焼結炉内の全域で加熱温度を均一にすることは困難である。したがって、R−T−B系焼結磁石において、焼結温度が変動しても所望する磁気特性を得ることが要求される。ここで、所望する磁気特性を得ることのできる温度範囲を焼結温度幅ということにする。
Among sintered magnets, RTB-based sintered magnets are used in various applications because they are excellent in magnetic properties and the main component Nd is abundant and relatively inexpensive. Yes.
Research and development for improving the magnetic properties of the RTB-based sintered magnet has been vigorously conducted. For example, in JP-A-1-219143 (Patent Document 1), by adding 0.02 to 0.5 at% Cu to an R-T-B system sintered magnet, the magnetic properties are improved and the heat treatment conditions are improved. Has also been reported to improve. However, the method described in Patent Document 1 is insufficient to obtain high magnetic properties required for high performance magnets, specifically, high coercive force (Hcj) and residual magnetic flux density (Br). .
Here, the magnetic properties of the RTB-based sintered magnet obtained by sintering depend on the sintering temperature. On the other hand, on an industrial production scale, it is difficult to make the heating temperature uniform throughout the sintering furnace. Therefore, the R-T-B system sintered magnet is required to obtain desired magnetic characteristics even if the sintering temperature varies. Here, the temperature range in which the desired magnetic characteristics can be obtained is referred to as a sintering temperature range.

R−T−B系焼結磁石の主相比率を高めて高特性化を図るには、合金中の酸素量を低下させることが必要である。そのためには磁石を製造するにあたりその工程で様々な制約を受ける。すなわち、合金から焼結に至るまで酸素量を増やさない管理が必要である。低酸素で得られた微粉を焼結する際、その結晶粒を微細な状態で維持することは難しく、最適な焼結温度よりわずかに焼結温度が高くなると、結晶粒は容易に焼結時に粒成長し、磁気特性、特に保磁力が低下する。これは微粉に占める酸素比率が少ないために非常に活性な状態にあることに起因しており、焼結時に容易に異常な粒成長を惹起するため、及び結晶粒の成長を抑制することのできる酸化物が不足するためである。
そこで、特開2002−75717号公報(特許文献2)では、Co、Al、Cu、さらにZr、Nb又はHfを含有するR−T−B系焼結磁石中に微細なZrB化合物、NbB化合物又はHfB化合物(以下、M−B化合物)を均一に分散して析出させることにより、焼結過程における異常な粒成長を抑制できることが開示されている。
In order to increase the main phase ratio of the RTB-based sintered magnet and achieve high performance, it is necessary to reduce the amount of oxygen in the alloy. To that end, various restrictions are imposed on the process of manufacturing the magnet. That is, it is necessary to manage not to increase the amount of oxygen from the alloy to sintering. When sintering fine powder obtained with low oxygen, it is difficult to maintain the crystal grains in a fine state, and if the sintering temperature is slightly higher than the optimum sintering temperature, the crystal grains are easily Grain grows and magnetic properties, especially coercive force, decrease. This is due to the fact that it is in a very active state due to the small proportion of oxygen in the fine powder, which easily induces abnormal grain growth during sintering, and can suppress the growth of crystal grains. This is because the oxide is insufficient.
Therefore, in Japanese Patent Application Laid-Open No. 2002-75717 (Patent Document 2), a fine ZrB compound, NbB compound or Rb-B-based sintered magnet containing Co, Al, Cu, and further Zr, Nb or Hf is used. It is disclosed that the abnormal grain growth in the sintering process can be suppressed by uniformly dispersing and precipitating the HfB compound (hereinafter referred to as the MB compound).

特開平1−219143号公報JP-A-1-219143 特開2002−75717号公報JP 2002-75717 A 特公平5−31807号公報Japanese Patent Publication No. 5-31807 特許第3254229号公報Japanese Patent No. 3254229

特許文献2によればM−B化合物を分散・析出することによって焼結温度幅が拡大されている。しかしながら、特許文献2に開示される実施例3−1では焼結温度幅が20℃程度と狭い。よって、量産炉などで高い磁気特性を得るには、さらに焼結温度幅を広げることが望ましい。
そこで本発明は、結晶粒が成長しやすい酸素量の少ないR−T−B系焼結磁石において、結晶粒の成長を抑制し磁気特性、特に保磁力を向上させることを目的とする。加えて本発明は、高い保磁力を有しつつ焼結温度幅の広いR−T−B系焼結磁石を提供することを目的とする。
According to Patent Document 2, the sintering temperature range is expanded by dispersing and precipitating the MB compound. However, in Example 3-1, disclosed in Patent Document 2, the sintering temperature range is as narrow as about 20 ° C. Therefore, it is desirable to further widen the sintering temperature range in order to obtain high magnetic characteristics in a mass production furnace or the like.
Accordingly, an object of the present invention is to suppress the growth of crystal grains and improve the magnetic properties, particularly the coercive force, in an RTB-based sintered magnet with a small amount of oxygen in which crystal grains are likely to grow. In addition, an object of the present invention is to provide an RTB-based sintered magnet having a high coercive force and a wide sintering temperature range.

近年、高性能なR−T−B系焼結磁石を製造する場合、組成の異なる合金粉末を混合、焼結する混合法が提案されている(例えば、特公平5−31807号公報(特許文献3)、特許第3254229号公報(特許文献4))。この混合法は、典型的には、R14B系金属間化合物(Rは希土類元素から選択される1種又は2種以上の元素、TはFe又はFe及びCoを含む遷移金属元素から選択される1種又は2種以上の元素)を主体とする主相形成用の合金と、主相間に存在する粒界相を形成するための合金とを混合する。ここで、主相形成用の合金はRの含有量が相対的に少ないために低R合金と呼ばれることがある。一方、粒界相形成用の合金はRの含有量が相対的に多いために高R合金と呼ばれることがある。
本発明者は、Taを高R合金に含有させ、混合法を用いてR−T−B系焼結磁石を得ると、保磁力の向上に有効であるとともに、焼結温度幅が広くなることを見出した。
In recent years, when manufacturing a high-performance RTB-based sintered magnet, a mixing method in which alloy powders having different compositions are mixed and sintered has been proposed (for example, Japanese Patent Publication No. 5-31807 (Patent Document). 3), Japanese Patent No. 3254229 (Patent Document 4)). This mixing method typically includes an R 2 T 14 B intermetallic compound (R is one or more elements selected from rare earth elements, T is a transition metal element including Fe or Fe and Co). An alloy for forming a main phase mainly composed of one or more selected elements) and an alloy for forming a grain boundary phase existing between the main phases are mixed. Here, the main phase forming alloy is sometimes referred to as a low R alloy because the R content is relatively small. On the other hand, an alloy for forming a grain boundary phase is sometimes called a high-R alloy because of its relatively high R content.
When the present inventor contains Ta in a high R alloy and obtains an R-T-B sintered magnet by using a mixing method, it is effective for improving the coercive force and widening the sintering temperature range. I found.

本発明は以上の知見に基づくものであり、R14B相(Rは希土類元素から選択される1種又は2種以上の元素、TはFe又はFe及びCoを含む遷移金属元素から選択される1種又は2種以上の元素)からなる主相結晶粒と、主相結晶粒よりRを多く含む粒界相とを備え、粒界相中にTaを含む焼結体からなることを特徴とするR−T−B系焼結磁石である。
本発明において、粒界相中のTaはTa−Fe化合物として存在することが重要である。このTa−Fe化合物は高融点であるため、焼結過程における主相結晶粒の粗大化を抑制することができる。その結果、焼結後の組織が微細となり、保磁力を向上することができる。
The present invention is based on the above knowledge, and R 2 T 14 B phase (R is one or more elements selected from rare earth elements, T is selected from transition metal elements including Fe or Fe and Co) Comprising a main phase crystal grain composed of one or more kinds of elements) and a grain boundary phase containing more R than the main phase crystal grain, and comprising a sintered body containing Ta in the grain boundary phase. It is a characteristic R-T-B system sintered magnet.
In the present invention, it is important that Ta in the grain boundary phase exists as a Ta—Fe compound. Since this Ta—Fe compound has a high melting point, the coarsening of the main phase crystal grains in the sintering process can be suppressed. As a result, the sintered structure becomes fine and the coercive force can be improved.

本発明において、Taを高R合金に含有させることによる保磁力の向上効果は、焼結体中に含まれる酸素量が2000ppm以下と低酸素量の場合に有効である。
また本発明のR−T−B系焼結磁石においては、R:25〜35wt%、B:0.5〜4.5wt%、Al及びCuの1種又は2種を0.02〜0.6wt%、Ta:0.1〜2.0wt%、Co:4wt%以下(0を含まず)、残部実質的にFeからなる組成とすることが望ましい。
In the present invention, the effect of improving the coercive force by containing Ta in the high R alloy is effective when the oxygen content in the sintered body is as low as 2000 ppm or less.
In the RTB-based sintered magnet of the present invention, R: 25 to 35 wt%, B: 0.5 to 4.5 wt%, and one or two of Al and Cu are 0.02 to 0.02. It is desirable that the composition be 6 wt%, Ta: 0.1 to 2.0 wt%, Co: 4 wt% or less (not including 0), and the balance substantially consisting of Fe.

本発明は以上のR−T−B系焼結磁石を製造する方法を提供する。この製造方法は、R14B化合物(Rは希土類元素から選択される1種又は2種以上の元素、TはFe又はFe及びCoを含む遷移金属元素から選択される1種又は2種以上の元素)からなる主相結晶粒と、主相結晶粒よりRを多く含む粒界相とを備える焼結体からなるR−T−B系焼結磁石の製造方法であって、R14B化合物を主体とする低R合金粉末と、低R合金粉末よりもRの量が多く、かつR及びTを主体としTaを含む高R合金粉末とから構成される成形体を作製し、この成形体を焼結することを特徴としている。 The present invention provides a method for producing the above RTB-based sintered magnet. This production method comprises R 2 T 14 B compound (R is one or more elements selected from rare earth elements, T is one or two elements selected from transition metal elements including Fe, Fe and Co) or more elements) and the main phase crystal grains consisting of a main phase method for producing a grain from a sintered body and a grain boundary phase rich in R R-T-B based sintered magnet, R 2 A compact formed of a low R alloy powder mainly composed of a T 14 B compound and a high R alloy powder having a larger amount of R than the low R alloy powder and mainly containing R and T and containing Ta is prepared. The molded body is sintered.

本発明のR−T−B系焼結磁石によれば、焼結体の酸素量が低い場合であっても、微細な結晶組織とすることにより、高い保磁力を得ることができる。しかも本発明のR−T−B系焼結磁石によれば、広い焼結温度幅を有している。   According to the RTB-based sintered magnet of the present invention, a high coercive force can be obtained by forming a fine crystal structure even when the sintered body has a low oxygen content. Moreover, according to the RTB-based sintered magnet of the present invention, it has a wide sintering temperature range.

<組織>
はじめに本発明の特徴であるR−T−B系焼結磁石の組織について説明する。
本発明において、焼結体組織中の粒界相中にTaが存在している点に特徴がある。特に、このTaは、Ta−Fe化合物として粒界相中に存在している。Ta−Fe化合物は、FeTaが1775℃、FeTaが1875℃と、融点が高い。このように高融点の化合物が粒界相中に存在することにより、焼結過程における主相結晶粒の粗大化を抑え、結果的に焼結後の組織を微細なものとすることができる。その結果、高い保磁力を得ることができる。
<Organization>
First, the structure of the RTB-based sintered magnet, which is a feature of the present invention, will be described.
The present invention is characterized in that Ta is present in the grain boundary phase in the sintered body structure. In particular, this Ta is present in the grain boundary phase as a Ta—Fe compound. The Ta—Fe compound has a high melting point of Fe 2 Ta at 1775 ° C. and FeTa at 1875 ° C. Thus, when the high melting point compound exists in the grain boundary phase, coarsening of the main phase crystal grains in the sintering process can be suppressed, and as a result, the structure after sintering can be made fine. As a result, a high coercive force can be obtained.

<化学組成>
次に、本発明によるR−T−B系焼結磁石の望ましい化学組成について説明する。ここでいう化学組成は焼結後における化学組成をいう。
本発明のR−T−B系焼結磁石は、Rを25〜35wt%含有する。
ここで、RはYを含む概念を有しており、La,Ce,Pr,Nd,Sm,Eu,Gd,Tb,Dy,Ho,Er,Yb,Lu及びYから選択される1種又は2種以上の元素である。Rの量が25wt%未満であると、R−T−B系焼結磁石の主相となるR14B結晶粒の生成が十分ではない。このため、軟磁性を持つα−Feなどが析出し、保磁力が著しく低下する。一方、Rの量が35wt%を超えると主相を構成するR14B結晶粒の体積比率が低下し、残留磁束密度が低下する。またRの量が35wt%を超えるとRが酸素と反応し、含有する酸素量が増え、これに伴い保磁力発生に有効なR−リッチ相が減少し、保磁力の低下を招く。したがって、Rの量は25〜35wt%とする。望ましいRの量は28〜33wt%、さらに望ましいRの量は29〜32wt%である。
Ndは資源的に豊富で比較的安価であることから、Rとしての主成分をNdとすることが好ましい。またDyの含有は異方性磁界を増加させるため、保磁力を向上させる上で有効である。よって、RとしてNd及びDyを選択し、Nd及びDyの合計を25〜35wt%とすることが望ましい。そして、この範囲において、Dyの量は0.1〜8wt%が望ましい。Dyは、残留磁束密度及び保磁力のいずれを重視するかによって上記範囲内においてその量を定めることが望ましい。つまり、高い残留磁束密度を得たい場合にはDy量を0.1〜3.5wt%とし、高い保磁力を得たい場合にはDy量を3.5〜8wt%とすることが望ましい。
<Chemical composition>
Next, a desirable chemical composition of the RTB-based sintered magnet according to the present invention will be described. The chemical composition here refers to the chemical composition after sintering.
The RTB-based sintered magnet of the present invention contains 25 to 35 wt% of R.
Here, R has a concept including Y, and one or two selected from La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Yb, Lu, and Y More than a seed element. When the amount of R is less than 25 wt%, the generation of R 2 T 14 B crystal grains that are the main phase of the R—T—B system sintered magnet is not sufficient. For this reason, α-Fe or the like having soft magnetism is precipitated, and the coercive force is remarkably lowered. On the other hand, when the amount of R exceeds 35 wt%, the volume ratio of R 2 T 14 B crystal grains constituting the main phase is lowered, and the residual magnetic flux density is lowered. On the other hand, when the amount of R exceeds 35 wt%, R reacts with oxygen, and the amount of oxygen contained increases, and as a result, the R-rich phase effective for the generation of coercive force decreases and the coercive force decreases. Therefore, the amount of R is set to 25 to 35 wt%. A desirable amount of R is 28 to 33 wt%, and a more desirable amount of R is 29 to 32 wt%.
Since Nd is abundant in resources and relatively inexpensive, it is preferable that the main component as R is Nd. Further, the inclusion of Dy is effective in improving the coercive force because it increases the anisotropic magnetic field. Therefore, it is desirable that Nd and Dy are selected as R and the total of Nd and Dy is 25 to 35 wt%. In this range, the amount of Dy is preferably 0.1 to 8 wt%. It is desirable to determine the amount of Dy within the above range depending on which of the residual magnetic flux density and the coercive force is important. That is, when it is desired to obtain a high residual magnetic flux density, the Dy amount is preferably 0.1 to 3.5 wt%, and when a high coercive force is desired, the Dy amount is desirably 3.5 to 8 wt%.

また、本発明のR−T−B系焼結磁石は、ホウ素(B)を0.5〜4.5wt%含有する。Bが0.5wt%未満の場合には高い保磁力を得ることができない。但し、Bが4.5wt%を超えると残留磁束密度が低下する傾向がある。したがって、上限を4.5wt%とする。望ましいBの量は0.5〜1.5wt%、さらに望ましいBの量は0.8〜1.2wt%である。   The RTB-based sintered magnet of the present invention contains 0.5 to 4.5 wt% of boron (B). When B is less than 0.5 wt%, a high coercive force cannot be obtained. However, when B exceeds 4.5 wt%, the residual magnetic flux density tends to decrease. Therefore, the upper limit is 4.5 wt%. A desirable amount of B is 0.5 to 1.5 wt%, and a more desirable amount of B is 0.8 to 1.2 wt%.

本発明のR−T−B系焼結磁石は、Al及びCuの1種又は2種を0.02〜0.6wt%の範囲で含有することができる。この範囲でAl及びCuの1種又は2種を含有させることにより、得られる希土類永久磁石の高保磁力化、高耐食性化、温度特性の改善が可能となる。Alを添加する場合において、望ましいAlの量は0.03〜0.3wt%、さらに望ましいAlの量は0.05〜0.25wt%である。また、Cuを添加する場合において、Cuの量は0.3wt%以下(0を含まず)、望ましくは0.15wt%以下(0を含まず)、さらに望ましいCuの量は0.03〜0.08wt%である。   The RTB-based sintered magnet of the present invention can contain one or two of Al and Cu in the range of 0.02 to 0.6 wt%. By containing one or two of Al and Cu within this range, it is possible to increase the coercive force, corrosion resistance, and temperature characteristics of the obtained rare earth permanent magnet. In the case of adding Al, a desirable amount of Al is 0.03 to 0.3 wt%, and a more desirable amount of Al is 0.05 to 0.25 wt%. In addition, in the case of adding Cu, the amount of Cu is 0.3 wt% or less (excluding 0), desirably 0.15 wt% or less (not including 0), and the more desirable amount of Cu is 0.03 to 0 0.08 wt%.

本発明のR−T−B系焼結磁石は、Taを0.1〜2.0wt%含有する。R−T−B系焼結磁石の磁気特性向上を図るために酸素含有量を低減する際に、Taは焼結過程での結晶粒の異常成長を抑制する効果を発揮し、焼結体の組織を均一かつ微細にする。したがって、Taは酸素量が低い場合にその効果が顕著になる。Taの望ましい量は0.2〜1.7wt%、さらに望ましい量は0.3〜1.5wt%である。   The RTB-based sintered magnet of the present invention contains 0.1 to 2.0 wt% of Ta. When reducing the oxygen content in order to improve the magnetic properties of the RTB-based sintered magnet, Ta exerts the effect of suppressing the abnormal growth of crystal grains during the sintering process. Make the tissue uniform and fine. Therefore, the effect of Ta becomes remarkable when the amount of oxygen is low. A desirable amount of Ta is 0.2 to 1.7 wt%, and a more desirable amount is 0.3 to 1.5 wt%.

本発明のR−T−B系焼結磁石は、その酸素量を2000ppm以下とする。酸素量が多いと非磁性成分である酸化物相が増大して、磁気特性を低下させる。そこで本発明では、焼結体中に含まれる酸素量を、2000ppm以下、望ましくは1500ppm以下、さらに望ましくは1000ppm以下とする。但し、単純に酸素量を低下させたのでは、粒成長抑制効果を有していた酸化物相が不足し、焼結時に十分な密度上昇を得る過程で粒成長が容易に起こる。そこで、本発明では、焼結過程での主相結晶粒の異常成長を抑制する効果を発揮するTaを、R−T−B系焼結磁石中、特に粒界相中に所定量含有させる。ただし、主相結晶粒中にTaが存在していても、本発明の効果を阻害することはない。   The RTB-based sintered magnet of the present invention has an oxygen content of 2000 ppm or less. When the amount of oxygen is large, the oxide phase, which is a nonmagnetic component, increases and the magnetic properties are deteriorated. Therefore, in the present invention, the amount of oxygen contained in the sintered body is set to 2000 ppm or less, desirably 1500 ppm or less, and more desirably 1000 ppm or less. However, when the oxygen amount is simply reduced, the oxide phase having the effect of suppressing grain growth is insufficient, and grain growth easily occurs in the process of obtaining a sufficient density increase during sintering. Therefore, in the present invention, a predetermined amount of Ta, which exhibits the effect of suppressing abnormal growth of main phase crystal grains during the sintering process, is contained in the R-T-B system sintered magnet, particularly in the grain boundary phase. However, even if Ta is present in the main phase crystal grains, the effect of the present invention is not hindered.

本発明のR−T−B系焼結磁石は、Coを4wt%以下(0を含まず)、望ましくは0.1〜2.0wt%、さらに望ましくは0.3〜1.0wt%含有する。CoはFeと同様の相を形成するが、キュリー温度の向上、粒界相の耐食性向上に効果がある。   The RTB-based sintered magnet of the present invention contains Co of 4 wt% or less (not including 0), preferably 0.1 to 2.0 wt%, more preferably 0.3 to 1.0 wt%. . Co forms the same phase as Fe, but is effective in improving the Curie temperature and improving the corrosion resistance of the grain boundary phase.

<製造方法>
次に、本発明によるR−T−B系焼結磁石の好適な製造方法について説明する。
本実施の形態では、R14B結晶粒を主体とする合金(低R合金)と、低R合金よりRを多く含む合金(高R合金)とを用いて本発明に係るR−T−B系焼結磁石を製造する方法について示す。
原料金属を真空又は不活性ガス、好ましくはAr雰囲気中でストリップキャスティングすることにより、低R合金及び高R合金を得る。原料金属としては、希土類金属あるいは希土類合金、純鉄、フェロボロン、さらにはこれらの合金等を使用することができる。得られた原料合金は、凝固偏析がある場合は必要に応じて溶体化処理を行なう。その条件は真空又はAr雰囲気下、700〜1500℃の領域で1時間以上保持すれば良い。
<Manufacturing method>
Next, the suitable manufacturing method of the RTB system sintered magnet by this invention is demonstrated.
In the present embodiment, the R-T according to the present invention is made using an alloy mainly composed of R 2 T 14 B crystal grains (low R alloy) and an alloy containing more R than the low R alloy (high R alloy). -It shows about the method of manufacturing a B type sintered magnet.
A low R alloy and a high R alloy are obtained by strip casting the raw metal in a vacuum or an inert gas, preferably in an Ar atmosphere. As the raw material metal, rare earth metals or rare earth alloys, pure iron, ferroboron, and alloys thereof can be used. The obtained raw material alloy is subjected to a solution treatment as necessary when there is solidification segregation. The conditions may be maintained for 1 hour or longer in a region of 700 to 1500 ° C. in a vacuum or Ar atmosphere.

本発明で特徴的な事項は、Taを高R合金から添加するという点である。これは、<組織>の欄で説明したように、高R合金からTaを添加することにより、粒界相中にTa−Fe化合物を生成して結晶粒の異常成長を抑制する。
低R合金は、R14B結晶粒を主体とするものであれば、その組成を限定する必要はないが、Rを25〜35wt%、Bを0.5〜4.5wt%、残部Tの組成とすればよい。また、高R合金は、Rを30〜65wt%、Bを0〜5wt%、残部Tの組成とすればよい。
低R合金には、R、T及びBの他に、Cu及びAlを含有させることができる。このとき低R合金は、R−Cu−Al−T(Fe)−B系の合金を構成する。また、高R合金には、R及びT(Fe)の他に、Cu、Co及びAlを含有させることができる。このとき高R合金は、R−Cu−Co−Al−Ta−T系の合金を構成する。
A characteristic feature of the present invention is that Ta is added from a high R alloy. As described in the section of <structure>, this adds Ta from a high R alloy to generate a Ta-Fe compound in the grain boundary phase and suppress abnormal growth of crystal grains.
If the low R alloy is mainly composed of R 2 T 14 B crystal grains, it is not necessary to limit the composition thereof, but R is 25 to 35 wt%, B is 0.5 to 4.5 wt%, and the balance The composition of T may be used. The high R alloy may have a composition of 30 to 65 wt% R, 0 to 5 wt% B, and the balance T.
In addition to R, T, and B, the low R alloy can contain Cu and Al. At this time, the low R alloy constitutes an R-Cu-Al-T (Fe) -B alloy. Further, the high R alloy can contain Cu, Co and Al in addition to R and T (Fe). At this time, the high R alloy constitutes an R-Cu-Co-Al-Ta-T alloy.

低R合金及び高R合金が作製された後、これらの各母合金は別々に又は一緒に粉砕される。粉砕工程には、粗粉砕工程と微粉砕工程とがある。まず、各母合金を、それぞれ粒径数百μm程度になるまで粗粉砕する。粗粉砕は、スタンプミル、ジョークラッシャー、ブラウンミル等の機械的手段を用い、不活性ガス雰囲気中にて行なうことができる。また、機械的な手段を用いることなく、水素を吸蔵させることにより粗粉砕を行うこともできる。さらに、水素吸蔵を行った後に、機械的な手段で粗粉砕を行うことができる。いずれの手法を用いるかは、母合金の形態によっても相違する。水素吸蔵を行った後は、脱水素することが望ましい。R−T−B系焼結磁石にとって、水素は不純物だからである。   After the low R and high R alloys are made, each of these master alloys is ground separately or together. The pulverization process includes a coarse pulverization process and a fine pulverization process. First, each mother alloy is coarsely pulverized until the particle size becomes about several hundred μm. Coarse pulverization can be performed in an inert gas atmosphere using mechanical means such as a stamp mill, a jaw crusher, and a brown mill. Further, coarse pulverization can be performed by occluding hydrogen without using mechanical means. Furthermore, after hydrogen storage, coarse pulverization can be performed by mechanical means. Which method is used depends on the form of the master alloy. It is desirable to dehydrogenate after hydrogen storage. This is because hydrogen is an impurity for the RTB-based sintered magnet.

粗粉砕工程後、微粉砕工程に移る。微粉砕は、主にジェットミルが用いられ、粒径数百μm程度の粗粉砕粉末が、平均粒径3〜5μmになるまで粉砕される。ジェットミルは、高圧の非酸化性ガス(例えば窒素ガス)を狭いノズルより開放して高速のガス流を発生させ、この高速のガス流により粗粉砕粉末を加速し、粗粉砕粉末同士の衝突やターゲットあるいは容器壁との衝突を発生させて粉砕する方法である。   After the coarse pulverization process, the process proceeds to the fine pulverization process. In the fine pulverization, a jet mill is mainly used, and a coarsely pulverized powder having a particle size of about several hundreds of μm is pulverized until the average particle size becomes 3 to 5 μm. The jet mill opens a high-pressure non-oxidizing gas (for example, nitrogen gas) from a narrow nozzle to generate a high-speed gas flow, accelerates the coarsely pulverized powder with this high-speed gas flow, This is a method of crushing by generating a collision with a target or a container wall.

微粉砕工程において低R合金及び高R合金を別々に粉砕した場合には、微粉砕された低R合金粉末及び高R合金粉末とを窒素雰囲気中で混合する。低R合金粉末及び高R合金粉末の混合比率は、重量比で80:20〜97:3程度とすればよい。同様に、低R合金及び高R合金を一緒に微粉砕する場合の混合比率も重量比で80:20〜97:3程度とすればよい。微粉砕時に、ステアリン酸亜鉛等の添加剤を0.01〜0.3wt%程度添加することにより、成形時の配向性が高い微粉を得ることができる。   When the low R alloy and the high R alloy are separately pulverized in the fine pulverization step, the finely pulverized low R alloy powder and high R alloy powder are mixed in a nitrogen atmosphere. The mixing ratio of the low R alloy powder and the high R alloy powder may be about 80:20 to 97: 3 by weight. Similarly, the mixing ratio when the low R alloy and the high R alloy are finely pulverized together may be about 80:20 to 97: 3 by weight. By adding about 0.01 to 0.3 wt% of an additive such as zinc stearate at the time of fine pulverization, a fine powder having high orientation during molding can be obtained.

次いで、低R合金粉末及び高R合金粉末からなる混合粉末を、磁場印加によってその結晶軸を配向させた状態で加圧成形する。この磁場中成形は、940〜1400kA/mの磁場中で、70〜150MPaの圧力で行なえばよい。   Next, the mixed powder composed of the low R alloy powder and the high R alloy powder is pressure-molded in a state where the crystal axis is oriented by applying a magnetic field. The forming in the magnetic field may be performed at a pressure of 70 to 150 MPa in a magnetic field of 940 to 1400 kA / m.

磁場中成形後、その成形体を真空又は不活性ガス雰囲気中で焼結する。焼結温度は、組成、粉砕方法、粒度と粒度分布の違い等、諸条件により調整する必要があるが、1000〜1100℃で1〜5時間程度焼結すればよい。   After molding in a magnetic field, the compact is sintered in a vacuum or an inert gas atmosphere. Although it is necessary to adjust sintering temperature by various conditions, such as a composition, a grinding | pulverization method, a particle size, and a particle size distribution difference, what is necessary is just to sinter at 1000-1100 degreeC for about 1 to 5 hours.

焼結後、得られた焼結体に時効処理を施すことができる。時効処理は、保磁力を制御する上で重要である。時効処理を2段に分けて行なう場合には、800℃近傍、600℃近傍での所定時間保持することが有効である。800℃近傍での熱処理を焼結後に行なうと、保磁力が増大するため、混合法においては特に有効である。また、600℃近傍の熱処理で保磁力が大きく増加するため、時効処理を1段で行なう場合には、600℃近傍の時効処理を施すとよい。   After sintering, the obtained sintered body can be subjected to an aging treatment. The aging treatment is important for controlling the coercive force. When the aging treatment is performed in two stages, it is effective to hold for a predetermined time in the vicinity of 800 ° C. and 600 ° C. When the heat treatment at around 800 ° C. is performed after sintering, the coercive force increases, which is particularly effective in the mixing method. In addition, since the coercive force is greatly increased by the heat treatment at around 600 ° C., the aging treatment at around 600 ° C. is preferably performed when the aging treatment is performed in one stage.

次に、具体的な実施例を挙げて本発明をさらに詳細に説明する。なお、以下では実施例1〜実施例2に分けて本発明によるR−T−B系焼結磁石を説明するが、用意した原料合金、各製造工程は共通するところがあるため、はじめにこの点について説明しておく。
1)原料合金
ストリップキャスティング法により、表1に示す組成の低R合金及び高R合金を作製した。
2)粉砕工程
室温にて水素を吸蔵させた後、Ar雰囲気中で600℃×1時間の脱水素を行なう水素粉砕処理を行なった。
高磁気特性を得るために、本実験では焼結体酸素量を2000ppm以下に抑えるために、水素処理(粉砕処理後の回収)から焼結(焼結炉に投入する)までの各工程の雰囲気を、100ppm未満の酸素濃度に抑えてある。以後、無酸素プロセスと称す。
Next, the present invention will be described in more detail with specific examples. In the following, the RTB-based sintered magnet according to the present invention will be described by dividing it into Example 1 to Example 2. However, since the prepared raw material alloy and each manufacturing process are common, this point is first introduced. Let me explain.
1) Raw material alloys Low R alloys and high R alloys having the compositions shown in Table 1 were prepared by strip casting.
2) Pulverization process After occluding hydrogen at room temperature, a hydrogen pulverization process was performed in which dehydrogenation was performed in an Ar atmosphere at 600 ° C. for 1 hour.
In order to obtain high magnetic properties, in this experiment, the atmosphere of each process from hydrogen treatment (recovery after pulverization) to sintering (put into the sintering furnace) to suppress the amount of oxygen in the sintered body to 2000 ppm or less Is suppressed to an oxygen concentration of less than 100 ppm. Hereinafter, it is referred to as an oxygen-free process.

Figure 2005286176
Figure 2005286176

3)粉砕工程
水素吸蔵処理された低R合金及び高R合金、さらには添加剤を混合する。添加剤の種類は特に限定されるものではなく、粉砕性の向上並びに成形時の配向性の向上に寄与するものを適宜選択すればよいが、本実施例ではステアリン酸亜鉛を0.05〜0.1wt%混合した。添加剤の混合は、例えばナウターミキサー等により5〜30分間ほど行なう程度でよい。
その後、ジェットミルを用いて合金粉末が平均粒径4.0μm程度になるまで微粉砕を行なった。
当然ながら、低R合金、高R合金及び添加剤の混合工程と微粉砕工程は、ともに無酸素プロセスで行っている。
3) Grinding step A low R alloy and a high R alloy which have been subjected to hydrogen storage treatment, and further additives are mixed. The type of the additive is not particularly limited, and any additive that contributes to improvement in grindability and orientation during molding may be appropriately selected. In this example, zinc stearate is added in an amount of 0.05 to 0. 1 wt% was mixed. The additive may be mixed for about 5 to 30 minutes using, for example, a Nauter mixer.
Thereafter, fine grinding was performed using a jet mill until the alloy powder had an average particle size of about 4.0 μm.
Of course, the mixing step and the fine pulverization step of the low R alloy, the high R alloy and the additive are both performed by an oxygen-free process.

微粉砕を行う前に、複数種類の高R合金を調合し、所望の組成(特にTa量)となるように混合することができる。この場合の混合も、例えばナウターミキサー等により5〜30分間ほど行なう程度でよい。   Before fine pulverization, a plurality of types of high R alloys can be prepared and mixed so as to have a desired composition (particularly, Ta amount). The mixing in this case may be performed only for about 5 to 30 minutes using, for example, a Nauta mixer.

4)成形工程
得られた微粉末を磁場中にて成形する。具体的には、1200kA/mの磁場中で120MPaの圧力で成形を行い、成形体を得た。本工程も無酸素プロセスにて行なった。
5)焼結、時効工程
この成形体を真空中において1020〜1080℃で4時間焼結した後、急冷した。次いで得られた焼結体に800℃×1時間と540℃×1時間(ともにAr雰囲気中)の2段時効処理を施した。
4) Molding step The obtained fine powder is molded in a magnetic field. Specifically, molding was performed at a pressure of 120 MPa in a magnetic field of 1200 kA / m to obtain a molded body. This step was also performed by an oxygen-free process.
5) Sintering and aging process This compact was sintered at 1020 to 1080 ° C for 4 hours in a vacuum and then rapidly cooled. Next, the obtained sintered body was subjected to a two-stage aging treatment of 800 ° C. × 1 hour and 540 ° C. × 1 hour (both in an Ar atmosphere).

表1に示す低R合金A1〜A2及び高R合金B1〜4を用い、表2に示す最終組成となるように配合した。その後、各々の混合物を水素粉砕処理し、次いでジェットミルにて微粉砕した。その後磁場中成形した後に、1020℃、1050℃及び1080℃で焼結(4時間保持)し、得られた焼結体に2段時効処理を施した。
得られたR−T−B系焼結磁石について、残留磁束密度(Br)、保磁力(HcJ)及び角形比(Hk/HcJ)をB−Hトレーサにより測定した。なお、Hkは磁気ヒステリシスループの第2象限において、磁束密度が残留磁束密度の90%になるときの外部磁界強度である。また、得られたR−T−B系焼結磁石について、焼結体に含まれる酸素量を測定した。その結果を表2に示す。
Using the low R alloys A1 to A2 and the high R alloys B1 to 4 shown in Table 1, the final compositions shown in Table 2 were blended. Thereafter, each mixture was subjected to hydrogen pulverization treatment and then pulverized in a jet mill. Then, after forming in a magnetic field, sintering was performed at 1020 ° C., 1050 ° C. and 1080 ° C. (held for 4 hours), and the obtained sintered body was subjected to a two-stage aging treatment.
About the obtained RTB system sintered magnet, the residual magnetic flux density (Br), the coercive force (HcJ), and the squareness ratio (Hk / HcJ) were measured with a BH tracer. Hk is the external magnetic field strength when the magnetic flux density is 90% of the residual magnetic flux density in the second quadrant of the magnetic hysteresis loop. Moreover, about the obtained RTB system sintered magnet, the amount of oxygen contained in the sintered body was measured. The results are shown in Table 2.

Figure 2005286176
Figure 2005286176

本実施例は、高い磁気特性を得るために、無酸素プロセスにより焼結体の酸素量を1000ppm以下と低減し、かつ粉砕粉末の平均粒径を4.0μmと微細なものとした。したがって、焼結過程における異常粒成長が生じやすくなっている。 図1に、焼結温度と、残留磁束密度(Br)、保磁力(HcJ)及び角形比(Hk/HcJ)の関係を示している。   In this example, in order to obtain high magnetic properties, the oxygen content of the sintered body was reduced to 1000 ppm or less by an oxygen-free process, and the average particle size of the pulverized powder was as fine as 4.0 μm. Accordingly, abnormal grain growth is likely to occur during the sintering process. FIG. 1 shows the relationship between the sintering temperature, the residual magnetic flux density (Br), the coercive force (HcJ), and the squareness ratio (Hk / HcJ).

表2及び図1に示すように、高R合金にTaを添加して得られた焼結磁石は、Taを含まない焼結磁石に比べて保磁力(HcJ)が高いことがわかる。
また、磁気特性の中で角形比(Hk/HcJ)は異常粒成長による低下傾向が最も早く現れる。つまり、角形比(Hk/HcJ)は異常粒成長の傾向を把握することのできる一指標となる。そこで、90%以上の角形比(Hk/HcJ)が得られた焼結温度域を、焼結温度幅と定義すると、Taを添加しない焼結磁石は焼結温度幅が0である。これに対して高R合金にTaを添加した焼結磁石は、1020〜1080℃において90%以上の角形比(Hk/HcJ)を得ている。つまり、Taを0.50%添加した焼結磁石の焼結温度幅は60℃以上である。
焼結温度が1080℃の焼結磁石の破断面のSEM(走査型電子顕微鏡、1000倍)像を示すが、Taを含まない焼結磁石(図2(a))と比べてTaを0.50wt%含む焼結磁石(図2(b))の方が微細な結晶組織を示すことがわかる。
As shown in Table 2 and FIG. 1, it can be seen that the sintered magnet obtained by adding Ta to the high R alloy has a higher coercive force (HcJ) than the sintered magnet not containing Ta.
In addition, among the magnetic properties, the squareness ratio (Hk / HcJ) tends to decrease most rapidly due to abnormal grain growth. That is, the squareness ratio (Hk / HcJ) is an index that can grasp the tendency of abnormal grain growth. Therefore, if the sintering temperature range in which the squareness ratio (Hk / HcJ) of 90% or more is obtained is defined as the sintering temperature range, the sintering temperature range of the sintered magnet not added with Ta is zero. In contrast, a sintered magnet obtained by adding Ta to a high R alloy has a squareness ratio (Hk / HcJ) of 90% or more at 1020 to 1080 ° C. That is, the sintering temperature width of the sintered magnet to which 0.50% of Ta is added is 60 ° C. or more.
An SEM (scanning electron microscope, 1000 times) image of a fracture surface of a sintered magnet having a sintering temperature of 1080 ° C. is shown, but Ta is reduced to 0. 0 as compared with a sintered magnet not containing Ta (FIG. 2A). It can be seen that the sintered magnet containing 50 wt% (FIG. 2B) shows a finer crystal structure.

表2のNo.8の焼結磁石について、TEM(透過型電子顕微鏡)による組織観察を行ったところ、図3に示すように、黒い点線で囲まれた粒界相(三重点)内である白い点線で囲まれた領域に、Ta−Fe化合物の存在が確認された。したがって、高R合金にTaを添加することにより得られた焼結磁石の保磁力が向上すること及び焼結温度幅が広いことは、このTa−Fe化合物の存在が要因と判断される。   No. in Table 2 When the structure of the sintered magnet 8 was observed with a TEM (transmission electron microscope), as shown in FIG. 3, it was surrounded by a white dotted line inside the grain boundary phase (triple point) surrounded by a black dotted line. The presence of Ta-Fe compound was confirmed in the region. Therefore, the presence of this Ta-Fe compound is considered to be the reason why the coercive force of the sintered magnet obtained by adding Ta to the high R alloy is improved and the sintering temperature range is wide.

高R合金にTaを添加した焼結磁石は、Ta量の増加に伴って保磁力(HcJ)が向上する傾向がある。但し、高R合金添加による焼結磁石であっても、Ta添加量を2.5wt%まで増加させると、Ta無添加焼結磁石よりも残留磁束密度(Br)が低くなる。一方で、Ta量が0.1wt%未満では、保磁力向上の効果が十分ではない。したがって、Taの量は、0.1〜2.0wt%の範囲とすることが望ましいことがわかる。   A sintered magnet obtained by adding Ta to a high R alloy tends to improve the coercive force (HcJ) as the amount of Ta increases. However, even in a sintered magnet with a high R alloy addition, when the Ta addition amount is increased to 2.5 wt%, the residual magnetic flux density (Br) becomes lower than that with a Ta-free additive magnet. On the other hand, if the amount of Ta is less than 0.1 wt%, the effect of improving the coercive force is not sufficient. Therefore, it can be seen that the amount of Ta is preferably in the range of 0.1 to 2.0 wt%.

表1に示す合金を用いて、表3に示す最終組成となるように配合した以外は実施例1と同様にしてR−T−B系焼結磁石を得たのちに、やはり実施例1と同様に磁気特性を測定した。その結果を表3に合わせて示す。   An R-T-B sintered magnet was obtained in the same manner as in Example 1 except that the alloy shown in Table 1 was used so that the final composition shown in Table 3 was obtained. Similarly, the magnetic characteristics were measured. The results are also shown in Table 3.

Figure 2005286176
Figure 2005286176

表3に示すように、Al量及びCu量を増加させることにより保磁力(HcJ)を向上できることがわかる。また、Dy量を増加させることによっても保磁力(HcJ)を向上できることがわかる。したがって、本発明によればTa−Fe化合物を粒界相内に存在させることによる保磁力(HcJ)向上効果に加えて、Al、Cu及びDyの量を調整することにより特に保磁力(HcJ)の高いR−T−B系焼結磁石を得ることができる。さらに、R(Nd+Dy)量及びB量を増減することによって磁気特性が変動することがわかる。   As shown in Table 3, it can be seen that the coercive force (HcJ) can be improved by increasing the amount of Al and the amount of Cu. It can also be seen that the coercive force (HcJ) can be improved by increasing the amount of Dy. Therefore, according to the present invention, in addition to the effect of improving the coercive force (HcJ) due to the presence of the Ta-Fe compound in the grain boundary phase, the coercive force (HcJ) is particularly adjusted by adjusting the amounts of Al, Cu and Dy. R-T-B system sintered magnet having a high C can be obtained. Furthermore, it can be seen that the magnetic characteristics fluctuate by increasing / decreasing the R (Nd + Dy) amount and the B amount.

実施例1における焼結温度と、残留磁束密度(Br)、保磁力(HcJ)及び角形比(Hk/HcJ)の関係を示すグラフである。It is a graph which shows the relationship between the sintering temperature in Example 1, residual magnetic flux density (Br), coercive force (HcJ), and squareness ratio (Hk / HcJ). 実施例1におけるR−T−B系焼結磁石の破断面のSEM(走査型電子顕微鏡、1000倍)像である。2 is a SEM (scanning electron microscope, 1000 times) image of a fractured surface of an RTB-based sintered magnet in Example 1. FIG. 実施例1におけるR−T−B系焼結磁石のTEM(透過型電子顕微鏡)像である。2 is a TEM (transmission electron microscope) image of an RTB-based sintered magnet in Example 1. FIG.

Claims (5)

14B相(Rは希土類元素から選択される1種又は2種以上の元素、TはFe又はFe及びCoを含む遷移金属元素から選択される1種又は2種以上の元素)からなる主相結晶粒と、前記主相結晶粒よりRを多く含む粒界相とを備え、前記粒界相中にTaを含む焼結体からなることを特徴とするR−T−B系焼結磁石。 From the R 2 T 14 B phase (R is one or more elements selected from rare earth elements, T is one or more elements selected from transition metal elements including Fe or Fe and Co) An R-T-B system firing comprising: a main phase crystal grain, and a grain boundary phase containing more R than the main phase crystal grain, and comprising a sintered body containing Ta in the grain boundary phase. Magnet. Taは前記粒界相中にTa−Fe化合物として存在することを特徴とする請求項1に記載のR−T−B系焼結磁石。   The RTB-based sintered magnet according to claim 1, wherein Ta is present as a Ta—Fe compound in the grain boundary phase. 酸素量が2000ppm以下であることを特徴とする請求項1又は2に記載のR−T−B系焼結磁石。   The RTB-based sintered magnet according to claim 1 or 2, wherein the oxygen content is 2000 ppm or less. R:25〜35wt%、B:0.5〜4.5wt%、Al及びCuの1種又は2種を0.02〜0.6wt%、Ta:0.1〜2.0wt%、Co:4wt%以下(0を含まず)、残部実質的にFeからなる組成を有することを特徴とする請求項1〜3のいずれかに記載のR−T−B系焼結磁石。   R: 25-35 wt%, B: 0.5-4.5 wt%, one or two of Al and Cu are 0.02-0.6 wt%, Ta: 0.1-2.0 wt%, Co: The RTB-based sintered magnet according to any one of claims 1 to 3, which has a composition of 4 wt% or less (excluding 0) and the balance substantially consisting of Fe. 14B化合物(Rは希土類元素から選択される1種又は2種以上の元素、TはFe又はFe及びCoを含む遷移金属元素から選択される1種又は2種以上の元素)からなる主相結晶粒と、前記主相結晶粒よりRを多く含む粒界相とを備える焼結体からなるR−T−B系焼結磁石の製造方法であって、
前記R14B化合物を主体とする低R合金粉末と、前記低R合金粉末よりもRの量が多く、かつR及びTを主体としTaを含む高R合金粉末とから構成される成形体を作製する工程と、
前記成形体を焼結する工程と、を含むことを特徴とするR−T−B系焼結磁石の製造方法。
From R 2 T 14 B compound (R is one or more elements selected from rare earth elements, T is one or more elements selected from transition metal elements including Fe or Fe and Co) An R-T-B system sintered magnet made of a sintered body comprising a main phase crystal grain and a grain boundary phase containing more R than the main phase crystal grain,
Molding composed of a low R alloy powder mainly composed of the R 2 T 14 B compound, and a high R alloy powder having a larger amount of R than the low R alloy powder and mainly composed of R and T and containing Ta. Producing a body;
And a step of sintering the molded body. A method for producing an RTB-based sintered magnet.
JP2004099450A 2004-03-30 2004-03-30 R-t-b-based sintered magnet and its manufacturing method Pending JP2005286176A (en)

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JPH05175026A (en) * 1991-12-24 1993-07-13 Shin Etsu Chem Co Ltd Manufacture of rare earth permanent magnet
JPH06340902A (en) * 1993-06-02 1994-12-13 Shin Etsu Chem Co Ltd Production of sintered rare earth base permanent magnet
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JP2011187734A (en) * 2010-03-09 2011-09-22 Tdk Corp Rare earth sintered magnet, and method for producing the same

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