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CA1100788A - Iron-phosphorus powder for manufacture of soft magnetic components - Google Patents

Iron-phosphorus powder for manufacture of soft magnetic components

Info

Publication number
CA1100788A
CA1100788A CA297,696A CA297696A CA1100788A CA 1100788 A CA1100788 A CA 1100788A CA 297696 A CA297696 A CA 297696A CA 1100788 A CA1100788 A CA 1100788A
Authority
CA
Canada
Prior art keywords
powder
phosphorus
less
iron
particle size
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA297,696A
Other languages
French (fr)
Inventor
Jan R. Tengzelius
Robert R. Fayles
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hoganas AB
Original Assignee
Hoganas AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hoganas AB filed Critical Hoganas AB
Application granted granted Critical
Publication of CA1100788A publication Critical patent/CA1100788A/en
Expired legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12Magnets 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
    • H01F1/14Magnets 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
    • H01F1/20Magnets 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
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C33/00Making ferrous alloys
    • C22C33/02Making ferrous alloys by powder metallurgy
    • C22C33/0207Using a mixture of prealloyed powders or a master alloy
    • C22C33/0214Using a mixture of prealloyed powders or a master alloy comprising P or a phosphorus compound

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Dispersion Chemistry (AREA)
  • Power Engineering (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)
  • Soft Magnetic Materials (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)

Abstract

Abstract of the Disclosure The soft magnetic properties and tensile strength of powder metallurgically produced components are improved by forming the components from an alloy powder comprising highly pure iron and up to 1.5% phosphorus.
The particle size of the powder is controlled such that less than 5% exceeds 35 Tyler mesh and less than 20% is less than 100 Tyler mesh.

Description

~1~()7~

The present invention relates to highly pure iron powders having a relatively large particle size with the addition of a phosphorus containing powder, especially intended for powder metallurgical manufacturing of com-ponents satisfying great demand for soft magnetic properties.
The powder metallurgical manufacturing technique is characterized by long series production of components having good dimensional accuracy.
The manufacturing se~uence is started by mixing a metallic powder, for example iron powder, if desired containing alloying elements in powder form, with a lubricant in order to simplify the subsequent compression operation. Thereby the powder mixture is compressed to a green compact, the shape of which approximately or exactly corresponds to the shape of the final component.
The green compact is then heated and is maintained at a temperature at which the green compact by means of sintering obtains its final characteristics with regard to strength, ductility, etc. Materials manufactured in this way differ basically from materials metallurgically manufactured by melting and casting in respect of their porosity. Components satisfying the demands for good soft magnetic properties are usually manufactured from materials having iron as their main component. The most common manufacturing method is represented by a method wherein the components are manufactured from a piece ¢ of highly pure solid material, for example, Armco~iron. However, the powder metallurgical technique is also used for the manufacture of such components because of the advantages of this method with regard to the saving of material, dimensional accuracy and the simplified shaping of the components. However, it has hitherto not been possible to obtain the same good soft magnetic pro-perties of materials manufactured by means of powder metallurgy including iron as the main component as for solid materials having the corresponding composition. Substantially, this difference is dependent on the porosity of the material manufactured by powder metallurgy.
According to the present invention,there is provided a powder intended for powder metallurgical manufacture of soft magnetic components, ~ r~

7~8 which powder comprises a highly pure iron powder containing up to 1.5 % phos-phorus as an alloying additive, wherein the main portion of the powder has a particle size between 35 and 100 Tyler mesh ~417 and 147 ~m), less than 5 %
of the powder has a particle size exceeding 35 Tyler mesh (417 ~m) and less than 20 % of the powder has a particle size less than 100 Tyler mesh (147 ~m).
Thus, it has proved possible to obtain a material manufactured by powder metallurgy which possesses soft magnetic properties which are about the same as the corresponding properties of highly pure solid iron, by using as the starting material an iron powder having a sieve analysis which is unusual within powder metallurgy by being moved in the direction of coarse particles. In addition to the fact that this iron powder shall be coarse, there is also required a very low content of impurities.
This highly pure iron powder, which is preferably manufactured by atomization, should have an iron content in excess of 99.8 %. Here, as well as in the following, "%" means "weight-%". The contents of impurities, which are known to reduce the magnetic properties of iron, should be as low as possible and should preferably be: C <0.01 %, 0-total <0.1 %, N <0.005 %.
In order to obtain the advantages of the present invention, there is used a powder wherein the particle size of the main portion of the particle is between 35 and 100 Tyler mesh ~417 and 147 ~m), the content of particles greater than 35 Tyler mesh (417 ~m) does not exceed 5 %, and the content of particles less than 100 Tyler mesh (147 ~m) is less than 20 %, preferably less than 10 %.
Because of the very low content of particles less than 147 ~m, the mechanical properties of components manufactured from coarse, highly pure iron powder would be very low. If a higher strength is desired, it is not possible to increase the content of particles having a size less than 147 ~m without simultaneously reducing the soft magnetic properties. A solution to this problem consists in adding a powdered alloying component to the highly pure coarse iron powder, said alloying component producing an increased strength V7~8 on sintering witllout deterioration of the soft magnetic properties of the material thus produced.
It is previously known that ferrophosphorus in powder form mixed with the iron powder types normally used within powder metallurgy, the powders having a particle size which is less than 147 ~m, brings about increased strength on sintering. See for example Swedish Patent NoO 7205754-Oo As appears from the following examples, the addition of ferrophosphorus in powder form to the above highly pure coarse iron powder can make the strength of the sintered material five times higher, and not only retaining but even further enhancing the soft magnetic properties. According to the invention the total phosphorus content of the mixture should not exceed 1.5 %. The maximum in-crease of the strength is obtained at a content of about 0.3 % phosphorus.
Preferably, the phosphorus is added as ferrophosphorus powder.
After compression and sintering under conditions normal in connec-tion with powder metallurgical manufacture, such a powder mixture gives components having good mechanical properties and soft magnetic properties which are better than those of the corresponding material without phosphorus and,depending on the phosphorus content, can be even better than the soft magnetic properties of solid highly pure iron.
Below the invention is exemplified and the surprising results ob-tained are reported.
Example 1.
Two iron powders having different particle size distributions were manufactured by atomizing a highly pure iron melt, drying, after-reduction and sieving. Chemical analysis of these two iron powders gave the following composition: 0.047 % 0, 0.0004 % N, 0.003 % S, <0.1 % C and balance Fe. The particle size distribution of these iron powders A and B was as follows:

Iron powder Sieve analysisTyler mesh, %:
>35 35-100 <100 A 1.3 97.4 1.3 B 0.0 3.6 96.4 7~38 These iron powders were mixed with ferrophosphorus containing 15 % phosphorus and having a particle size less than 45 ~m, to a phosphorus content of 0.45 %. In the following, powder A with an addition of 0.45 %
phosphorus is designated C and powder B with an addition of 0.45 % phosphorus is designated D.
The powders A to D mixed with 0.8 % zinc stearate, were compressed at a pressure of 589 MPa to bars having the dimensions 55xlOxlO mm and to tensile test bars. After burning-off the lubricant by heating for 30 minutes at 400C in air, the bars were sintered in a belt furnace for 60 minutes at 1120C under a hydrogen atmosphere. As the coercive force is a relevant measure of the soft magnetic properties of a material, this was measured by means of a so-called coercimeter. The four materials showed the following coercive forces:
Material A 1.02 Oe B 1.56 Oe C 0.89 Oe D 1.34 Oe The abo~e results show the great advantages which are obtained when using a coarse iron powder mixed with phosphorus. The low coercive force value of material C is about the same as the coercive force of Armco-iron which is about 0.9 Oe.
It has also been found that at the same time as the coercive force decreases the resistivity of the material increases when phosphorus is added, which results in reduced eddy current losses, which means that the total magnetic losses are reduced.
The density, the tensile strength and the elongation at rupture appear from the following table:

1~()(~7~8 Material DensityTensile strengthElongation at rupture g/cm3 N/mm2 %
A 7.28 r~ 50 ~ 5 B 7~29 184 15.4 C 7.24 254 2.6 D 7.25 400 14.0 The strength properties given in this example show very low values for material A manufactured from iron powder having a low content of particles with a size less than 147 ~m. From the results it can also be seen that an addition of phosphorus to this powder improves the tensile strength about five times.
Example 2. -An iron powder A according to Example 1 was mixed with various amounts of ferrophosphorus containing 15 % phosphorus and having a particle size less than 45 ~m to produce phosphorus contents of from 0.3 to 1.5 %, 0.8 % Zn-stearate was added to each of these mixtures. Test bars were com-pressed, burned-off and sintered in the same way as described in Example 1.
The following results were obtained:

Material DensityTensile strengthElongation at rupture g/cm3 N/mm2 A ~ 0.30 % P 7.23 265 8.6 A 1 0.45 % P 7.24 254 2.6 A ~ 0.60 % P 7.23 240 0.9 A ~ 1.00 % P 7.18 234 0.7 A ~ 1.50 % p 7.15 150 0.5 A + 0 % P 7.28 ~ 50 ~ 5 These results show that the tensile strength of sintered bars having iron powder A as the basic material is substantially increased by the addition of phosphorus. The fact that this substantial increase of the tensile strength, which is dependent on the addition of phosphorus, has been obtained together with an improvement of the soft magnetic properties appears from the following table and Figures 1 and 2 of the accompanying drawings, which illustrate the tensile strength and the coercive forceJ respectively, as a function of the phosphorus content.
Material Coercive force _Oe A + 0.30 % P 0.95 A + 0.45 % P 0.89 A + 0.60 % P 0.82 A + 1.00 % P 0.73 A + 1.50 % P 0.85 A + 0 % P 1.02 All these coercive force values are very low and show that these materials are extremely well suited for components wherein good soft magnetic properties are desired.

Claims (5)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A powder intended for powder metallurgical manu-facture of soft magnetic components, which powder comprises a highly pure iron powder containing up to 1.5% by weight of phosphorus as an alloying additive, wherein the main portion of the powder has a particle size between 35 and 100 Tyler mesh (417 and 147 pm), less than 5% by weight of the powder has a particle size exceeding 35 Tyler mesh (417 pm) and less than 20% by weight of the powder has a particle size less than 100 Tyler mesh (147 pm).
2. A powder as claimed in claim 1 wherein the phos-phorus content is between 0.15 and 1.0% by weight.
3. A powder as claimed in claim 1 wherein less than 10% by weight of the powder has a particle size less than 100 Tyler mesh.
4. A powder as claimed in claim 1, 2 or 3 wherein the phosphorus is added in the form of ferrophosphorus in powder form.
5. A powder as claimed in claim 1, 2 or 3 wherein the phosphorus is added in the form of ferrophosphorus in powder form having a phosphorus content of about 15% by weight and a particle size less than 45 pm.
CA297,696A 1977-02-25 1978-02-24 Iron-phosphorus powder for manufacture of soft magnetic components Expired CA1100788A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE7702084A SE407641B (en) 1977-02-25 1977-02-25 POWDER INTENDED FOR POWDER METALLURGIC MANUFACTURE OF SOFT MAGNETIC PRODUCTS
SE7702084-0 1977-02-25

Publications (1)

Publication Number Publication Date
CA1100788A true CA1100788A (en) 1981-05-12

Family

ID=20330554

Family Applications (1)

Application Number Title Priority Date Filing Date
CA297,696A Expired CA1100788A (en) 1977-02-25 1978-02-24 Iron-phosphorus powder for manufacture of soft magnetic components

Country Status (8)

Country Link
JP (1) JPS53127310A (en)
CA (1) CA1100788A (en)
DE (1) DE2807602C2 (en)
ES (1) ES467302A1 (en)
FR (1) FR2381584A1 (en)
GB (1) GB1599081A (en)
IT (1) IT1101808B (en)
SE (1) SE407641B (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4236945A (en) * 1978-11-27 1980-12-02 Allegheny Ludlum Steel Corporation Phosphorus-iron powder and method of producing soft magnetic material therefrom
DE10020083A1 (en) * 2000-04-22 2001-10-31 Bosch Gmbh Robert Sintered soft magnetic material and process for its production

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB679413A (en) * 1950-03-04 1952-09-17 Metro Cutanit Ltd Improvements relating to magnetic material with good electrical conductivity
DE2118053A1 (en) * 1971-04-14 1972-10-26 Brown, Boveri & Cie AG, 6800 Mann heim Earth core for choke made from a mixture of ferromagnetic powder and insulating material binder
JPS4845472A (en) * 1971-10-13 1973-06-29
SE372293B (en) * 1972-05-02 1974-12-16 Hoeganaes Ab
JPS518368A (en) * 1974-07-09 1976-01-23 Noryuki Ikeda Burashiruino seizoho
DE2535377A1 (en) * 1975-08-08 1977-02-24 Huettermann Sintered iron element absorbing vibration and noise - esp. for mounting brake shoes in motor vehicle disc brakes
JPS5442644A (en) * 1977-09-09 1979-04-04 Nippon Electric Co Method of positioning electrodes of laminated condenser

Also Published As

Publication number Publication date
DE2807602C2 (en) 1986-10-16
SE407641B (en) 1979-04-02
FR2381584A1 (en) 1978-09-22
FR2381584B1 (en) 1983-01-14
JPS53127310A (en) 1978-11-07
IT1101808B (en) 1985-10-07
SE7702084L (en) 1978-08-26
IT7848186A0 (en) 1978-02-24
DE2807602A1 (en) 1978-10-19
JPS6323241B2 (en) 1988-05-16
ES467302A1 (en) 1979-11-01
GB1599081A (en) 1981-09-30

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