CN119008216A - Preparation method of high-superposition low-loss Fe-Si-Al metal magnetic powder core - Google Patents
Preparation method of high-superposition low-loss Fe-Si-Al metal magnetic powder core Download PDFInfo
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- 229910052751 metal Inorganic materials 0.000 title claims abstract description 25
- 239000002184 metal Substances 0.000 title claims abstract description 25
- 239000006247 magnetic powder Substances 0.000 title abstract description 42
- 229910002796 Si–Al Inorganic materials 0.000 title description 26
- 238000002360 preparation method Methods 0.000 title description 11
- 239000000843 powder Substances 0.000 claims abstract description 137
- 229910000702 sendust Inorganic materials 0.000 claims abstract description 78
- 238000010438 heat treatment Methods 0.000 claims abstract description 18
- 238000000576 coating method Methods 0.000 claims abstract description 16
- 239000011248 coating agent Substances 0.000 claims abstract description 15
- 238000000034 method Methods 0.000 claims abstract description 15
- 239000002245 particle Substances 0.000 claims abstract description 12
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 9
- 238000005507 spraying Methods 0.000 claims abstract description 9
- 238000009413 insulation Methods 0.000 claims abstract description 8
- 238000005470 impregnation Methods 0.000 claims abstract description 7
- 238000003825 pressing Methods 0.000 claims abstract description 4
- 238000000889 atomisation Methods 0.000 claims abstract 3
- 229910052742 iron Inorganic materials 0.000 claims abstract 2
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 24
- 239000007789 gas Substances 0.000 claims description 22
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 claims description 18
- 238000002161 passivation Methods 0.000 claims description 18
- VWDWKYIASSYTQR-UHFFFAOYSA-N sodium nitrate Chemical compound [Na+].[O-][N+]([O-])=O VWDWKYIASSYTQR-UHFFFAOYSA-N 0.000 claims description 18
- -1 iron silicon aluminum Chemical compound 0.000 claims description 17
- 238000003756 stirring Methods 0.000 claims description 14
- 238000003723 Smelting Methods 0.000 claims description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical group O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
- 238000001035 drying Methods 0.000 claims description 9
- 239000004317 sodium nitrate Substances 0.000 claims description 9
- 235000010344 sodium nitrate Nutrition 0.000 claims description 9
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 8
- 239000011521 glass Substances 0.000 claims description 8
- 238000001816 cooling Methods 0.000 claims description 7
- 239000007788 liquid Substances 0.000 claims description 7
- 239000000463 material Substances 0.000 claims description 7
- 238000000465 moulding Methods 0.000 claims description 7
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 claims description 6
- 238000000137 annealing Methods 0.000 claims description 6
- 239000003795 chemical substances by application Substances 0.000 claims description 6
- 239000008367 deionised water Substances 0.000 claims description 6
- 229910021641 deionized water Inorganic materials 0.000 claims description 6
- 239000003822 epoxy resin Substances 0.000 claims description 6
- 229920000647 polyepoxide Polymers 0.000 claims description 6
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 claims description 6
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- 239000002253 acid Substances 0.000 claims description 4
- 239000012298 atmosphere Substances 0.000 claims description 4
- 229910052757 nitrogen Inorganic materials 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- 239000002994 raw material Substances 0.000 claims description 3
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 2
- 229910052786 argon Inorganic materials 0.000 claims description 2
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 claims description 2
- 239000004327 boric acid Substances 0.000 claims description 2
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 claims description 2
- 235000013539 calcium stearate Nutrition 0.000 claims description 2
- 239000008116 calcium stearate Substances 0.000 claims description 2
- 239000001257 hydrogen Substances 0.000 claims description 2
- 229910052739 hydrogen Inorganic materials 0.000 claims description 2
- 125000004435 hydrogen atom Chemical class [H]* 0.000 claims description 2
- 239000000203 mixture Substances 0.000 claims description 2
- 235000006408 oxalic acid Nutrition 0.000 claims description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 2
- 239000012188 paraffin wax Substances 0.000 claims description 2
- 230000001681 protective effect Effects 0.000 claims description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims 2
- 238000007254 oxidation reaction Methods 0.000 claims 1
- 229920002050 silicone resin Polymers 0.000 claims 1
- 230000035699 permeability Effects 0.000 abstract description 6
- 239000011162 core material Substances 0.000 description 56
- 238000007873 sieving Methods 0.000 description 9
- 230000000052 comparative effect Effects 0.000 description 6
- 238000002156 mixing Methods 0.000 description 6
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 5
- 238000004140 cleaning Methods 0.000 description 5
- 229920005989 resin Polymers 0.000 description 5
- 239000011347 resin Substances 0.000 description 5
- 239000010703 silicon Substances 0.000 description 5
- 238000005245 sintering Methods 0.000 description 5
- 239000012300 argon atmosphere Substances 0.000 description 4
- 239000002131 composite material Substances 0.000 description 4
- 238000009689 gas atomisation Methods 0.000 description 4
- 238000002791 soaking Methods 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 235000019580 granularity Nutrition 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- DLINORNFHVEIFE-UHFFFAOYSA-N hydrogen peroxide;zinc Chemical compound [Zn].OO DLINORNFHVEIFE-UHFFFAOYSA-N 0.000 description 2
- 238000009740 moulding (composite fabrication) Methods 0.000 description 2
- 238000004321 preservation Methods 0.000 description 2
- 238000005253 cladding Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 230000003116 impacting effect Effects 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- 230000005389 magnetism Effects 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Classifications
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- 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
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
-
- 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
- H01F1/12—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 soft-magnetic materials
- H01F1/14—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 soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
- H01F1/14766—Fe-Si based alloys
- H01F1/14791—Fe-Si-Al based alloys, e.g. Sendust
-
- 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
- H01F1/12—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 soft-magnetic materials
- H01F1/14—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 soft-magnetic materials metals or alloys
- H01F1/20—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 soft-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/22—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 soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—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 soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
-
- 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
- Y02P10/20—Recycling
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Manufacturing & Machinery (AREA)
- Soft Magnetic Materials (AREA)
Abstract
本发明公开了一种高叠加低损耗铁硅铝金属磁粉芯制备方法，该铁硅铝金属磁粉芯包括以下组分和重量含量：气雾化的铁硅铝粉末1：30％～50％；气雾化的铁硅铝粉末2：50％～70％；其中，气雾化的铁硅铝粉末1由以下组分和重量含量组成：Al 5.4％、Si 9.6％、Fe 81％；气雾化的铁硅铝粉末2由以下组分和重量含量组成：Al 5.0‑6.0％、Si 7.8‑9.0％、其余为Fe；并通过雾化制粉、粒度配比、绝缘包覆、压制成型、热处理、含浸与喷涂等工艺，制备的铁硅铝金属磁粉芯实现了制备得到磁导率在60左右、磁芯损耗在150mW/cm3以下，直流叠加特性最高可达到68.5％的高叠加、低损耗性能。
The invention discloses a method for preparing a high-superposition low-loss sendust metal magnetic powder core. The sendust metal magnetic powder core comprises the following components and weight contents: aerosolized sendust powder 1: 30% to 50%; aerosolized sendust powder 2: 50% to 70%; wherein the aerosolized sendust powder 1 consists of the following components and weight contents: 5.4% Al, 9.6% Si, and 81% Fe; the aerosolized sendust powder 2 consists of the following components and weight contents: 5.0-6.0% Al, 7.8-9.0% Si, and the rest Fe; and through atomization powder making, particle size ratio, insulation coating, pressing, heat treatment, impregnation, spraying and other processes, the sendust metal magnetic powder core prepared realizes the high superposition and low-loss performance of the prepared magnetic permeability of about 60, the core loss of less than 150mW/ cm3 , and the DC superposition characteristic can reach up to 68.5%.
Description
Technical Field
The invention relates to the field of metal soft magnetism, in particular to a preparation method of a high-superposition low-loss iron-silicon-aluminum metal magnetic powder core.
Background
With the technological development of the recent trend, miniaturization and light weight of devices have led to miniaturization and high power density of electronic devices, and thus magnetic powder core materials having high magnetic flux density, high dc bias performance, and high frequency and low loss have been used. The iron-silicon-aluminum magnetic powder core is used as a soft magnetic material with good high-frequency performance and low cost, is widely applied to devices such as an output inductance line filter, a power factor corrector and the like, and has increasingly increased market demands, but because of factors of the material, the direct current superposition performance of the iron-silicon-aluminum material is the lowest in all alloy magnetic powder cores, and the application of the iron-silicon-aluminum material in high direct current and alternating current bias fields is severely limited. How to improve the direct current superposition performance on the basis of reducing the loss of the direct current superposition circuit becomes a great challenge in the research nowadays.
In the patent application with publication number CN 114551021A, a preparation method of a low-loss sendust-based composite soft magnetic powder core is disclosed, wherein 400-mesh gas atomized sendust powder and 200-mesh sendust powder are selected, and the mass percentage of alloy components is 55%:45 percent, the prepared low-loss 60 mu iron-silicon-aluminum-based composite soft magnetic powder core has the advantages of low loss and high direct current bias performance, the direct current bias performance of the powder core under the condition of 100Oe is higher than 70 percent, the volume loss Pcv under the conditions of 50kHz and 100mT is lower than 100mW/cm 3, the performance of the magnetic powder core is very excellent, but the iron-nickel magnetic powder is added, the component elements of the iron-silicon-aluminum powder are deviated, and the price and the cost are high. Publication number CN109979740a discloses a low-loss sendust core insulating coating method, which comprises the following steps: preparing metal soft magnetic powder, phosphating, drying, insulating coating, drying and sieving, press forming, annealing and sintering, wherein the invention can obtain the magnetic powder core with the following properties: the magnetic permeability was 60-70, the low core loss was 270mW/cm 3, the test conditions were 50kHz,100mT, but no mention was made of improving the DC superposition characteristics.
Disclosure of Invention
In order to solve the technical problems, the invention aims to provide a preparation method of a high-superposition low-loss sendust magnetic powder core, wherein powder component adjustment and particle size optimization are performed on the magnetic powder core, and the prepared sendust magnetic powder core is low in loss and high in direct current bias performance.
In order to achieve the above purpose, the technical scheme provided by the invention is as follows:
a high-superposition low-loss sendust magnetic powder core comprises the following components in parts by weight:
1 to 50 percent of gas atomized Fe-Si-Al powder;
2 to 70 percent of gas atomized Fe-Si-Al powder;
wherein, the aerosolised sendust powder 1 consists of the following components in percentage by weight: 5.4% of Al, 9.6% of Si and 81% of Fe; the aerosolized sendust 2 consists of the following components in weight content: 5.0-6.0% of Al, 7.8-9.0% of Si and the balance of Fe.
Preferably, the gas atomized sendust powder 1 is selected from a granularity interval of-200 to +400 meshes, and the gas atomized sendust powder 2 is selected from a granularity interval of-400 meshes.
The preparation method of the high-superposition low-loss sendust magnetic powder core comprises the following specific steps:
Step one: atomizing and pulverizing: weighing the raw materials according to the component proportion, putting the raw materials into a vacuum intermediate frequency furnace for smelting, pouring the smelted molten steel into atomizing equipment, and simultaneously, impacting the molten steel with high-pressure nitrogen to prepare gas atomized Fe-Si-Al powder 1 and gas atomized Fe-Si-Al powder 2;
Step two: particle size ratio: the method comprises the steps of (1) screening the gas-atomized Fe-Si-Al powder 1 and the gas-atomized Fe-Si-Al powder 2 according to the particle size of a region, selecting the powder particle sizes required by the gas-atomized Fe-Si-Al powder 1 and the gas-atomized Fe-Si-Al powder 2, carrying out particle size proportioning, and mixing according to a proportion to obtain raw powder to be passivated;
Step three: insulating coating: adding the prepared passivation solution into the raw powder to be passivated in the second step, uniformly stirring, then parching on a heating furnace, cooling to form passivated powder, adding 1.0wt.% of organic silicon resin acetone solution into the passivated powder, uniformly stirring, heating, parching, then placing in an oven for drying, taking out, and cooling to obtain the iron-silicon-aluminum powder with the insulation coating completed;
Step four: and (5) press forming: adding a release agent and auxiliary materials into the iron-silicon-aluminum powder subjected to insulating coating, uniformly stirring, and pressing into a ring shape to obtain a ring-shaped sample;
Step five: and (3) heat treatment: placing the annular sample in a tube furnace for heat treatment under a protective atmosphere to obtain a magnetic core;
step six: impregnating and spraying: and (3) placing the magnetic core into an immersion liquid prepared by mixing epoxy resin and acetone in proportion, immersing for a certain time, cleaning, placing into an oven for baking, and then placing into a coating machine for spraying to obtain the high-superposition low-loss sendust magnetic powder core.
Preferably, in the third step, the passivation solution comprises the following components in percentage by mass: weak acid 0.1-0.3%, sodium nitrate solution 0.2-0.8%, nano-oxide powder 0.3-5%, deionized water for the rest, and controlling pH value of passivation solution to 4-7. The sodium nitrate solution is 80-90% sodium nitrate solution which is commercially available.
Preferably, the weak acid is one or more of oxalic acid, acetic acid and boric acid.
Preferably, the nano-oxide powder is one or more of zinc oxide powder, aluminum oxide powder and silicon dioxide powder.
Preferably, in the third step, the temperature of the oven is 150-200 ℃ and the drying time is 20-30 min.
Preferably, in the fourth step, the auxiliary material is glass powder, and the release agent is one or more of zinc stearate, calcium stearate and paraffin wax.
Preferably, in the fourth step, the mass ratio of the iron-silicon-aluminum powder, the release agent and the glass powder which are subjected to insulating coating is 100:0.6:0.2, and the molding pressure is 800-1200 MPa.
Preferably, in the fifth step, the annealing temperature is 600-700 ℃, the heating rate is 10 ℃/min, the heat preservation time is 1 hour, the annealing atmosphere is one or a mixture of a plurality of gases selected from hydrogen, nitrogen and argon, and the annealing is rapidly cooled after the heat preservation is finished.
Compared with the prior art, the technical scheme provided by the invention has the following remarkable effects: the invention relates to a high-superposition low-loss sendust magnetic powder core, which comprises aerosolised sendust powder 1 and aerosolised sendust powder 2, wherein the powder of the two components is screened by different granularities, and sendust powder with better comprehensive performance is selected; in the preparation method of the magnetic powder core, a passivation method is optimized to form a main composite insulating layer and an auxiliary composite insulating layer, so that the insulating layers are more uniform and compact, the concentration and the pH value of passivation solution are controlled pertinently, the magnetic powder with different components is effectively subjected to corrosion passivation, sodium nitrate is used as an oxidizing salt to perform in-situ passivation on the magnetic powder, the reaction is mild, the main insulating layer is effectively formed, nano oxidized powder is used for carrying out auxiliary insulating layer, the gap of the main insulating layer is repaired, and the iron-silicon-aluminum metal magnetic powder core with high superposition and low loss performance, wherein the magnetic permeability is about 60, the magnetic core loss is below 150mW/cm 3, and the direct current superposition characteristic can reach 68.5% maximally.
Drawings
FIG. 1 is a graph of DC-Bias for the sendust core product of example 1;
Fig. 2 is a graph of loss of the sendust core product of example 1.
Detailed Description
The low-loss sendust core insulation cladding method will be described in connection with examples.
Example 1:
the embodiment 1 discloses a high-superposition low-loss sendust magnetic powder core, which comprises the following components in parts by weight:
1% of aerosolised Fe-Si-Al powder;
2% of aerosolised Fe-Si-Al powder;
wherein, the aerosolised sendust powder 1 consists of the following components in percentage by weight: 5.4% of Al, 9.6% of Si and 81% of Fe; the aerosolized sendust 2 consists of the following components in weight content: 5.0% of Al, 8.2% of Si and the balance of Fe.
The embodiment 1 also discloses a preparation method of the high-superposition low-loss sendust magnetic powder core, which comprises the following specific steps:
Step one: smelting the gas-atomized sendust powder 1 and the gas-atomized sendust powder 2 by adopting a vacuum gas-atomization smelting furnace;
step two: sieving out the gas atomized Fe-Si-Al powder 1 in the step one to obtain powder of-200 to +400 meshes, and sieving out the gas atomized Fe-Si-Al powder 2 to obtain powder of-400 meshes according to the following steps: 1, mixing powder and feeding to form raw powder to be passivated;
Step three: preparing a passivation solution with pH of 5 according to the proportion of 0.1% of acetic acid, 0.8% of sodium nitrate solution, 0.3% of nano zinc dioxide powder and the balance of deionized water, pouring raw powder to be passivated into the passivation solution, heating in a water bath at 90 ℃, stirring until the solution is evaporated to dryness, adding the passivated powder into 1.0wt.% of organic silicon resin acetone solution, stirring uniformly, heating and parching to dryness, then placing in a baking oven at 180 ℃ for 20min, taking out and cooling;
step four: the cooled powder is added with zinc stearate and glass powder with the mass ratio of 0.6wt% and 0.2wt% and is evenly mixed, and pressed and molded under the molding pressure of 1200 MPa.
Step five: placing the sample in an argon atmosphere furnace at 600 ℃ for sintering for 1 hour to obtain a magnetic core;
Step six: and (3) placing the magnetic core into 40% epoxy resin acetone impregnation liquid, soaking for a certain time, cleaning, placing into an oven for baking, and then placing into a coating machine for spraying to obtain the iron-silicon-aluminum metal magnetic powder core.
Comparative example 1:
The embodiment 1 discloses a high-superposition low-loss sendust magnetic powder core, which consists of the following components in percentage by weight:
1% of aerosolised Fe-Si-Al powder;
2% of gas atomized Fe-Si-Al powder;
wherein, the aerosolised sendust powder 1 consists of the following components in percentage by weight: 5.4% of Al, 9.6% of Si and 81% of Fe; the aerosolized sendust 2 consists of the following components in weight content: 5.0% of Al, 8.2% of Si and the balance of Fe.
The embodiment 1 also discloses a preparation method of the high-superposition low-loss sendust magnetic powder core, which comprises the following specific steps:
Step one: smelting the gas-atomized sendust powder 1 and the gas-atomized sendust powder 2 by adopting a vacuum gas-atomization smelting furnace;
Step two: sieving out the gas atomized Fe-Si-Al powder 1 in the step one to obtain powder of-200 to +400 meshes, and sieving out the gas atomized Fe-Si-Al powder 2 to obtain powder of-400 meshes according to the following steps: 9, mixing powder and feeding to form raw powder to be passivated;
step three: preparing a passivation solution with the pH value of 5 according to the proportion of 0.1 percent of acetic acid, 0.8 percent of sodium nitrate solution, 0.3 percent of nano zinc dioxide powder and the balance of deionized water, pouring raw powder to be passivated into the passivation solution, heating in a water bath at 90 ℃, stirring until the solution is evaporated to dryness, adding the passivated powder into 1.0wt.% of organic silicon resin acetone solution, stirring uniformly, heating and parching to dryness, then placing in a baking oven at 180 ℃ for drying for 20min, taking out and cooling;
step four: the cooled powder is added with zinc stearate and glass powder with the mass ratio of 0.6wt% and 0.2wt% and is evenly mixed, and pressed and molded under the molding pressure of 1200 MPa.
Step five: placing the sample in an argon atmosphere furnace at 600 ℃ for sintering for 1 hour to obtain a magnetic core;
Step six: and (3) placing the magnetic core into 40% epoxy resin acetone impregnation liquid, soaking for a certain time, cleaning, placing into an oven for baking, and then placing into a coating machine for spraying to obtain the iron-silicon-aluminum metal magnetic powder core.
Example 2:
The embodiment 1 discloses a high-superposition low-loss sendust magnetic powder core, which consists of the following components in percentage by weight:
1% of aerosolised Fe-Si-Al powder;
2% of gas atomized Fe-Si-Al powder;
wherein, the aerosolised sendust powder 1 consists of the following components in percentage by weight: 5.4% of Al, 9.6% of Si and 81% of Fe; the aerosolized sendust 2 consists of the following components in weight content: 5.0% of Al, 8.9% of Si and the balance of Fe.
The embodiment 1 also discloses a preparation method of the high-superposition low-loss sendust magnetic powder core, which comprises the following specific steps:
Step one: smelting the gas-atomized sendust powder 1 and the gas-atomized sendust powder 2 by adopting a vacuum gas-atomization smelting furnace;
Step two: sieving out the gas atomized Fe-Si-Al powder 1 in the step one to obtain powder of-200 to +400 meshes, and sieving out the gas atomized Fe-Si-Al powder 2 to obtain powder of-400 meshes according to the following steps: mixing and feeding to form raw powder to be passivated;
Step three: preparing a passivation solution with the pH value of 4 according to the proportion of 0.3 percent of acetic acid, 0.5 percent of sodium nitrate solution, 0.5 percent of nano silicon dioxide powder and the balance of deionized water, pouring the raw powder to be passivated into the passivation solution, heating in a water bath at 90 ℃, stirring until the solution is evaporated to dryness, adding the passivated powder into 0.9wt.% of organic silicon resin acetone solution, stirring uniformly, heating and parching to dryness, then placing in a baking oven at 150 ℃ for drying for 30min, taking out and cooling;
step four: the cooled powder is added with zinc stearate and glass powder with the mass ratio of 0.6wt% and 0.2wt% and is evenly mixed, and pressed and molded under the molding pressure of 1200 MPa.
Step five: placing the sample in an argon atmosphere furnace at 600 ℃ for sintering for 1 hour to obtain a magnetic core;
Step six: and (3) placing the magnetic core into 40% epoxy resin acetone impregnation liquid, soaking for a certain time, cleaning, placing into an oven for baking, and then placing into a coating machine for spraying to obtain the iron-silicon-aluminum metal magnetic powder core.
Comparative example 2:
The embodiment 1 discloses a high-superposition low-loss sendust magnetic powder core, which consists of the following components in percentage by weight:
1% of aerosolised sendust powder;
2% of gas atomized Fe-Si-Al powder;
wherein, the aerosolised sendust powder 1 consists of the following components in percentage by weight: 5.4% of Al, 9.6% of Si and 81% of Fe; the aerosolized sendust 2 consists of the following components in weight content: 5.0% of Al, 8.9% of Si and the balance of Fe.
The embodiment 1 also discloses a preparation method of the high-superposition low-loss sendust magnetic powder core, which comprises the following specific steps:
Step one: smelting the gas-atomized sendust powder 1 and the gas-atomized sendust powder 2 by adopting a vacuum gas-atomization smelting furnace;
Step two: sieving out the gas atomized Fe-Si-Al powder 1 in the step one to obtain powder of-200 to +400 meshes, and sieving out the gas atomized Fe-Si-Al powder 2 to obtain powder of-400 meshes according to the following steps of 9:1, mixing powder and feeding to form raw powder to be passivated;
Step three: preparing a passivation solution with the pH value of 4 according to the proportion of 0.3 percent of acetic acid, 0.5 percent of sodium nitrate solution, 0.5 percent of nano silicon dioxide powder and the balance of deionized water, pouring the raw powder to be passivated into the passivation solution, heating in a water bath at 90 ℃, stirring until the solution is evaporated to dryness, adding the passivated powder into 0.9wt.% of organic silicon resin acetone solution, stirring uniformly, heating and parching to dryness, then placing in a baking oven at 150 ℃ for drying for 30min, taking out and cooling;
step four: the cooled powder is added with zinc stearate and glass powder with the mass ratio of 0.6wt% and 0.2wt% and is evenly mixed, and pressed and molded under the molding pressure of 1200 MPa.
Step five: placing the sample in an argon atmosphere furnace at 600 ℃ for sintering for 1 hour to obtain a magnetic core;
Step six: and (3) placing the magnetic core into 40% epoxy resin acetone impregnation liquid, soaking for a certain time, cleaning, placing into an oven for baking, and then placing into a coating machine for spraying to obtain the iron-silicon-aluminum metal magnetic powder core.
The sendust core samples obtained in example 1, example 2 and comparative examples 1 and 2 were subjected to performance test, wherein the DC-Bias graph of the sendust core sample of example 1 is shown in fig. 1, the loss graph of the sendust core sample of example 1 is shown in fig. 2, and the specific test results of each example and comparative example are shown in table 1 below:
Table 1: test data of magnetic permeability, magnetic core loss and DC superposition characteristic performance of each Fe-Si-Al metal magnetic powder core sample
| Group of | Permeability (20 khz,1.0 v) | Pcv(mW/cm3)(50kHz/100mT) | DC-Bias(100Oe) |
| Example 1 | 59.1 | 148 | 68.1％ |
| Comparative example 1 | 57.5 | 225 | 71％ |
| Example 2 | 58.8 | 144 | 68.5％ |
| Comparative example 2 | 59.2 | 124 | 60.2％ |
The test result shows that the permeability of the sendust magnetic powder core prepared by the method is about 60, the magnetic core loss is controllable to be below 150mW/cm 3, the direct current superposition characteristic is as high as 68.5%, and the comprehensive performance is excellent, so that the sendust magnetic powder core with high superposition performance and low loss can be obtained by the method, and the sendust magnetic powder core can be applied to devices such as an output inductance line filter, a power factor corrector and the like.
The present embodiment is only illustrative of the present patent and does not limit the scope of protection thereof, and those skilled in the art can make local changes thereto, and the equivalent replacement of the present patent is considered to be within the scope of protection of the present patent as long as the spirit of the present patent is not exceeded.
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