CN104348264B - 混合动力汽车驱动电机专用磁钢及其制备方法 - Google Patents
混合动力汽车驱动电机专用磁钢及其制备方法 Download PDFInfo
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Abstract
本发明涉及一种混合动力汽车驱动电机专用磁钢及其制备方法。所述混合动力汽车驱动电机专用磁钢的成分表达式为：(RE)y‑Mz‑Fe100‑y‑ zB0.95‑1.05，其中25≤y≤32，2.5≤z≤5，RE由下列稀土元素组成：镨钕、镝和铽，其中镨钕的含量为22~24.5，镝的含量为2.5~6，铽的含量为0.5~1.5，镨钕、镝和铽含量之和范围为y的范围，即25~32，M由下列几种元素组成：Co、Al、Ga、Cu和Zr，其中Co的含量至少为2.0，其余四种元素含量之和为0.5~3.0，五种元素含量之和范围为Z的范围，即2.5~5.0。本发明通过对混合动力汽车驱动电机专用磁钢的成分进行设计及生产工艺进行改进，使产品的材料成本降低，综合性能提高，在性价比方面全面提升，提高了磁性能、抗退磁性。
Description
技术领域
本发明涉及一种混合动力汽车驱动电机专用磁钢及其制备方法。
背景技术
随着全球能源日趋紧张，汽车尾气污染日趋严重，环保节能的产品将成为新的宠儿，混合动力汽车因具有能耗低、排放有害气体少而必将大力提倡使用，需求逐渐增加。而制造驱动电机的耐高温、抗退磁钕铁硼磁钢在混合动力汽车中的应用也日趋增大，具有巨大的发展空间。
目前汽车对驱动电机有着特殊的要求，电动汽车驱动电机需要有4-5倍的过载以满足短时加速或爬坡的要求，而工业电机只要求有2倍的过载；电动汽车的最高转速要求达到在公路上巡航时基本速度的4-5倍，而工业电机只需要达到恒功率是基本速度的2倍即可；电动汽车驱动电机需要根据车型和驾驶员的驾驶习惯设计，而工业电机只需根据典型的工作模式设计；电动汽车驱动电机要求有高度功率密度(一般要求达到1KG/KW以内)和好的效率图(在较宽的转速范围和转矩范围内都有较高的效率)，从而能够降低车重，延长续驶里程；而工业电机通常对功率密度、效率和成本进行综合考虑，在额定工作点附近对效率进行优化；电动汽车驱动电机要求工作可控性高、稳定精度高、动态性能好；而工业电机只有某一种特定的性能要求；电动汽车驱动电机被装在机动车上，空间小，工作在高温、坏天气、及频繁振动等等恶劣环境下，而工业电机通常在某一固定位置工作。
相比传统工业电机，电动汽车驱动电机的设计要求和参数更高，而电机的核心性能是根据电机内的磁体来决定的，这就对电机磁钢的性能要求相当高，需要磁钢具有高性能、高矫顽力和耐高温、抗退磁等特性，需要将磁钢的综合性能达到极限，本发明旨在设计一种混合动力汽车驱动电机专用磁钢及其制备方法。
发明内容
本发明的目的在于解决现有技术的不足，提供一种混合动力汽车驱动电机专用磁钢。
本发明的另一个目的是提供一种混合动力汽车驱动电机专用磁钢的制备方法。
本发明解决其技术问题所采用的技术方案是：
混合动力汽车驱动电机专用磁钢，所述混合动力汽车驱动电机专用磁钢的成分表达式为：(RE)y-Mz-Fe100-y-zB0.95-1.05，其中25≤y≤32，2.5≤z≤5，RE由下列稀土元素组成：镨钕、镝和铽，其中镨钕的含量为22～24.5，镝的含量为2.5～6，铽的含量为0.5～1.5，镨钕、镝和铽含量之和范围为y的范围，即25～32，M由下列几种元素组成：Co、Al、Ga、Cu和Zr，其中Co的含量至少为2.0，其余四种元素含量之和为0.5～3.0，五种元素含量之和范围为Z的范围，即2.5～5.0。
要实现混合动力汽车驱动电机专用磁钢耐高温、高性能、高矫顽力和抗退磁，磁钢的各元素组成非常关键，尤其是镝、铽和Co元素的含量，本发明的混合动力汽车驱动电机专用磁钢通过对其成分合理设计，调整各微量元素的含量，其中镝的含量为2.5～6，铽的含量为0.5～1.5，Co的含量至少为2.0，配以本发明的生产工艺，获得的磁钢产品性价比方面全面提升，尤其是耐高温和抗退磁性能显著提高。另外本申请的发明人研究发现当镝和铽的含量不在本发明的范围内，以及Co的含量少于2.0，通过本发明的生产工艺制得的磁钢性能达不到本发明的混合动力汽车驱动电机专用磁钢的性能。
一种混合动力汽车驱动电机专用磁钢的制备方法，所述方法按如下步骤进行：
(1)利用真空感应速凝炉，将准备好的所有原料在氩气保护下，在1480-1580℃温度下熔化，熔化后在1450～1550℃精炼30～35min，然后冷却浇铸成0.3-0.6μm厚的铸片；
(2)步骤(1)的铸片经过氢破碎，获得粒径小于40目的粗磁粉；
(3)将步骤(2)得到的粗磁粉与抗氧化剂混合均匀，然后进一步经过气流磨破碎成2.5-3.0μm的细磁粉，抗氧化剂的用量为粗磁粉质量的1.0％；
(4)将步骤(3)得到的细磁粉与抗氧化剂混合均匀，抗氧化剂的用量为细磁粉质量的1.2％，采用氮气保护密封箱压机成型，真空封装坯料，经过冷等静压，然后在氮气保护密封箱中拆袋，装盒；
(5)装盒完毕后进真空烧结炉中于真空度0.1pa下脱蜡处理，脱蜡完毕后于1050℃～1090℃烧结处理4-5h，再分别于890℃-920℃和470℃-510℃时效处理2h和3-4.5h，最终获得混合动力汽车驱动电机专用磁钢。
所述步骤(3)和步骤(4)中的抗氧化剂由山梨醇、聚环氧乙烷烷基醚和石油醚充分搅拌混合均匀组成，山梨醇和聚环氧乙烷烷基醚二者的质量百分比含量≤10％。
步骤(3)气流磨碎中系统中含氧量控制在60-80ppm。
本发明的有益效果是：
1、通过对混合动力汽车驱动电机专用磁钢的成分进行设计及生产工艺进行改进，使产品的材料成本降低，综合性能提高，在性价比方面全面提升，提高了磁性能、抗退磁性；
2.采用快凝铸片、氢破碎工艺路线，同时采取强力气流磨粉，控制磁粉粒度分布范围，实现平均粒度在2.5～3.0微米之间，采用分段烧结及时效处理，降低最高烧结温度，实现细化晶粒、改善微结构的目标；
3.实行过程抗氧化防护体系，采用自主研发的抗氧化剂，在制粉和压制成型时全过程保护磁粉，避免氧化发生，消除因氧化造成的磁性能下降和耐温特性降低；
4.改进细粉粒度分布，改善磁体结构，提高磁体的稳定性和磁性能均匀性。
具体实施方式
下面通过具体实施例，对本发明的技术方案作进一步的具体说明。
镨钕：购自包钢稀土新材料有限公司；硼铁：购自辽阳国际硼合金有限公司，纯铁，选用武钢纯铁，其它原料采用市购常规原料。
气流磨：吉林新大科机电技术有限责任公司，型号QLMR-300，喷嘴压力设置为0.58-0.62Mpa，分选轮转速设置在3300-3700r/min。
实施例1：
混合动力汽车驱动电机专用磁钢，所述混合动力汽车驱动电机专用磁钢的成分表达式为：(RE)25-M2.5-Fe72.5B0.95，RE由下列稀土元素组成：镨钕、镝和铽，其中镨钕的含量为22，镝的含量为2.5，铽的含量为0.5，M由下列几种元素组成：Co、Al、Ga、Cu和Zr，其中Co的含量为2.0，Al的含量为0.1，Ga的含量为0.2、Cu的含量为0.1和Zr的含量为0.1。
上述混合动力汽车驱动电机专用磁钢的制备方法按如下步骤进行：
(1)利用真空感应速凝炉，将准备好的所有原料在氩气保护下，在1480-1530℃温度下熔化，熔化后在1450～1500℃精炼30～35min，然后冷却浇铸成0.3-0.4μm厚的铸片；
(2)步骤(1)的铸片经过氢破碎，获得粒径小于40目的粗磁粉；
(3)将步骤(2)得到的粗磁粉与抗氧化剂混合均匀，然后进一步经过气流磨破碎成2.5-2.8μm的细磁粉，抗氧化剂的用量为粗磁粉质量的1.0％，气流磨碎中系统中含氧量控制在60-80ppm；
(4)将步骤(3)得到的细磁粉与抗氧化剂混合均匀，抗氧化剂的用量为细磁粉质量的1.2％，采用氮气保护密封箱压机成型，真空封装坯料，经过冷等静压，然后在氮气保护密封箱中拆袋，装盒；
(5)装盒完毕后进真空烧结炉中于真空度0.1pa下脱蜡处理，脱蜡完毕后于1050℃～1070℃烧结处理5h，再分别于890℃-900℃和470℃-490℃时效处理2h和4.5h，最终获得混合动力汽车驱动电机专用磁钢。
所述步骤(3)和步骤(4)中的抗氧化剂由山梨醇4％(质量百分数)、聚环氧乙烷烷基醚4％和石油醚92％充分搅拌混合均匀组成。
实施例2：
混合动力汽车驱动电机专用磁钢，所述混合动力汽车驱动电机专用磁钢的成分表达式为：(RE)32-M5.0-Fe63B1.05，RE由下列稀土元素组成：镨钕、镝和铽，其中镨钕的含量为24.5，镝的含量为6，铽的含量为1.5，M由下列几种元素组成：Co、Al、Ga、Cu和Zr，其中Co的含量为3.0，Al的含量为0.5，Ga的含量为0.5、Cu的含量为0.5和Zr的含量为0.5。
上述混合动力汽车驱动电机专用磁钢的制备方法按如下步骤进行：
(1)利用真空感应速凝炉，将准备好的所有原料在氩气保护下，在1550-1580℃温度下熔化，熔化后在1500～1550℃精炼30～35min，然后冷却浇铸成0.5-0.6μm厚的铸片；
(2)步骤(1)的铸片经过氢破碎，获得粒径小于40目的粗磁粉；
(3)将步骤(2)得到的粗磁粉与抗氧化剂混合均匀，然后进一步经过气流磨破碎成2.8-3.0μm的细磁粉，抗氧化剂的用量为粗磁粉质量的1.0％，气流磨碎中系统中含氧量控制在60-80ppm；
(4)将步骤(3)得到的细磁粉与抗氧化剂混合均匀，抗氧化剂的用量为细磁粉质量的1.2％，采用氮气保护密封箱压机成型，真空封装坯料，经过冷等静压，然后在氮气保护密封箱中拆袋，装盒；
(5)装盒完毕后进真空烧结炉中于真空度0.1pa下脱蜡处理，脱蜡完毕后于1070℃～1090℃烧结处理4h，再分别于910℃-920℃和500℃-510℃时效处理2h和3h，最终获得混合动力汽车驱动电机专用磁钢。
所述步骤(3)和步骤(4)中的抗氧化剂由山梨醇2％(质量百分数)、聚环氧乙烷烷基醚8％和石油醚90％充分搅拌混合均匀组成。
对比例：
对比例磁钢的成分表达式同实施例2，不同点是镝、铽和Co元素的含量不同于本发明所设计的保护范围。
对比例磁钢，成分表达式为：(RE)32-M5.0-Fe63B1.05，RE由下列稀土元素组成：镨钕、镝和铽，其中镨钕的含量为22，镝的含量为8，铽的含量为2，M由下列几种元素组成：Co、Al、Ga、Cu和Zr，其中Co的含量为1.5，Al的含量为1.0，Ga的含量为1.5、Cu的含量为1.0和Zr的含量为1.0。
上述混合动力汽车驱动电机专用磁钢的制备方法按如下步骤进行：
(1)利用真空感应速凝炉，将准备好的所有原料在氩气保护下，在1550-1580℃温度下熔化，熔化后在1500～1550℃精炼30～35min，然后冷却浇铸成0.5-0.6μm厚的铸片；
(2)步骤(1)的铸片经过氢破碎，获得粒径小于40目的粗磁粉；
(3)将步骤(2)得到的粗磁粉与抗氧化剂混合均匀，然后进一步经过气流磨破碎成2.8-3.0μm的细磁粉，抗氧化剂的用量为粗磁粉质量的1.0％，气流磨碎中系统中含氧量控制在60-80ppm；
(4)将步骤(3)得到的细磁粉与抗氧化剂混合均匀，抗氧化剂的用量为细磁粉质量的1.2％，采用氮气保护密封箱压机成型，真空封装坯料，经过冷等静压，然后在氮气保护密封箱中拆袋，装盒；
(5)装盒完毕后进真空烧结炉中于真空度0.1pa下脱蜡处理，脱蜡完毕后于1070℃～1090℃烧结处理4h，再分别于910℃-920℃和500℃-510℃时效处理2h和3h，最终获得混合动力汽车驱动电机专用磁钢。
所述步骤(3)和步骤(4)中的抗氧化剂由山梨醇2％(质量百分数)、聚环氧乙烷烷基醚8％和石油醚90％充分搅拌混合均匀组成。
实施例1和2制得的混合动力汽车驱动电机专用磁钢、对比例制得的磁钢以及市购的日本NEOMAX(牌号NMX-S34GH)、TDK(35NX)磁钢的磁性能检测结果如下：
工作温度定义：在指定温度下保温2小时，当磁体的磁不可逆损失小于5％时，该指定温度定义为该磁体的工作温度。
通过比较，可以看出本发明的专用磁钢在剩磁、矫顽力、内禀矫顽力、最大磁能积及最大工作温度等方面达到甚至在某些方面超过国外知名企业相近牌号产品的技术水平。
以上所述的实施例只是本发明的一种较佳的方案，并非对本发明作任何形式上的限制，在不超出权利要求所记载的技术方案的前提下还有其它的变体及改型。
Claims (3)
1.混合动力汽车驱动电机专用磁钢，其特征在于：所述混合动力汽车驱动电机专用磁钢的成分表达式为：(RE)y-Mz-Fe100-y-zB0.95-1.05，其中25≤y≤32，2.5≤z≤5，RE由下列稀土元素组成：镨钕、镝和铽，其中镨钕的含量为22～24.5，镝的含量为2.5～6，铽的含量为0.5～1.5，M由下列几种元素组成：Co、Al、Ga、Cu和Zr，其中Co的含量至少为2.0。
2.一种权利要求1所述的混合动力汽车驱动电机专用磁钢的制备方法，其特征在于：所述方法按如下步骤进行：
(1)利用真空感应速凝炉，将准备好的所有原料在氩气保护下，在1480-1580℃温度下熔化，熔化后在1450～1550℃精炼30～35min，然后冷却浇铸成0.3-0.6μm厚的铸片；
(2)步骤(1)的铸片经过氢破碎，获得粒径小于40目的粗磁粉；
(3)将步骤(2)得到的粗磁粉与抗氧化剂混合均匀，然后进一步经过气流磨破碎成2.5-3.0μm的细磁粉，抗氧化剂的用量为粗磁粉质量的1.0％；
(4)将步骤(3)得到的细磁粉与抗氧化剂混合均匀，抗氧化剂的用量为细磁粉质量的1.2％，采用氮气保护密封箱压机成型，真空封装坯料，经过冷等静压，然后在氮气保护密封箱中拆袋，装盒；
(5)装盒完毕后进真空烧结炉中于真空度0.1pa下脱蜡处理，脱蜡完毕后于1050℃～1090℃烧结处理4-5h，再分别于890℃-920℃和470℃-510℃时效处理2h和3-4.5h，最终获得混合动力汽车驱动电机专用磁钢；
所述步骤(3)和步骤(4)中的抗氧化剂由山梨醇、聚环氧乙烷烷基醚和石油醚充分搅拌混合均匀组成，山梨醇和聚环氧乙烷烷基醚二者的质量百分比含量≤10％。
3.根据权利要求2所述的混合动力汽车驱动电机专用磁钢的制备方法，其特征在于：步骤(3)气流磨破碎中气流含氧量控制在60-80ppm。
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Date of cancellation: 20230814 Granted publication date: 20170222 Pledgee: Bank of China Limited by Share Ltd. Anji county subbranch Pledgor: ZHEJIANG SHEENSEN MAGNETICS TECHNOLOGY Co.,Ltd. Registration number: Y2022980012084 |
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Denomination of invention: Special magnetic steel for driving motors of hybrid electric vehicles and its preparation method Effective date of registration: 20231022 Granted publication date: 20170222 Pledgee: Zhejiang Anji Rural Commercial Bank of the West Branch of Limited by Share Ltd. Pledgor: Zhejiang Xinsheng Permanent Magnet Technology Co.,Ltd. Registration number: Y2023330002415 |
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