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WO2021114648A1 - 一种r-t-b系永磁材料、原料组合物、制备方法、应用 - Google Patents

一种r-t-b系永磁材料、原料组合物、制备方法、应用 Download PDF

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WO2021114648A1
WO2021114648A1 PCT/CN2020/100577 CN2020100577W WO2021114648A1 WO 2021114648 A1 WO2021114648 A1 WO 2021114648A1 CN 2020100577 W CN2020100577 W CN 2020100577W WO 2021114648 A1 WO2021114648 A1 WO 2021114648A1
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rtb
mass percentage
refers
permanent magnet
magnetic material
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PCT/CN2020/100577
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English (en)
French (fr)
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蓝琴
黄佳莹
陈大崑
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厦门钨业股份有限公司
福建省长汀金龙稀土有限公司
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Priority to EP20899124.0A priority Critical patent/EP4016560A4/en
Priority to US17/635,156 priority patent/US20220301754A1/en
Priority to KR1020227006967A priority patent/KR102589806B1/ko
Priority to JP2022513848A priority patent/JP7214044B2/ja
Publication of WO2021114648A1 publication Critical patent/WO2021114648A1/zh

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    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/10—Ferrous alloys, e.g. steel alloys containing cobalt
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/12—Ferrous alloys, e.g. steel alloys containing tungsten, tantalum, molybdenum, vanadium, or niobium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/16—Ferrous alloys, e.g. steel alloys containing copper
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C2202/00—Physical properties
    • C22C2202/02—Magnetic
    • 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
    • H01F41/0266—Moulding; Pressing
    • 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
    • H01F41/0293—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 diffusion of rare earth elements, e.g. Tb, Dy or Ho, into permanent magnets

Definitions

  • the invention relates to an R-T-B series permanent magnet material, raw material composition, preparation method and application.
  • Permanent magnet materials have been developed as a key material for supporting electronic devices, and the development direction is moving in the direction of high magnetic energy product and high coercivity.
  • RTB-based permanent magnet materials (R is at least one of rare earth elements) are known as the highest performance magnets in permanent magnets, and are used in voice coil motors (VCM) of hard disk drives and electric vehicles (EV, HV, PHV) Etc.)
  • VCM voice coil motors
  • EV, HV, PHV electric vehicles
  • Various motors such as motors, industrial equipment motors, and home appliances.
  • neodymium iron boron with conventional B content cannot produce R 6 -T 13 -X phase, and its magnetic properties are poor; under the premise of having a similar formulation system, if the B content (B The content is about 0.93wt.% or less), adding Ga, Cu, Al, Si, Ti to generate R 6 -T 13 -X phase (X includes Ga, Cu, Al, Si, etc.) in the magnet to improve the performance of the magnet, then Due to the decrease of B content, R 2 T 17 , TiBx and other impurity phases are easily formed in the magnet, which reduces the mechanical properties of the magnet and makes the material more brittle, which is not conducive to processing and use in high-speed motors.
  • the technical problem to be solved by the present invention is to overcome the defect in the prior art that the mechanical properties of the magnet decrease when the R 6 -T 13 -X phase is generated to improve the magnetic properties of the RTB-based permanent magnet material, and to provide an RTB-based permanent magnet Material, raw material composition, preparation method, application.
  • the present invention provides an R-T-B series permanent magnetic material I.
  • the R-T-B series permanent magnetic material I contains R, T and X;
  • the R is a rare earth element including at least Nd, and R includes RH; the RH is a heavy rare earth element;
  • the RH includes at least Dy and/or Tb;
  • the T contains at least Fe
  • the X is one or more of Al, Ga and Cu, and the X must include Al;
  • the R-T-B series permanent magnet material I satisfies the following relationship:
  • the RTB-based permanent magnetic material I includes R 2 T 14 B main phase crystalline particles, a two-grain boundary phase and a rare earth-rich phase between two adjacent R 2 T 14 B main phase crystalline particles, and the two-grain boundary
  • the phase and the rare earth-rich phase include a phase having a composition of R 6 T 13 X.
  • the ratio of Fe and B is changed by increasing the content of X and adjusting the amount of rare earths, so that R 6 -T 13 -X phase (X is one of Al, Ga and Cu can be generated with only the conventional B content). Species or multiple).
  • the T contains Fe and Co.
  • X is Al and Cu
  • Nd is 27.9 at%
  • Dy is 1.85 at%
  • Fe is 64.25 at%
  • Co is 0.77 at%
  • Al is 4.63 at%
  • Cu is 0.42 at%
  • at% refers to the percentage of the atomic content of each element in the RTB-based permanent magnet material.
  • the atom of (Fe+Co)/B is preferably 12.8-13.39, such as 12.5, 12.86, 12.88, 12.89, 12.9 or 13.9.
  • the atom of B/X is preferably 2.8-4, such as 2.8, 2.9, 3.2, 3.6, 3.8, 3.9 or 4.
  • the R-T-B series permanent magnetic material I in terms of mass percentage, includes:
  • R 31.0-32.5wt.%, and the R includes RH;
  • Ga 0-0.30wt.%
  • wt.% refers to the mass percentage in the R-T-B series permanent magnetic material I
  • the R is a rare earth element including at least Nd
  • the RH is a heavy rare earth element; the RH includes at least Dy and/or Tb;
  • the balance is Fe and unavoidable impurities.
  • the R may also include rare earth elements conventional in the art, such as Pr.
  • the content of R is preferably in the range of 31.5-32.5wt.%, such as 31wt.%, 31.5wt.%, 32wt.% or 32.5wt.%, and wt.% refers to the RTB system permanent magnet
  • wt.% refers to the RTB system permanent magnet
  • the content of the RH is preferably 0.8-2.2wt.%, such as 0.8wt.%, 1.5wt.% or 2wt.%, and wt.% refers to the content in the RTB-based permanent magnetic material I The mass percentage.
  • the Cu content is preferably in the range of 0.2-0.4wt.% or 0.3-0.5wt.%, such as 0.2wt.%, 0.3wt.%, 0.35wt.%, 0.4wt.%, 0.45wt. % Or 0.5wt.%, wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the content of Al is preferably in the range of 0.4-0.6wt.% or 0.5-0.8wt.%, such as 0.4wt.%, 0.5wt.%, 0.51wt.%, 0.6wt.%, 0.65wt. %, 0.7wt.% or 0.8wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the Ga content range is preferably 0 wt.% or 0.3 wt.%, and wt.% refers to the mass percentage in the R-T-B series permanent magnetic material I.
  • the Nb content range is preferably 0.1-0.2wt.% or 0.12-0.25wt.%, such as 0.1wt.%, 0.12wt.%, 0.15wt.%, 0.2wt.% or 0.25wt. %, wt.% refers to the mass percentage in the RTB-based permanent magnet material I.
  • the content of Co is preferably in the range of 0.5-1.5wt.% or 1-2wt.%, such as 0.5wt.%, 1wt.%, 1.2wt.% or 1.5wt.%, and wt.% means The mass percentage in the RTB-based permanent magnetic material I.
  • the content of B is preferably in the range of 0.97-1wt.% or 0.99-1.03wt.%, such as 0.97wt.%, 0.98wt.%, 0.99wt.%, 1wt.% or 1.03wt.%, wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the RTB-based permanent magnet material I includes: R is 31.0-32.5wt.%; RH is 0.8-2.2wt.%; Cu is 0.30-0.50wt.% ; Al is 0.50-0.70wt.%; Nb is 0.10-0.25wt.%; Co is 0.5-2.0wt.%; B is 0.97-1.03wt.%; wt.% refers to the RTB-based permanent magnet material
  • the RTB-based permanent magnet material I includes: R is 31.5-32.5wt.%, RH is 0.8-2.2wt.%, and Cu is 0.2-0.4wt.% ; Al is 0.4-0.6wt.%; Ga is 0-0.3wt.%; Nb is 0.1-0.2wt.%; Co is 0.5-1.5wt.%; B is 0.97-1wt.%; wt.% means The mass percentage in the RTB-based permanent magnetic material I; the R is a rare earth element including at least Nd; the RH is a heavy rare earth element; the RH includes at least Dy and/or Tb; the balance is Fe and non Impurities to avoid.
  • the RTB-based permanent magnet material I includes: PrNd is 31wt.%, Tb is 0.8wt.%, Cu is 0.3wt.%, and Al is 0.5wt.% , Nb is 0.1wt.%, Co is 0.5wt.%, B is 0.97wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the RTB-based permanent magnetic material I includes: PrNd is 31wt.%, Dy is 1.5wt.%, Cu is 0.5wt.%, and Al is 0.7wt.% , Nb is 0.25wt.%, Co is 0.5wt.%, B is 1.03wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the RTB-based permanent magnetic material I includes: PrNd is 32wt.%, Dy is 2wt.%, Cu is 0.4wt.%, and Al is 0.6wt.%, Nb is 0.2 wt.%, Co is 1 wt.%, B is 0.99 wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the RTB-based permanent magnetic material I includes: PrNd is 31.5wt.%, Dy is 1.5wt.%, Cu is 0.35wt.%, Al is 0.51wt. %, Nb is 0.15wt.%, Co is 1.5wt.%, B is 1wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the RTB-based permanent magnetic material I includes: Nd is 32.5wt.%, Dy is 2wt.%, Cu is 0.45wt.%, and Al is 0.65wt.% , Nb is 0.12wt.%, Co is 1.2wt.%, B is 0.98wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the RTB-based permanent magnetic material I includes: PrNd is 32wt.%, Dy is 2wt.%, Cu is 0.2wt.%, Al is 0.6wt.%, Nb is 0.2 wt.%, Co is 1 wt.%, B is 0.99 wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the RTB-based permanent magnetic material I includes: PrNd is 32wt.%, Dy is 2wt.%, Cu is 0.5wt.%, and Al is 0.4wt.%, Nb is 0.2 wt.%, Co is 1 wt.%, B is 0.99 wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the RTB-based permanent magnetic material I includes: PrNd is 32wt.%, Dy is 2wt.%, Cu is 0.2wt.%, and Al is 0.8wt.%, Nb is 0.2 wt.%, Co is 1 wt.%, B is 0.99 wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the RTB-based permanent magnetic material I includes: PrNd is 32wt.%, Dy is 2wt.%, Cu is 0.4wt.%, and Al is 0.4wt.%, Ga is 0.3wt.%, Nb is 0.2wt.%, Co is 1wt.%, B is 0.99wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material I.
  • the present invention also provides an R-T-B series permanent magnet material II, the R-T-B series permanent magnet material II contains R, T and X;
  • the R is a rare earth element including at least Nd, and R includes RH; the RH is a heavy rare earth element;
  • the RH includes at least Dy and/or Tb;
  • the T contains at least Fe
  • the X is one or more of Al, Ga and Cu, and the X must include Al;
  • the R-T-B series permanent magnet material II satisfies the following relationship:
  • the T contains Fe and Co.
  • the atom of (Fe+Co)/B is preferably 12.9-13, such as 12.94, 12.95, 12.96, 12.98, 12.99 or 13.
  • the atom of B/X is preferably 2.9-3.9, such as 3.2, 3.6 or 3.8.
  • the R-T-B series permanent magnet material II includes the following components:
  • R 30.5-32wt.%, and the R includes RH;
  • Ga 0-0.30wt.%
  • wt.% refers to the mass percentage in the R-T-B series permanent magnet material II
  • the R is a rare earth element including at least Nd
  • the RH is a heavy rare earth element; the RH includes at least Dy and/or Tb;
  • the balance is Fe and unavoidable impurities.
  • the R may also include rare earth elements conventional in the art, such as Pr.
  • the content of R is preferably in the range of 31-32wt.%, such as 31wt.%, 31.5wt.%, or 32wt.%, and wt.% refers to the mass in the RTB-based permanent magnetic material II percentage.
  • the content of the RH is preferably in the range of 0.3-1.7 wt.%, such as 0.3 wt.%, 1 wt.%, or 1.5 wt.%, and wt.% refers to the content in the RTB-based permanent magnetic material II The mass percentage.
  • the Cu content is preferably in the range of 0.2-0.4wt.% or 0.3-0.5wt.%, such as 0.2wt.%, 0.3wt.%, 0.35wt.%, 0.4wt.%, 0.45wt. % Or 0.5wt.%, wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the content of Al is preferably in the range of 0.4-0.6wt.% or 0.5-0.8wt.%, such as 0.4wt.%, 0.5wt.%, 0.51wt.%, 0.6wt.%, 0.65wt. %, 0.7wt.% or 0.8wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the Ga content range is preferably 0 wt.% or 0.3 wt.%, and wt.% refers to the mass percentage in the R-T-B series permanent magnetic material II.
  • the Nb content range is preferably 0.1-0.2wt.% or 0.12-0.25wt.%, such as 0.1wt.%, 0.12wt.%, 0.15wt.%, 0.2wt.% or 0.25wt. %, wt.% refers to the mass percentage in the RTB-based permanent magnet material II.
  • the content of Co is preferably in the range of 0.5-1.5wt.% or 1-2wt.%, such as 0.5wt.%, 1wt.%, 1.2wt.% or 1.5wt.%, and wt.% means The mass percentage in the RTB-based permanent magnet material II.
  • the content of B is preferably in the range of 0.97-1wt.% or 0.99-1.03wt.%, such as 0.97wt.%, 0.98wt.%, 0.99wt.%, 1wt.% or 1.03wt.%, wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the RTB-based permanent magnet material II includes: R is 30.5-32wt.%; RH is 0.3-1.7wt.%; Cu is 0.30-0.50wt.%; Al is 0.50-0.70wt.%; Nb is 0.10-0.25wt.%; Co is 0.5-2.0wt.%; B is 0.97-1.03wt.%;
  • the R is a rare earth element including at least Nd; the RH is a heavy rare earth element; the RH includes at least Dy and/or Tb; the balance is Fe and unavoidable impurities.
  • the RTB-based permanent magnet material II includes: R is 31-32wt.%, RH is 0.3-1wt.%; Cu is 0.2-0.4wt.%; Al 0.4-0.6wt.%; Ga is 0-0.3wt.%; Nb is 0.1-0.2wt.%; Co is 0.5-1.5wt.%; B is 0.97-1wt.%; wt.% refers to the The mass percentage of the RTB-based permanent magnet material II; the R is a rare earth element including at least Nd; the RH is a heavy rare earth element; the RH includes at least Dy and/or Tb; the balance is Fe and unavoidable Impurities.
  • the RTB-based permanent magnetic material II includes: PrNd is 30.5wt.%, Tb is 0.3wt.%, Cu is 0.3wt.%, Al is 0.5wt. %, Nb is 0.1wt.%, Co is 0.5wt.%, B is 0.97wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the RTB-based permanent magnetic material II includes: PrNd is 30.5wt.%, Dy is 1wt.%, Cu is 0.5wt.%, and Al is 0.7wt.% , Nb is 0.25 wt.%, Co is 0.5 wt.%, B is 1.03 wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the RTB-based permanent magnet material II includes: PrNd is 31.5wt.%, Dy is 1.5wt.%, Cu is 0.4wt.%, Al is 0.6wt. %, Nb is 0.2wt.%, Co is 1wt.%, B is 0.99wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the RTB-based permanent magnetic material II includes: PrNd is 31wt.%, Dy is 1wt.%, Cu is 0.35wt.%, and Al is 0.51wt.%, Nb is 0.15 wt.%, Co is 1.5 wt.%, B is 1 wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the RTB-based permanent magnet material II includes: Nd is 32wt.%, Dy is 1.5wt.%, Cu is 0.45wt.%, and Al is 0.65wt.% , Nb is 0.12wt.%, Co is 1.2wt.%, B is 0.98wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the RTB-based permanent magnet material II includes: PrNd is 31.5wt.%, Dy is 1.5wt.%, Cu is 0.2wt.%, Al is 0.6wt. %, Nb is 0.2wt.%, Co is 1wt.%, B is 0.99wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the RTB-based permanent magnet material II includes: PrNd is 31.5wt.%, Dy is 1.5wt.%, Cu is 0.5wt.%, Al is 0.4wt. %, Nb is 0.2wt.%, Co is 1wt.%, B is 0.99wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the RTB-based permanent magnet material II includes: PrNd is 31.5wt.%, Dy is 1.5wt.%, Cu is 0.2wt.%, Al is 0.8wt. %, Nb is 0.2wt.%, Co is 1wt.%, B is 0.99wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the RTB-based permanent magnet material II includes: PrNd is 31.5wt.%, Dy is 1.5wt.%, Cu is 0.4wt.%, Al is 0.4wt. %, Ga is 0.3wt.%, Nb is 0.2wt.%, Co is 1wt.%, B is 0.99wt.%, and wt.% refers to the mass percentage in the RTB-based permanent magnetic material II.
  • the present invention also provides a raw material composition of R-T-B series permanent magnet material II, which comprises the following components in terms of mass percentage:
  • R 30.5-32wt.%, and the R includes RH;
  • Ga 0-0.30wt.%
  • wt.% refers to the mass percentage in the raw material composition of the R-T-B series permanent magnet material II;
  • the R is a rare earth element including at least Nd
  • the RH is a heavy rare earth element; the RH includes at least Dy and/or Tb;
  • the balance is Fe and unavoidable impurities.
  • the R may also include rare earth elements conventional in the art, such as Pr.
  • the content of R is preferably in the range of 31-32wt.%, such as 31wt.%, 31.5wt.%, or 32wt.%, and wt.% refers to the content of the RTB-based permanent magnet material II.
  • the mass percentage in the raw material composition is preferably in the range of 31-32wt.%, such as 31wt.%, 31.5wt.%, or 32wt.%, and wt.% refers to the content of the RTB-based permanent magnet material II.
  • the RH content is preferably in the range of 0.3-1.7 wt.%, such as 0.3 wt.%, 1 wt.%, or 1.5 wt.%, and wt.% refers to the RTB-based permanent magnet material II The percentage of mass in the composition of raw materials.
  • the Cu content is preferably in the range of 0.2-0.4wt.% or 0.3-0.5wt.%, such as 0.2wt.%, 0.3wt.%, 0.35wt.%, 0.4wt.%, 0.45 wt.% or 0.5 wt.%, wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnetic material II.
  • the content of Al is preferably 0.4-0.6wt.% or 0.5-0.8wt.%, such as 0.4wt.%, 0.5wt.%, 0.51wt.%, 0.6wt.%, 0.65. wt.%, 0.7 wt.% or 0.8 wt.%, wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnetic material II.
  • the Ga content range is preferably 0 wt.% or 0.3 wt.%, and wt.% refers to the mass percentage in the raw material composition of the R-T-B series permanent magnetic material II.
  • the content of Nb is preferably in the range of 0.1-0.2wt.% or 0.12-0.25wt.%, such as 0.1wt.%, 0.12wt.%, 0.15wt.%, 0.2wt.% or 0.25 wt.%, wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnetic material II.
  • the content of Co is preferably in the range of 0.5-1.5wt.% or 1-2wt.%, for example 0.5wt.%, 1wt.%, 1.2wt.% or 1.5wt.%, wt.% It refers to the mass percentage in the raw material composition of the RTB-based permanent magnet material II.
  • the content of B is preferably in the range of 0.97-1wt.% or 0.99-1.03wt.%, such as 0.97wt.%, 0.98wt.%, 0.99wt.%, 1wt.% or 1.03wt. %, wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnetic material II.
  • the raw material composition of the RTB-based permanent magnet material II includes: R is 30.5-32wt.%; RH is 0.3-1.7wt.%; Cu is 0.30-0.50 wt.%; Al is 0.50-0.70wt.%; Nb is 0.10-0.25wt.%; Co is 0.5-2.0wt.%; B is 0.97-1.03wt.%; wt.% refers to the RTB system
  • the raw material composition of the RTB-based permanent magnetic material II includes: R is 31-32wt.%, RH is 0.3-1wt.%; Cu is 0.2-0.4wt. %; Al is 0.4-0.6wt.%; Ga is 0-0.3wt.%; Nb is 0.1-0.2wt.%; Co is 0.5-1.5wt.%; B is 0.97-1wt.%; wt.% Refers to the mass percentage in the raw material composition of the RTB-based permanent magnet material II; the R is a rare earth element including at least Nd; the RH is a heavy rare earth element; the RH includes at least Dy and/or Tb; The balance is Fe and unavoidable impurities.
  • the raw material composition of the RTB-based permanent magnetic material II includes: PrNd is 30.5wt.%, Tb is 0.3wt.%, Cu is 0.3wt.%, Al It is 0.5wt.%, Nb is 0.1wt.%, Co is 0.5wt.%, B is 0.97wt.%, and wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnetic material II.
  • the raw material composition of the RTB-based permanent magnet material II includes: PrNd is 30.5wt.%, Dy is 1wt.%, Cu is 0.5wt.%, and Al is 0.7wt.%, Nb is 0.25wt.%, Co is 0.5wt.%, B is 1.03wt.%, and wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnetic material II.
  • the raw material composition of the RTB-based permanent magnet material II includes: PrNd is 31.5wt.%, Dy is 1.5wt.%, Cu is 0.4wt.%, Al It is 0.6 wt.%, Nb is 0.2 wt.%, Co is 1 wt.%, B is 0.99 wt.%, and wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnetic material II.
  • the raw material composition of the RTB-based permanent magnet material II includes: PrNd is 31wt.%, Dy is 1wt.%, Cu is 0.35wt.%, and Al is 0.51. wt.%, Nb is 0.15 wt.%, Co is 1.5 wt.%, B is 1 wt.%, and wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnetic material II.
  • the raw material composition of the RTB-based permanent magnet material II includes: Nd is 32wt.%, Dy is 1.5wt.%, Cu is 0.45wt.%, and Al is 0.65wt.%, Nb is 0.12wt.%, Co is 1.2wt.%, B is 0.98wt.%, and wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnet material II.
  • the raw material composition of the RTB-based permanent magnet material II includes: PrNd is 31.5wt.%, Dy is 1.5wt.%, Cu is 0.2wt.%, Al It is 0.6 wt.%, Nb is 0.2 wt.%, Co is 1 wt.%, B is 0.99 wt.%, and wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnetic material II.
  • the raw material composition of the RTB-based permanent magnet material II includes: PrNd is 31.5wt.%, Dy is 1.5wt.%, Cu is 0.5wt.%, Al %, Nb is 0.2 wt. %, Co is 1 wt. %, B is 0.99 wt. %, and wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnetic material II.
  • the raw material composition of the RTB-based permanent magnet material II includes: PrNd is 31.5wt.%, Dy is 1.5wt.%, Cu is 0.2wt.%, Al It is 0.8 wt.%, Nb is 0.2 wt.%, Co is 1 wt.%, B is 0.99 wt.%, and wt.% refers to the mass percentage in the raw material composition of the RTB-based permanent magnetic material II.
  • the raw material composition of the RTB-based permanent magnet material II includes: PrNd is 31.5wt.%, Dy is 1.5wt.%, Cu is 0.4wt.%, Al % Is 0.4wt.%, Ga is 0.3wt.%, Nb is 0.2wt.%, Co is 1wt.%, B is 0.99wt.%, and wt.% refers to the combination of raw materials in the RTB-based permanent magnet material II The mass percentage in the product.
  • the present invention also provides a method for preparing RTB-based permanent magnet material II, which includes the following steps: casting, crushing, crushing, forming, and sintering the molten liquid of the raw material composition of the RTB-based permanent magnet material II , You can.
  • the molten liquid of the raw material composition of the RTB-based permanent magnet material II can be prepared according to a conventional method in the art, for example, smelting in a high-frequency vacuum induction melting furnace.
  • the vacuum degree of the melting furnace may be 5 ⁇ 10 -2 Pa.
  • the melting temperature may be 1500°C or less.
  • the casting process can be a conventional casting process in the field, for example: in an Ar gas atmosphere (for example, under an Ar gas atmosphere of 5.5 ⁇ 10 4 Pa), at 10 2 °C/sec-10 4 °C/ Cool down at a rate of seconds, that's it.
  • an Ar gas atmosphere for example, under an Ar gas atmosphere of 5.5 ⁇ 10 4 Pa
  • 10 2 °C/sec-10 4 °C/ Cool down at a rate of seconds, that's it.
  • the crushing process can be a conventional crushing process in the field, such as hydrogen absorption, dehydrogenation, and cooling treatment.
  • the hydrogen absorption can be performed under the condition of a hydrogen pressure of 0.15 MPa.
  • the dehydrogenation can be carried out under conditions of raising the temperature while drawing a vacuum.
  • the pulverization process can be a conventional pulverization process in the field, such as jet mill pulverization.
  • the pulverization process is performed in an atmosphere with an oxidizing gas content of 100 ppm or less.
  • the oxidizing gas refers to oxygen or moisture content.
  • the pressure of the crushing chamber of the jet mill crushing may be 0.38 MPa.
  • the pulverization time of the jet mill may be 3 hours.
  • a lubricant such as zinc stearate
  • the added amount of the lubricant may be 0.10-0.15% of the weight of the powder after mixing, for example 0.12%.
  • the forming process may be a conventional forming process in the field, such as a magnetic field forming method or a hot pressing and thermal deformation method.
  • the sintering process can be a conventional sintering process in the field, for example, preheating, sintering, and cooling under vacuum conditions (for example, under a vacuum of 5 ⁇ 10 -3 Pa).
  • the preheating temperature may be 300-600°C.
  • the preheating time may be 1 to 2 hours.
  • the preheating is a preheating at a temperature of 300°C and 600°C for 1 hour each.
  • the sintering temperature may be a conventional sintering temperature in the art, for example, 900°C to 1100°C, and for example 1040°C.
  • the sintering time may be a conventional sintering time in the field, for example, 2h.
  • Ar gas can be introduced before the cooling to make the gas pressure reach 0.1 MPa.
  • the present invention also provides an R-T-B series permanent magnetic material II prepared by the above-mentioned method.
  • the present invention also provides a method for preparing the R-T-B series permanent magnetic material I, which can be achieved by subjecting the R-T-B series permanent magnetic material II to the grain boundary diffusion treatment.
  • the heavy rare earth elements in the grain boundary diffusion treatment include Dy and/or Tb.
  • the grain boundary diffusion treatment can be processed according to conventional processes in the art, such as Dy vapor diffusion.
  • the temperature of the diffusion heat treatment may be 800-900°C, for example 850°C.
  • the time of the diffusion heat treatment may be 12 to 48 hours, such as 24 hours.
  • heat treatment may also be performed.
  • the temperature of the heat treatment may be 450-550°C, for example 500°C.
  • the heat treatment time may be 3h.
  • the present invention also provides an R-T-B series permanent magnetic material I prepared by the above-mentioned method.
  • the invention also provides an application of the R-T-B series permanent magnet material as an electronic component.
  • the electronic components can be conventional in the field, such as electronic components in motors.
  • the R-T-B series permanent magnetic material may be the above-mentioned R-T-B series permanent magnetic material I and/or R-T-B series permanent magnetic material II.
  • the reagents and raw materials used in the present invention are all commercially available.
  • the permanent magnetic material of the present invention maintains good mechanical properties: the existing low-B permanent magnet has a bending strength of 270-300Mpa; and the permanent magnet material of the present invention has a bending strength of 370-402Mpa.
  • the permanent magnet material of the present invention has good magnetic properties: Br ⁇ 13.20 kGs, Hcj ⁇ 25.1 kOe, which realizes the synchronous increase of Br and Hcj; and the maximum energy product (BHmax) ⁇ 42.5MGOe.
  • FIG. 1 is the FE-EPMA backscatter image of Example 5.
  • Figure 2 is a FE-EPMA backscatter image of Comparative Example 3.
  • Example 1 30.5 / 30.2 0.3 / 0.3 0.5 / 0.1 0.5 0.97 margin
  • Example 2 29.5 / 29.5 / 1 0.5 0.7 / 0.25 0.5 1.03 margin
  • Example 3 30 / 30 / 1.5 0.4 0.6 / 0.2 1 0.99 margin
  • Example 4 30 / 30 / 1 0.35 0.51 / 0.15 1.5 1 margin
  • Example 5 32 30.5 / / 1.5 0.45 0.65 / 0.12 1.2 0.98 margin
  • Example 6 30 / 30 / 1.5 0.2 0.6 / 0.2 1 0.99 margin
  • Example 7 30 / 30 / 1.5 0.5 0.4 / 0.2 1 0.99 margin
  • Example 8 30 / 30 / 1.5 0.2 0.8 / 0.2 1 0.99 margin
  • Example 9 30 / 30 / 1.5 0.4 0.4 0.3 0.2 1 0.99 margin Comparative example 1 33.5 / 32 / 1.5 0.3 0.8 / 0.1 0.5 1.03 margin Comparative example 2 29.5 / 28 / 1.5 0.25
  • R refers to the total rare earth content, specifically, the total content of Nd, PrNd, Tb and Dy.
  • R refers to the total rare earth content, specifically, the total content of Nd, PrNd, Tb and Dy.
  • Fine pulverization step under a nitrogen atmosphere with an oxidizing gas content of 100 ppm or less and a pulverization chamber pressure of 0.38 MPa, the powder after hydrogen pulverization is subjected to jet mill pulverization for 3 hours to obtain a fine powder.
  • Oxidizing gas refers to oxygen or moisture.
  • Magnetic field forming process using a right-angle orientation type magnetic field forming machine, in a 1.6T orientation magnetic field and under a forming pressure of 0.35ton/cm 2 , the above-mentioned zinc stearate-added powder is formed into a side length at one time It is a 25mm cube; it is demagnetized in a 0.2T magnetic field after one-time forming.
  • a secondary molding machine isostatic press
  • each compact is moved to a sintering furnace for sintering, sintered under a vacuum of 5 ⁇ 10 -3 Pa and at a temperature of 300°C and 600°C, respectively, for 1 hour; then, at 1040°C After sintering at a temperature of 2 hours, Ar gas is introduced to make the pressure reach 0.1MPa, and then cooled to room temperature to obtain RTB-based permanent magnet material II.
  • Grain boundary diffusion treatment process Place the metal Dy and RTB permanent magnet material II in the furnace, and heat it at high temperature to make the Dy metal evaporate at a high temperature, and be deposited on the surface of the magnet under the induction of the rare gas from outside, and along the crystal The boundary diffuses into the magnet.
  • the NdFeB sintered magnet of Example 1 was prepared according to the formula shown in Table 1 and the preparation process of Example 2. The difference is that during the grain boundary diffusion process, the metal of Tb element is sputtered and adhered to the surface of the magnet.
  • RTB series sintered magnets prepared in Examples 1-9 and Comparative Examples 1-7 were measured, including the sintered magnet before grain boundary diffusion (ie RTB series permanent magnet material II) and grain boundary After diffusion, the sintered magnet (RTB series permanent magnet material I), and the phase composition of the magnet was observed by FE-EPMA.
  • R refers to the total rare earth content, specifically, the total content of Nd, PrNd, Tb and Dy.
  • the sintered magnet uses the NIM-10000H BH bulk rare earth permanent magnet non-destructive measurement system of China Metrology Institute for magnetic performance testing.
  • the sample size is 45mm ⁇ 10mm ⁇ 3mm.
  • the measured bending strength is the fracture strength of the fracture along the direction of the parallel magnetic field orientation.
  • Table 4 below shows the magnetic properties and mechanical properties test results.
  • the R-T-B series permanent magnet material I in this application has excellent performance, Br ⁇ 13.20kGs, Hcj ⁇ 25.1kOe, which realizes the synchronous increase of Br and Hcj; and the maximum magnetic energy product ⁇ 42.5MGOe (Example 1-9);
  • FE-EPMA detection polishing the vertical orientation surface of the sintered magnet, using a field emission electron probe microanalyzer (FE-EPMA) (JEOL, 8530F) to detect. First, the backscatter image is taken, and then the phases with different contrasts are quantitatively analyzed to determine the phase composition.
  • the test conditions are the acceleration voltage of 15kV and the probe beam current of 50nA.
  • the gray-white region 1 is the R 6 -T 13 -X phase
  • R It is Nd and Dy
  • T is mainly Fe and Co
  • X is Al and Cu
  • the black area 2 is the main phase of R 2 Fe 14 B
  • the bright white area 3 is other R-rich phases.
  • the FE-EPMA backscatter results of Comparative Example 3 are mainly the main phase in the black area and the bright white R-rich phase, and the R 6 -T 13 -X phase is not detected (see Figure 2).

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Abstract

一种R-T-B系永磁材料、原料组合物、制备方法和应用。其中，R-T-B系永磁材料Ⅰ中包含R，T和X；其满足以下关系式：(1)(Fe+Co)/B的原子比为12.5-13.5；(2)B/X的原子比为2.7-4.1；X为Al、Ga和Cu中的一种或多种，其包含R 2T 14B主相结晶颗粒、邻接两个R 2T 14B主相结晶颗粒间的二颗粒晶界相和富稀土相，二颗粒晶界相和富稀土相包含组成为R 6T 13X的相。R-T-B系永磁材料Ⅰ中形成了R 6T 13X相，使得Hcj和力学性能实现了同步提升。

Description

一种R-T-B系永磁材料、原料组合物、制备方法、应用 技术领域
本发明涉及一种R-T-B系永磁材料、原料组合物、制备方法、应用。
背景技术
永磁材料作为支撑电子器件的关键材料被开发出来，发展方向向着高磁能积及高矫顽力的方向进行。R-T-B系永磁材料(R为稀土类元素中的至少一种)已知为永久磁铁中性能最高的磁铁，被用于硬盘驱动器的音圈电机(VCM)、电动车用(EV、HV、PHV等)电机、工业设备用电机等各种电机和家电制品等。
现有技术中，具有常规B含量的钕铁硼无法生成R 6-T 13-X相，磁性能较差；在具有类似配方体系的前提下，若通过降低钕铁硼成分中B含量(B含量大约在0.93wt.％以下)，添加Ga、Cu、Al、Si、Ti使磁体中生成R 6-T 13-X相(X包括Ga、Cu、Al、Si等)来提升磁体性能，则由于B含量降低，磁体中极易形成R 2T 17、TiBx等杂相，使磁体的力学性能下降，材料更脆，不利于加工及高速电机中使用。
因此，亟需一种既能保证R-T-B系永磁材料磁性能，又能够不降低材料力学性能的R-T-B永磁材料。
发明内容
本发明要解决的技术问题是为了克服现有技术中通过生成R 6-T 13-X相提升R-T-B系永磁材料磁性能时，磁体的力学性能下降的缺陷，而提供一种R-T-B系永磁材料、原料组合物、制备方法、应用。
本发明是通过以下技术方案来解决上述技术问题的：
本发明提供一种R-T-B系永磁材料Ⅰ，所述R-T-B系永磁材料Ⅰ中包含R，T和X；
所述R为至少包括Nd的稀土元素，且R包括RH；所述RH为重稀土元素；
所述RH至少包括Dy和/或Tb；
所述T至少包含Fe；
所述X为Al、Ga和Cu中的一种或多种，且所述X必须包括Al；
所述R-T-B系永磁材料Ⅰ满足以下关系式：
(1)(Fe+Co)/B的原子比为12.5-13.5；
(2)B/X的原子比为2.7-4.1；
所述R-T-B系永磁材料Ⅰ中包含R 2T 14B主相结晶颗粒、邻接两个R 2T 14B主相结晶颗粒间的二颗粒晶界相和富稀土相，所述二颗粒晶界相和所述富稀土相包含组成为R 6T 13X的相。
本发明中，上述关系式(1)(2)的建立依据为：发明人在研究R 6-T 13-X相的生成过程中发现，含有R 6-T 13-X相的磁体中存在富B贫X(X为Al、Ga和Cu中的一种或多种，且所述X必须包括Al)区域，由此推断B与X有一定对应关系；而B含量少时，稀土量相对较高，从而Fe的比例也发生变化。因此，本发明通过提高X含量，调整稀土量，使Fe和B的比例发生变化，从而只需要常规B含量也能够生成R 6-T 13-X相(X为Al、Ga和Cu中的一种或多种)。
本发明中，所述T包含Fe和Co。
本发明中，较佳地，所述R 6-T 13-X相中，X为Al和Cu，例如Nd为27.9at％，Dy为1.85at％，Fe为64.25at％，Co为0.77at％，Al为4.63at％，Cu为0.42at％，at％是指所述R-T-B系永磁材料中各元素的原子含量所占百分比。
本发明中，所述(Fe+Co)/B的原子比较佳地为12.8-13.39，例如12.5、12.86、12.88、12.89、12.9或13.9。
本发明中，所述B/X的原子比较佳地为2.8-4，例如2.8、2.9、3.2、3.6、3.8、3.9或4。
本发明中，较佳地，所述R-T-B系永磁材料Ⅰ，以质量百分比计，其包括：
R：31.0-32.5wt.％，且所述R中包含RH；
Cu：0.20-0.50wt.％；
Al：0.40-0.80wt.％；
Ga：0-0.30wt.％；
Nb：0.10-0.25wt.％；
Co：0.5-2.0wt.％；
B：0.97-1.03wt.％；
wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比；
所述R为至少包括Nd的稀土元素；
所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；
余量为Fe及不可避免的杂质。
其中，所述R中还可包括本领域常规的稀土元素，例如Pr。
其中，所述R的含量范围较佳地为31.5-32.5wt.％，例如31wt.％、31.5wt.％、32wt.％或32.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
其中，所述RH的含量范围较佳地为0.8-2.2wt.％，例如0.8wt.％、1.5wt.％或2wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
其中，所述Cu的含量范围较佳地为0.2-0.4wt.％或0.3-0.5wt.％，例如0.2wt.％、0.3wt.％、0.35wt.％、0.4wt.％、0.45wt.％或0.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
其中，所述Al的含量范围较佳地为0.4-0.6wt.％或0.5-0.8wt.％，例如0.4wt.％、0.5wt.％、0.51wt.％、0.6wt.％、0.65wt.％、0.7wt.％或0.8wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
其中，所述Ga的含量范围较佳地为0wt.％或0.3wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
其中，所述Nb的含量范围较佳地为0.1-0.2wt.％或0.12-0.25wt.％，例如0.1wt.％、0.12wt.％、0.15wt.％、0.2wt.％或0.25wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
其中，所述Co的含量范围较佳地为0.5-1.5wt.％或1-2wt.％，例如0.5wt.％、1wt.％、1.2wt.％或1.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
其中，所述B的含量范围较佳地为0.97-1wt.％或0.99-1.03wt.％，例如0.97wt.％、 0.98wt.％、0.99wt.％、1wt.％或1.03wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅰ包括：R为31.0-32.5wt.％；RH为0.8-2.2wt.％；Cu为0.30-0.50wt.％；Al为0.50-0.70wt.％；Nb为0.10-0.25wt.％；Co为0.5-2.0wt.％；B为0.97-1.03wt.％；wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比；所述R为至少包括Nd的稀土元素；所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；余量为Fe及不可避免的杂质。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅰ包括：R为31.5-32.5wt.％，RH为0.8-2.2wt.％；Cu为0.2-0.4wt.％；Al为0.4-0.6wt.％；Ga为0-0.3wt.％；Nb为0.1-0.2wt.％；Co为0.5-1.5wt.％；B为0.97-1wt.％；wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比；所述R为至少包括Nd的稀土元素；所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；余量为Fe及不可避免的杂质。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅰ包括：PrNd为31wt.％，Tb为0.8wt.％，Cu为0.3wt.％，Al为0.5wt.％，Nb为0.1wt.％，Co为0.5wt.％，B为0.97wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅰ包括：PrNd为31wt.％，Dy为1.5wt.％，Cu为0.5wt.％，Al为0.7wt.％，Nb为0.25wt.％，Co为0.5wt.％，B为1.03wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅰ包括：PrNd为32wt.％，Dy为2wt.％，Cu为0.4wt.％，Al为0.6wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅰ包括：PrNd为31.5wt.％，Dy为1.5wt.％，Cu为0.35wt.％，Al为0.51wt.％，Nb为0.15wt.％，Co为1.5wt.％，B为1wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅰ包括：Nd为32.5wt.％，Dy为2wt.％，Cu为0.45wt.％，Al为0.65wt.％，Nb为0.12wt.％，Co为1.2wt.％，B为0.98wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅰ包括：PrNd为32wt.％，Dy为2wt.％，Cu为0.2wt.％，Al为0.6wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅰ包括：PrNd为32wt.％，Dy为2wt.％，Cu为0.5wt.％，Al为0.4wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅰ包括：PrNd为32wt.％，Dy为2wt.％，Cu为0.2wt.％，Al为0.8wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅰ包括：PrNd为32wt.％，Dy为2wt.％，Cu为0.4wt.％，Al为0.4wt.％，Ga为0.3wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
本发明还提供了一种R-T-B系永磁材料Ⅱ，所述R-T-B系永磁材料Ⅱ中包含R，T和X；
所述R为至少包括Nd的稀土元素，且R包括RH；所述RH为重稀土元素；
所述RH至少包括Dy和/或Tb；
所述T至少包含Fe；
所述X为Al、Ga和Cu中的一种或多种，且所述X必须包括Al；
所述R-T-B系永磁材料Ⅱ满足以下关系式：
(1)(Fe+Co)/B的原子比为12.5-13.7；
(2)B/X的原子比为2.8-4.0。
本发明中，较佳地，所述T包含Fe和Co。
本发明中，所述(Fe+Co)/B的原子比较佳地为12.9-13，例如12.94、12.95、12.96、12.98、12.99或13。
本发明中，所述B/X的原子比较佳地为2.9-3.9，例如3.2、3.6或3.8。
本发明中，较佳地，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括以下组分：
R：30.5-32wt.％，且所述R中包含RH；
Cu：0.20-0.50wt.％；
Al：0.40-0.80wt.％；
Ga：0-0.30wt.％；
Nb：0.10-0.25wt.％；
Co：0.5-2.0wt.％；
B：0.97-1.03wt.％；
wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比；
所述R为至少包括Nd的稀土元素；
所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；
余量为Fe及不可避免的杂质。
其中，所述R中还可包括本领域常规的稀土元素，例如Pr。
其中，所述R的含量范围较佳地为31-32wt.％，例如31wt.％、31.5wt.％、或32wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
其中，所述RH的含量范围较佳地为0.3-1.7wt.％，例如0.3wt.％、1wt.％或1.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
其中，所述Cu的含量范围较佳地为0.2-0.4wt.％或0.3-0.5wt.％，例如0.2wt.％、0.3wt.％、0.35wt.％、0.4wt.％、0.45wt.％或0.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
其中，所述Al的含量范围较佳地为0.4-0.6wt.％或0.5-0.8wt.％，例如0.4wt.％、0.5wt.％、0.51wt.％、0.6wt.％、0.65wt.％、0.7wt.％或0.8wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
其中，所述Ga的含量范围较佳地为0wt.％或0.3wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
其中，所述Nb的含量范围较佳地为0.1-0.2wt.％或0.12-0.25wt.％，例如0.1wt.％、0.12wt.％、0.15wt.％、0.2wt.％或0.25wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
其中，所述Co的含量范围较佳地为0.5-1.5wt.％或1-2wt.％，例如0.5wt.％、1wt.％、 1.2wt.％或1.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
其中，所述B的含量范围较佳地为0.97-1wt.％或0.99-1.03wt.％，例如0.97wt.％、0.98wt.％、0.99wt.％、1wt.％或1.03wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括：R为30.5-32wt.％；RH为0.3-1.7wt.％；Cu为0.30-0.50wt.％；Al为0.50-0.70wt.％；Nb为0.10-0.25wt.％；Co为0.5-2.0wt.％；B为0.97-1.03wt.％；wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比；所述R为至少包括Nd的稀土元素；所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；余量为Fe及不可避免的杂质。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括：R为31-32wt.％，RH为0.3-1wt.％；Cu为0.2-0.4wt.％；Al为0.4-0.6wt.％；Ga为0-0.3wt.％；Nb为0.1-0.2wt.％；Co为0.5-1.5wt.％；B为0.97-1wt.％；wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比；所述R为至少包括Nd的稀土元素；所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；余量为Fe及不可避免的杂质。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括：PrNd为30.5wt.％，Tb为0.3wt.％，Cu为0.3wt.％，Al为0.5wt.％，Nb为0.1wt.％，Co为0.5wt.％，B为0.97wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括：PrNd为30.5wt.％，Dy为1wt.％，Cu为0.5wt.％，Al为0.7wt.％，Nb为0.25wt.％，Co为0.5wt.％，B为1.03wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括：PrNd为31.5wt.％，Dy为1.5wt.％，Cu为0.4wt.％，Al为0.6wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括：PrNd为31wt.％，Dy为1wt.％，Cu为0.35wt.％，Al为0.51wt.％，Nb为0.15wt.％，Co为1.5wt.％，B为1wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括：Nd 为32wt.％，Dy为1.5wt.％，Cu为0.45wt.％，Al为0.65wt.％，Nb为0.12wt.％，Co为1.2wt.％，B为0.98wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括：PrNd为31.5wt.％，Dy为1.5wt.％，Cu为0.2wt.％，Al为0.6wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括：PrNd为31.5wt.％，Dy为1.5wt.％，Cu为0.5wt.％，Al为0.4wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括：PrNd为31.5wt.％，Dy为1.5wt.％，Cu为0.2wt.％，Al为0.8wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括：PrNd为31.5wt.％，Dy为1.5wt.％，Cu为0.4wt.％，Al为0.4wt.％，Ga为0.3wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
本发明还提供了一种R-T-B系永磁材料Ⅱ的原料组合物，以质量百分比计，其包括以下组分：
R：30.5-32wt.％，且所述R中包含RH；
Cu：0.20-0.50wt.％；
Al：0.40-0.80wt.％；
Ga：0-0.30wt.％；
Nb：0.10-0.25wt.％；
Co：0.5-2.0wt.％；
B：0.97-1.03wt.％；
wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比；
所述R为至少包括Nd的稀土元素；
所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；
余量为Fe及不可避免的杂质。
本发明中，所述R中还可包括本领域常规的稀土元素，例如Pr。
本发明中，所述R的含量范围较佳地为31-32wt.％，例如31wt.％、31.5wt.％、或32wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
本发明中，所述RH的含量范围较佳地为0.3-1.7wt.％，例如0.3wt.％、1wt.％或1.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
本发明中，所述Cu的含量范围较佳地为0.2-0.4wt.％或0.3-0.5wt.％，例如0.2wt.％、0.3wt.％、0.35wt.％、0.4wt.％、0.45wt.％或0.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
本发明中，所述Al的含量范围较佳地为0.4-0.6wt.％或0.5-0.8wt.％，例如0.4wt.％、0.5wt.％、0.51wt.％、0.6wt.％、0.65wt.％、0.7wt.％或0.8wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
本发明中，所述Ga的含量范围较佳地为0wt.％或0.3wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
本发明中，所述Nb的含量范围较佳地为0.1-0.2wt.％或0.12-0.25wt.％，例如0.1wt.％、0.12wt.％、0.15wt.％、0.2wt.％或0.25wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
本发明中，所述Co的含量范围较佳地为0.5-1.5wt.％或1-2wt.％，例如0.5wt.％、1wt.％、1.2wt.％或1.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
本发明中，所述B的含量范围较佳地为0.97-1wt.％或0.99-1.03wt.％，例如0.97wt.％、0.98wt.％、0.99wt.％、1wt.％或1.03wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ的原料组合物包括：R为30.5-32wt.％；RH为0.3-1.7wt.％；Cu为0.30-0.50wt.％；Al为0.50-0.70wt.％；Nb为0.10-0.25wt.％；Co为0.5-2.0wt.％；B为0.97-1.03wt.％；wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比；所述R为至少包括Nd的稀土元素；所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；余量为Fe及不可避免的杂质。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ的原料组合 物包括：R为31-32wt.％，RH为0.3-1wt.％；Cu为0.2-0.4wt.％；Al为0.4-0.6wt.％；Ga为0-0.3wt.％；Nb为0.1-0.2wt.％；Co为0.5-1.5wt.％；B为0.97-1wt.％；wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比；所述R为至少包括Nd的稀土元素；所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；余量为Fe及不可避免的杂质。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ的原料组合物包括：PrNd为30.5wt.％，Tb为0.3wt.％，Cu为0.3wt.％，Al为0.5wt.％，Nb为0.1wt.％，Co为0.5wt.％，B为0.97wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ的原料组合物包括：PrNd为30.5wt.％，Dy为1wt.％，Cu为0.5wt.％，Al为0.7wt.％，Nb为0.25wt.％，Co为0.5wt.％，B为1.03wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ的原料组合物包括：PrNd为31.5wt.％，Dy为1.5wt.％，Cu为0.4wt.％，Al为0.6wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ的原料组合物包括：PrNd为31wt.％，Dy为1wt.％，Cu为0.35wt.％，Al为0.51wt.％，Nb为0.15wt.％，Co为1.5wt.％，B为1wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ的原料组合物包括：Nd为32wt.％，Dy为1.5wt.％，Cu为0.45wt.％，Al为0.65wt.％，Nb为0.12wt.％，Co为1.2wt.％，B为0.98wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ的原料组合物包括：PrNd为31.5wt.％，Dy为1.5wt.％，Cu为0.2wt.％，Al为0.6wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量 百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ的原料组合物包括：PrNd为31.5wt.％，Dy为1.5wt.％，Cu为0.5wt.％，Al为0.4wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ的原料组合物包括：PrNd为31.5wt.％，Dy为1.5wt.％，Cu为0.2wt.％，Al为0.8wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
在本发明一优选实施方式中，以质量百分比计，所述R-T-B系永磁材料Ⅱ的原料组合物包括：PrNd为31.5wt.％，Dy为1.5wt.％，Cu为0.4wt.％，Al为0.4wt.％，Ga为0.3wt.％，Nb为0.2wt.％，Co为1wt.％，B为0.99wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
本发明还提供了一种R-T-B系永磁材料Ⅱ的制备方法，其包括下述步骤：将所述的R-T-B系永磁材料Ⅱ的原料组合物的熔融液经铸造、破碎、粉碎、成形、烧结，即可。
本发明中，所述R-T-B系永磁材料Ⅱ的原料组合物的熔融液可按本领域常规方法制得，例如：在高频真空感应熔炼炉中熔炼，即可。所述熔炼炉的真空度可为5×10 -2Pa。所述熔炼的温度可为1500℃以下。
本发明中，所述铸造的工艺可为本领域常规的铸造工艺，例如：在Ar气气氛中(例如5.5×10 4Pa的Ar气气氛下)，以10 2℃/秒-10 4℃/秒的速度冷却，即可。
本发明中，所述破碎的工艺可为本领域常规的破碎工艺，例如经吸氢、脱氢、冷却处理，即可。
其中，所述吸氢可在氢气压力0.15MPa的条件下进行。
其中，所述脱氢可在边抽真空边升温的条件下进行。
本发明中，所述粉碎的工艺可为本领域常规的粉碎工艺，例如气流磨粉碎。
其中，较佳地，所述粉碎的工艺在氧化气体含量100ppm以下的气氛下进行。
所述氧化气体指的是氧气或水分含量。
其中，所述气流磨粉碎的粉碎室压力可为0.38MPa。
其中，所述气流磨粉碎的时间可为3小时。
其中，所述粉碎后，可按本领域常规手段添加润滑剂，例如硬脂酸锌。所述润滑剂的添加量可为混合后粉末重量的0.10～0.15％，例如0.12％。
本发明中，所述成形的工艺可为本领域常规的成形工艺，例如磁场成形法或热压热变形法。
本发明中，所述烧结的工艺可为本领域常规的烧结工艺，例如，在真空条件下(例如在5×10 -3Pa的真空下)，经预热、烧结、冷却，即可。
其中，所述预热的温度可为300-600℃。所述预热的时间可为1～2h。优选地，所述预热为在300℃和600℃的温度下各预热1h。
其中，所述烧结的温度可为本领域常规的烧结温度，例如900℃～1100℃，再例如1040℃。
其中，所述烧结的时间可为本领域常规的烧结时间，例如2h。
其中，所述冷却前可通入Ar气体使气压达到0.1MPa。
本发明还提供了一种采用上述方法制得的R-T-B系永磁材料Ⅱ。
本发明还提供了一种R-T-B系永磁材料Ⅰ的制备方法，将所述的R-T-B系永磁材料Ⅱ进行晶界扩散处理，即可。
所述晶界扩散处理中的重稀土元素包括Dy和/或Tb。
本发明中，所述晶界扩散处理可按本领域常规的工艺进行处理，例如Dy蒸汽扩散。
其中，所述扩散热处理的温度可为800～900℃，例如850℃。
其中，所述扩散热处理的时间可为12～48h，例如24h。
其中，所述晶界扩散处理后，还可进行热处理。所述热处理的温度可为450-550℃，例如500℃。所述热处理的时间可为3h。
本发明还提供了一种采用上述方法制得的R-T-B系永磁材料Ⅰ。
本发明还提供了一种R-T-B系永磁材料作为电子元器件的应用。
其中，所述电子元器件可为本领域常规，例如马达中的电子元器件。
其中，所述R-T-B系永磁材料可为上述R-T-B系永磁材料Ⅰ和/或R-T-B系永磁材料Ⅱ。
在符合本领域常识的基础上，上述各优选条件，可任意组合，即得本发明各较佳实例。
本发明所用试剂和原料均市售可得。
本发明的积极进步效果在于：
(1)本发明的永磁材料力学性能保持良好：现有的低B永磁体，抗弯强度为270-300Mpa；而本发明的永磁材料的抗弯强度为370-402Mpa。
(2)本发明的永磁材料磁性能良好：Br≥13.20kGs，Hcj≥25.1kOe，实现了Br和Hcj的同步提升；并且最大磁能积(maximum energy product，简称BHmax)≥42.5MGOe。
附图说明
图1为实施例5的FE-EPMA背散射图像。
图2为对比例3的FE-EPMA背散射图像。
具体实施方式
下面通过实施例的方式进一步说明本发明，但并不因此将本发明限制在下述的实施例范围之中。下述实施例中未注明具体条件的实验方法，将按照常规方法和条件，或按照商品说明书进行选择。
实施例及对比例中R-T-B系永磁材料Ⅱ的原料配方如表1所示。在下述的表中，“/”表示未添加该元素，“Br”为剩余磁通密度，“Hcj”为内禀矫顽力(intrinsic coercivity)，“BHmax”为最大磁能积，“BHH”为BHmax和Hcj的总和。
表1 R-T-B系永磁材料Ⅱ的原料组合物的组分和含量(wt.％)
编号 R Nd PrNd Tb Dy Cu Al Ga Nb Co B Fe
实施例1 30.5 / 30.2 0.3 / 0.3 0.5 / 0.1 0.5 0.97 余量
实施例2 29.5 / 29.5 / 1 0.5 0.7 / 0.25 0.5 1.03 余量
实施例3 30 / 30 / 1.5 0.4 0.6 / 0.2 1 0.99 余量
实施例4 30 / 30 / 1 0.35 0.51 / 0.15 1.5 1 余量
实施例5 32 30.5 / / 1.5 0.45 0.65 / 0.12 1.2 0.98 余量
实施例6 30 / 30 / 1.5 0.2 0.6 / 0.2 1 0.99 余量
实施例7 30 / 30 / 1.5 0.5 0.4 / 0.2 1 0.99 余量
实施例8 30 / 30 / 1.5 0.2 0.8 / 0.2 1 0.99 余量
实施例9 30 / 30 / 1.5 0.4 0.4 0.3 0.2 1 0.99 余量
对比例1 33.5 / 32 / 1.5 0.3 0.8 / 0.1 0.5 1.03 余量
对比例2 29.5 / 28 / 1.5 0.25 0.4 / 0.3 0.4 0.97 余量
对比例3 30 / 28.5 / 1.5 0.3 0.4 / 0.1 0.5 0.99 余量
对比例4 32 / 30.5 / 1.5 0.4 0.6 / 0 1 1.05 余量
对比例5 30 / 28.5 / 1.5 0.2 0.6 / 0.2 1 0.93 余量
对比例6 29.5 / 28 / 1.5 0.4 0.6 / 0.2 1 0.9 余量
对比例7 32 / 30.5 / 1.5 0.35 0.45 / 0 1.8 1.1 余量
注：R是指总稀土含量，具体地，是指Nd、PrNd、Tb和Dy的总含量。
表2 R-T-B系永磁材料II的组分和含量(wt.％)
Figure PCTCN2020100577-appb-000001
注：R是指总稀土含量，具体地，是指Nd、PrNd、Tb和Dy的总含量。
实施例2-9，以及对比例1-7中R-T-B系烧结磁铁制备方法如下：
(1)熔炼过程：按表1所示配方，将配制好的原料放入氧化铝制的坩埚中，在高频真空感应熔炼炉中且在5×10 -2Pa的真空中，以1500℃以下的温度进行真空熔炼。
(2)铸造过程：在真空熔炼后的熔炼炉中通入Ar气体，使气压达到5.5万Pa后，进行铸造，并以10 2℃/秒-10 4℃/秒的冷却速度获得急冷合金。
(3)氢破粉碎过程：在室温下，将放置急冷合金的氢破用炉抽真空，然后向氢破用炉内通入纯度为99.9％的氢气，维持氢气压力0.15MPa；充分吸氢后，边抽真空边升温，充分脱氢；然后进行冷却，取出氢破粉碎后的粉末。
(4)微粉碎工序：在氧化气体含量100ppm以下的氮气气氛下以及在粉碎室压力为0.38MPa的条件下，对氢破粉碎后的粉末进行3小时的气流磨粉碎，得到细粉。氧化气体指的是氧或水分。
(5)在气流磨粉碎后的粉末中添加硬脂酸锌，硬脂酸锌的添加量为混合后粉末重量的0.12％，再用V型混料机充分混合。
(6)磁场成形过程：使用直角取向型的磁场成型机，在1.6T的取向磁场中以及在0.35ton/cm 2的成型压力下，将上述添加了硬脂酸锌的粉末一次成形成边长为25mm的立方体；一次成形后在0.2T的磁场中退磁。为了使一次成形后的成形体不接触到空气，将其进行密封，然后再使用二次成形机(等静压成形机)，在1.3ton/cm 2的压力下进行二次成形。
(7)烧结过程：将各成形体搬至烧结炉进行烧结，烧结在5×10 -3Pa的真空下以及分别在300℃和600℃的温度下，各保持1小时；然后，以1040℃的温度烧结2小时；然后通入Ar气体使气压达到0.1MPa后，冷却至室温，得到R-T-B系永磁材料Ⅱ。
(8)晶界扩散处理过程：将金属Dy以及R-T-B系永磁材料Ⅱ放置于炉内，并高温加热使得Dy金属高温蒸发，并且在外来稀有气体的诱导下沉积在磁体表面，并沿着晶界向磁体内部扩散。
(9)热处理过程：烧结体在高纯度Ar气中，以500℃温度进行3小时热处理后，冷却至室温后取出，得到R-T-B系永磁材料Ⅰ。
实施例1中R-T-B系烧结磁铁制备方法如下：
按照按表1所示配方，以及实施例2的制备工艺制备实施例1钕铁硼烧结磁铁，不同之处在于：晶界扩散过程中，在磁铁表面溅射附着Tb元素的金属。
效果实施例
分别测定实施例1-9和对比例1-7制得的R-T-B系烧结磁铁的磁性能、力学性能和成分，包括晶界扩散前的烧结磁铁(也就是R-T-B系永磁材料Ⅱ)和晶界扩散后的烧结磁铁(R-T-B系永磁材料Ⅰ)，并通过FE-EPMA观察其磁体的相组成。
(1)R-T-B系永磁材料Ⅰ的各成分使用高频电感耦合等离子体发射光谱仪(ICP-OES)进行测定，其中R 6T 13X相根据FE-EPMA测试得到。下表3所示为成分检测结果。
表3 R-T-B系永磁材料Ⅰ的组分和含量(wt.％)
Figure PCTCN2020100577-appb-000002
注：R是指总稀土含量，具体地，是指Nd、PrNd、Tb和Dy的总含量。
(2)磁性能评价：烧结磁铁使用中国计量院的NIM-10000H型BH大块稀土永磁无损测量系统进行磁性能检测。
力学性能：在万能试验机设备上采用三点弯曲法进行测定，试样尺寸为45mm×10mm×3mm，所测抗弯强度是断口沿平行磁场取向方向的断裂强度。
下表4所示为磁性能和力学性能检测结果。
表4 R-T-B系永磁材料Ⅰ的性能
Figure PCTCN2020100577-appb-000003
由表4可知：
1)本申请中的R-T-B系永磁材料Ⅰ性能优异，Br≥13.20kGs，Hcj≥25.1kOe，实现了Br和Hcj的同步提升；并且最大磁能积≥42.5MGOe(实施例1-9)；
2)基于本申请的配方，无论是调高R和Al的含量，还是降低R和Al的含量，均不能生成R 6T 13X相，R-T-B系永磁材料Ⅰ的磁性能和抗弯强度均下降(对比例1和对比例3)；
3)基于本申请的配方，将B的含量调至常规含量，但是若其他组分含量不在本申请限定的范围内，也无法生成R 6T 13X相，R-T-B系永磁材料Ⅰ的磁性能和抗弯强度均下降(对比例2)；
4)基于本申请的配方，若不能保证(Fe+Co)/B和B/X的比值在本申请限定的范围内，即使生成了R 6T 13X相，R-T-B系永磁材料Ⅰ的磁性能和抗弯强度也不能得到同时的提升(对比例4～7)。
(3)FE-EPMA检测：对烧结磁铁的垂直取向面进行抛光，采用场发射电子探针显微分析仪(FE-EPMA)(日本电子株式会社(JEOL)，8530F)检测。首先拍摄背散射图像，然后对不同对比度的相进行定量分析确定相组成，测试条件为加速电压15kV，探针束流50nA。
将实施例5和对比例3所制得的R-T-B系永磁材料Ⅰ进行FE-EPMA检测，结果下表 4、图1和图2所示。其中：
根据实施例5所制得的R-T-B系永磁材料I的FE-EPMA背散射图像(如图1)，结合表5中定量分析结果可知：灰白色区域1为R 6-T 13-X相，R为Nd和Dy，T主要为Fe和Co，X为Al和Cu，黑色区域2为R 2Fe 14B主相，亮白色区域3为其他富R相。
对比例3的FE-EPMA背散射结果主要为黑色区域的主相和亮白色的富R相，未检测到R 6-T 13-X相(如图2)。
表5
(at％) Nd Dy Fe Co Al Cu B 相成分
点1 27.9 1.85 64.25 0.77 4.63 0.42 0 R 6-T 13-X
点2 10.6 0.33 81.33 0.68 1.18 0.06 5.72 R 2-T 14-B

Claims (10)

  1. 一种R-T-B系永磁材料Ⅰ，其特征在于，所述R-T-B系永磁材料Ⅰ中包含R、T和X；
    所述R为至少包括Nd的稀土元素，且R包括RH；所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；
    所述T至少包含Fe；
    所述X为Al、Ga和Cu中的一种或多种，且所述X必须包括Al；
    所述R-T-B系永磁材料Ⅰ满足以下关系式：
    (1)(Fe+Co)/B的原子比为12.5-13.5；
    (2)B/X的原子比为2.7-4.1；
    所述R-T-B系永磁材料Ⅰ中包含R 2T 14B主相结晶颗粒、邻接两个R 2T 14B主相结晶颗粒间的二颗粒晶界相和富稀土相，所述二颗粒晶界相和所述富稀土相包含组成为R 6T 13X的相；
    较佳地，所述T包括Fe和Co；
    较佳地，所述R 6-T 13-X相中，X为Al和Cu；
    较佳地，所述(Fe+Co)/B的原子比为12.8-13.39，例如12.5、12.86、12.88、12.89、12.9或13.9；
    较佳地，所述B/X的原子比为2.8-4，例如2.8、2.9、3.2、3.6、3.8、3.9或4。
  2. 如权利要求1所述的R-T-B系永磁材料Ⅰ，其特征在于，所述R-T-B系永磁材料Ⅰ，以质量百分比计，其包括：
    R：31.0-32.5wt.％，且所述R中包含RH；
    Cu：0.20-0.50wt.％；
    Al：0.40-0.80wt.％；
    Ga：0-0.30wt.％；
    Nb：0.10-0.25wt.％；
    Co：0.5-2.0wt.％；
    B：0.97-1.03wt.％；
    wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比；
    所述R为至少包括Nd的稀土元素；所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；
    余量为Fe及不可避免的杂质；
    较佳地，所述R中还包括Pr元素；
    较佳地，所述R的含量范围为31.5-32.5wt.％，例如31wt.％、31.5wt.％、32wt.％或32.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比；
    较佳地，所述RH的含量范围为0.8-2.2wt.％，例如0.8wt.％、1.5wt.％或2wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比；
    较佳地，所述Cu的含量范围为0.2-0.4wt.％或0.3-0.5wt.％，例如0.2wt.％、0.3wt.％、0.35wt.％、0.4wt.％、0.45wt.％或0.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比；
    较佳地，所述Al的含量范围为0.4-0.6wt.％或0.5-0.8wt.％，例如0.4wt.％、0.5wt.％、0.51wt.％、0.6wt.％、0.65wt.％、0.7wt.％或0.8wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比；
    较佳地，所述Ga的含量范围为0wt.％或0.3wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比；
    较佳地，所述Nb的含量范围为0.1-0.2wt.％或0.12-0.25wt.％，例如0.1wt.％、0.12wt.％、0.15wt.％、0.2wt.％或0.25wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比；
    较佳地，所述Co的含量范围为0.5-1.5wt.％或1-2wt.％，例如0.5wt.％、1wt.％、1.2wt.％或1.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比；
    较佳地，所述B的含量范围为0.97-1wt.％或0.99-1.03wt.％，例如0.97wt.％、0.98wt.％、0.99wt.％、1wt.％或1.03wt.％，wt.％是指在所述R-T-B系永磁材料Ⅰ中的质量百分比。
  3. 一种R-T-B系永磁材料Ⅱ，其特征在于，所述R-T-B系永磁材料Ⅱ中包含R、T和X；
    所述R为至少包括Nd的稀土元素，且R包括RH；所述RH为重稀土元素；
    所述RH至少包括Dy和/或Tb；
    所述T至少包含Fe；
    所述X为Al、Ga和Cu中的一种或多种，且所述X必须包括Al；
    所述R-T-B系永磁材料Ⅱ满足以下关系式：
    (1)(Fe+Co)/B的原子比为12.5-13.7；
    (2)B/X的原子比为2.8-4.0；
    较佳地，所述T包括Fe和Co；
    较佳地，所述(Fe+Co)/B的原子比为12.9-13，例如12.94、12.95、12.96、12.98、12.99或13；
    较佳地，所述B/X的原子比为2.9-3.9，例如3.2、3.6或3.8。
  4. 如权利要求3所述的R-T-B系永磁材料Ⅱ，其特征在于，以质量百分比计，所述R-T-B系永磁材料Ⅱ包括以下组分：
    R：30.5-32wt.％，且所述R中包含RH；
    Cu：0.20-0.50wt.％；
    Al：0.40-0.80wt.％；
    Ga：0-0.30wt.％；
    Nb：0.10-0.25wt.％；
    Co：0.5-2.0wt.％；
    B：0.97-1.03wt.％；
    wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比；
    所述R为至少包括Nd的稀土元素；
    所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；
    余量为Fe及不可避免的杂质；
    较佳地，所述R中还包括Pr元素；
    较佳地，所述R的含量范围为31-32wt.％，例如31wt.％、31.5wt.％、或32wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比；
    较佳地，所述RH的含量范围为0.3-1.7wt.％，例如0.3wt.％、1wt.％或1.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比；
    较佳地，所述Cu的含量范围为0.2-0.4wt.％或0.3-0.5wt.％，例如0.2wt.％、0.3wt.％、0.35wt.％、0.4wt.％、0.45wt.％或0.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比；
    较佳地，所述Al的含量范围为0.4-0.6wt.％或0.5-0.8wt.％，例如0.4wt.％、0.5wt.％、0.51wt.％、0.6wt.％、0.65wt.％、0.7wt.％或0.8wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比；
    较佳地，所述Ga的含量范围为0wt.％或0.3wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比；
    较佳地，所述Nb的含量范围为0.1-0.2wt.％或0.12-0.25wt.％，例如0.1wt.％、0.12wt.％、0.15wt.％、0.2wt.％或0.25wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比；
    较佳地，所述Co的含量范围为0.5-1.5wt.％或1-2wt.％，例如0.5wt.％、1wt.％、1.2wt.％或1.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比；
    较佳地，所述B的含量范围为0.97-1wt.％或0.99-1.03wt.％，例如0.97wt.％、0.98wt.％、0.99wt.％、1wt.％或1.03wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ中的质量百分比。
  5. 一种R-T-B系永磁材料Ⅱ的原料组合物，其特征在于，以质量百分比计，其包括以下组分：
    R：30.5-32wt.％，且所述R中包含RH；
    Cu：0.20-0.50wt.％；
    Al：0.40-0.80wt.％；
    Ga：0-0.30wt.％；
    Nb：0.10-0.25wt.％；
    Co：0.5-2.0wt.％；
    B：0.97-1.03wt.％；
    wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比；
    所述R为至少包括Nd的稀土元素；
    所述RH为重稀土元素；所述RH至少包括Dy和/或Tb；
    余量为Fe及不可避免的杂质；
    较佳地，所述R的含量范围为31-32wt.％，例如31wt.％、31.5wt.％、或32wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比；
    较佳地，所述RH的含量范围为0.3-1.7wt.％，例如0.3wt.％、1wt.％或1.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比；
    较佳地，所述Cu的含量范围为0.2-0.4wt.％或0.3-0.5wt.％，例如0.2wt.％、0.3wt.％、0.35wt.％、0.4wt.％、0.45wt.％或0.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比；
    较佳地，所述Al的含量范围为0.4-0.6wt.％或0.5-0.8wt.％，例如0.4wt.％、0.5wt.％、0.51wt.％、0.6wt.％、0.65wt.％、0.7wt.％或0.8wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比；
    较佳地，所述Ga的含量范围为0wt.％或0.3wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比；
    较佳地，所述Nb的含量范围为0.1-0.2wt.％或0.12-0.25wt.％，例如0.1wt.％、0.12wt.％、0.15wt.％、0.2wt.％或0.25wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比；
    较佳地，所述Co的含量范围为0.5-1.5wt.％或1-2wt.％，例如0.5wt.％、1wt.％、1.2wt.％或1.5wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比；
    较佳地，所述B的含量范围为0.97-1wt.％或0.99-1.03wt.％，例如0.97wt.％、0.98wt.％、0.99wt.％、1wt.％或1.03wt.％，wt.％是指在所述R-T-B系永磁材料Ⅱ的原料组合物中的质量百分比。
  6. 一种R-T-B系永磁材料Ⅱ的制备方法，其特征在于，其包括下述步骤：将如权利要求5所述的R-T-B系永磁材料Ⅱ的原料组合物的熔融液经铸造、破碎、粉碎、成形、烧结，即可。
  7. 一种如权利要求6所述的制备方法制得的R-T-B系永磁材料Ⅱ。
  8. 一种R-T-B系永磁材料Ⅰ的制备方法，将如权利要求3、4和7中任一项所述的R-T-B系永磁材料Ⅱ进行晶界扩散处理，即可。
  9. 一种如权利要求8所述的制备方法制得的R-T-B系永磁材料Ⅰ。
  10. 一种R-T-B系永磁材料作为电子元器件的应用；
    所述R-T-B系永磁材料为如权利要求1、2和9任一项所述的R-T-B系永磁材料Ⅰ；
    和/或，所述R-T-B系永磁材料为如权利要求3、4和7中任一项所述的R-T-B系永磁材料Ⅱ。
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