Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
  • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
  • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
  • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
  • H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
  • H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
  • H01F1/047—Alloys characterised by their composition
  • H01F1/053—Alloys characterised by their composition containing rare earth metals
  • H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
  • H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
  • H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
  • H01F1/0575—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together
  • H01F1/0577—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together sintered
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/20—Direct sintering or melting
  • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
  • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C28/00—Alloys based on a metal not provided for in groups C22C5/00 - C22C27/00
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
  • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
  • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
  • H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/30—Process control
  • B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2207/00—Aspects of the compositions, gradients
  • B22F2207/01—Composition gradients
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2207/00—Aspects of the compositions, gradients
  • B22F2207/11—Gradients other than composition gradients, e.g. size gradients
  • B22F2207/17—Gradients other than composition gradients, e.g. size gradients density or porosity gradients
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y80/00—Products made by additive manufacturing
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P10/00—Technologies related to metal processing
  • Y02P10/25—Process efficiency

Definitions

• the invention relates to a method for producing a permanent magnet.
• Rare earths Materials from rare earths are becoming increasingly important in various areas. Rare earths are used, for example, in phosphors for energy-saving lamps, in generators for wind turbines and electric motors for drives. Permanent magnets in generators or electric motors are based in particular on the rare earth compound neodymium-iron-boron (Nd 2 Fei 4 B).
• Permanent magnets are currently produced either metallurgically or as composite materials of magnetic particles and plastic.
• the powder of the magnetic particles which in turn have a nanoscale structure, is mixed with a plastic matrix and cold pre-pressed.
• the magnetic particles are then aligned in a magnetic field and then hot pressed to polymer crosslinking.
• these permanent magnets have a very high plastic content, which deteriorates the magnetic properties. For the same magnetic properties, this increases the volume of the permanent magnet.
• the production of permanent magnets is currently powder metallurgy.
• the object of the present invention is to provide a process for the production of permanent magnets, which overcomes the disadvantages mentioned.
• a focused energy beam is used to produce a permanent magnet.
• a material encompassing at least one magnetic material is sintered.
• a rapidly solidified magnetic powder which has a nanoscale microstructure and which forms an electrically insulating grain boundary phase during the melting process, as a result of which eddy current losses are reduced.
• This electrically insulating grain boundary phase is achieved by only melting the material during sintering and thus preserving its microstructure.
• selective laser sintering is used as the focused energy beam method.
• the laser is a locally regulated controllable energization of the material. This leads to the preservation of the microstructure with simultaneous construction of complex final contour shapes. Grain size growth is advantageously prevented.
• the material comprising magnetic material is sintered directly as a porous body. The trapped air serves as insulation. This reduces eddy current losses advantageous.
• an electron beam method is used as the focused energy beam method. The energy input is fast and easy to dose in the electron beam process. As a result, the material comprising magnetic particles is only melted. The microstructure is maintained without grain size growth occurring. This reduces the eddy current losses in the permanent magnet advantageous.
• At least one non-metallic material is used as the insulating material as the material.
• these are glass and / or a polymer.
• the incorporation of this non-metallic material increases the mechanical stability and at the same time the electrical resistance. As a result, eddy current losses are advantageously reduced.
• the direct incorporation of the non-metallic material into the permanent magnets advantageously saves additional process steps, such as cutting and bonding of the permanent magnet for introducing a non-metallic insulating material.
• the proportion by weight of non-metallic material is less than 10%. Such a small proportion of the non-metallic material in the permanent magnet advantageously leads to a smaller size of the permanent magnet with the same magnetic properties.
• At least two layers are sintered with different proportions of magnetic material and non-metallic material.
• the energy input required for sintering the material is metered for each layer.
• the permanent magnet is produced as a gradient component with at least two materials. By using different materials, the natural shafts of the permanent magnet can be advantageously changed.
• the permanent magnet is produced as a gradient component with at least two mechanical material material shanks.
• These mechanical material properties are, in particular, porosity and / or density of the gradient component.
• the permanent magnet is produced as a gradient component with at least two material layers of different geometries.
• the gradient refers to the materials, the mechanical properties of the materials and the geometry.
• the figure shows schematically the production of a permanent magnet 1 by means of an exemplary method according to the invention.
• the permanent magnet 1 is formed in this example of a first layer 7 and a second layer 8. Both layers 7, 8 are sintered by means of a laser beam 2, wherein the working region 9 of the laser beam passes over the layers in the manufacture of one end of the layer 7, 8 to the other end of the respective layer 7, 8.
• the starting material of the first layer 7 is a powder of magnetic material 6, preferably of spherical particles, with neodymium-iron-boron (Nd 2 Fei 4 B). These are heated in the working area 9, the laser beam 2 and to sintered material 3.
• the spherical shape of the magnetic material 6 is almost retained during sintering, without grain size growth takes place. This results in a grain boundary phase 4.
• This grain boundary phase 4 has electrically insulating properties. This reduces the eddy current losses in the permanent magnet 1 during operation in, for example, an electric motor or generator. During sintering, air trapped in the magnetic material 6 between the grains also remains trapped. The trapped air 10 also has an electrically insulating effect, so that eddy current losses are further reduced.
• the sintering can be carried out instead of in air also under a protective gas atmosphere, preferably under nitrogen or argon, so that these gases are trapped and have an insulating effect.
• the likewise laser-sintered second layer 8 also comprises neodymium-iron-boron as magnetic material 6 in this example, but also glass particles 11 as non-metallic material and air 10 still trapped next thereto. Also in the second layer 8 remains the spherical shape of the magnetic material 6 during sintering almost without grain size growth in the particle takes place.
• the introduction of non-metallic material is carried out with a maximum weight fraction ⁇ 10%, preferably ⁇ 5%.
• the size of the permanent magnet 1 decreases at constant magnetic properties in comparison to currently used permanent magnets with a weight fraction of non-metallic materials of 20%.
• an electron beam is used at the location of the laser beam 2.

Landscapes

• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Power Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Materials Engineering (AREA)
• Plasma & Fusion (AREA)
• Physics & Mathematics (AREA)
• Crystallography & Structural Chemistry (AREA)
• Inorganic Chemistry (AREA)
• Mechanical Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Composite Materials (AREA)
• Hard Magnetic Materials (AREA)
• Permanent Field Magnets Of Synchronous Machinery (AREA)

Applications Claiming Priority (2)

Publications (1)

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Cited By (7)

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Citations (2)

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• 2012
  • 2012-06-15 DE DE102012210081A patent/DE102012210081A1/de not_active Withdrawn
• 2013
  • 2013-04-24 WO PCT/EP2013/058519 patent/WO2013185967A1/fr not_active Ceased

Patent Citations (2)

Non-Patent Citations (2)

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