MAGFINE TECHNICAL DATASHEET World s Strongest Bonded Magnet

Transcription

1 マグファイン NdFeB 系 異 方 性 ボンド 磁 石 January 215 MAGFINE TECHNICAL DATASHEET World s Strongest Bonded Magnet 1

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3 Index 1 MagFine Technology 4 Magfine Magnet Lineup 6 2 Powders 21 Magnetic Characteristics 7 22 Particle Distribution and Shape 8 3 Injection Molding 31 Magnetic Properties 9 32 Characteristics 9 4 Compression Molding 41 Magnetic Properties Characteristics 13 5 Mechanical / Physical properties 19 3

4 MAGFINE Company Outline As a material maker for the Toyota Group, Aichi Steel has continued to supply new materials that support the reduction in weight and increase in performance of motor vehicles. As motor vehicles become increasingly electrified and connected, the growing need for lighter high performance electric motors is increasing attention on high powered bonded magnets. The world s strongest bonded magnet, MagFine, developed by Aichi Steel, is attracting attention as the core material for realizing the next generation of revolutionary motors. What is MagFine? 1 MagFine Technology The anisotropic NdFeB bonded magnet MagFine (MF) is a superior bonded magnet with the world s strongest magnetism of 25MGOe and heat resistance to 15. Discovered in 1982, the world s strongest NdFeB magnets have been produced by sintering or as isotropic bonded magnets. Due to the poorer magnetic properties of isotropic bonded magnets, the development of anisotropic bonded magnets has been awaited for 2 years. Aichi Steel discovered the fundamental process (dhddr) for making anisotropic magnet powder and have succeeded in commercializing an anisotropic bonded magnet. The name MagFine comes from the word Magnet and the Fine microstructure of the powder which is created by our dhddr process. Microstructure of MagFine Powder.2μm History of Anisotropic Bonded Magnets Principle of dhddr GM withdrew in 95 Aichi Steel (Toyota) succeeded in 3 Magnetic Performance (MGOe) ~Bonded Ferrite Began development in '85 Reached 25MGOe 85 A Co filed patent Failed to commercialize 88 B Co. file patent Did not commercialize 95 C Co announced Stopped in 99 Success in commercializing MagFine To downsize motors, GM developed isotropic bonded Nd magnet (GM Sold to M. Co in 95) Succeeded in commercializing MagFine with 25MGOe, operating to 15 2 (Year) (BH)max (MGOe) MAGFINE (Anisotropic) Crystal Direction: Aligned Isotropic H 2 Pressure (atm) Principle of dhddr (discovered1996) Crystal Direction: Random 2. Controlling the speed of the absorption/desorption reaction between NdFeB allow and Hydrogen to a critical speed makes it possible to realize the miniaturization and anisotropy of the crystal grains, producing a superior magnetic powder. 4

5 1 nm 1 nm MAGFINE Operating Temperature of 15 without Dy or Ga (21) Until now,the rare earth elements Dy and Ga have been added to increase the maximum operating temperature.now by utilizing fine grain crystals and nonmagnetic grain boundary film combined with the development of our microcapsule technology, we have succeeded in massproducing a low cost magnet that is heat resistant to 15 without using Dy, Ga. Prices of component metals (Nov 213) Nd:$1/kg Dy:$7/kg Ga:$26/kg Co:$29/kg Miniaturization+Nonmagnetic grain boundary Mother Material dhddr process Nd volume of NdFeB alloy2727.5% Fine crystal grain Crystal grain~1μm ~.3μm Caxis Nd 2Fe 14B (Main phase).3μm Low melting point alloy (NdCuAl) Grain boundary diffusion process Nd 2Fe 14B (Main phase) Nd rich grain boundary phase Nd Sintered:up to 5% Dy, 4% Co Isotropic :up to 4% Co Previous Method (Ga + Dy diffusion) Dy diff Std alloy Add Ga NdFeB Nd +1.5% Magnetic Field μ H / T Magnetic Polarity J /T New Alloy Dy, Ga free NdFeB Nd +.5% Nd+CuAl Diffusion Process Magnetic Field μ H / T Magnetic Polarity J /T TEM observation(eds Map) 1) After NdFeNbB dhddr process 2) After NdCuAl grain boundary diffusion process TEM Cu Nd Al Toyota Central R&D Labs TEM Cu Nd Al Nd Cu concentrate in grain boundary forming grain boundary phase Microcapsule technology improves reliability (21) In addition, we developed technology to encapsulate the magnetic powder giving superior reliability to isotropic magnets even without coating. Microcapsule Technology NdCuAl layer Oxidized coating (passive coat) Hard resin coating Magnet Powder Microcapsule Magnet Powder 1) Oxidation Resistance Flux Loss at 15 2) Corrosion Resistance Flux Loss at 8 95%RH Condition: Uncoated Flux Loss [%] 5 1 Target New MAGFINE ( 1) First MAGFINE( 5) Isotropic Pc=2.(Assembly) Flux Loss [%] 5 1 Target New MAGFINE ( 1) Isotropic Pc=2.(Assembly) Time [hr] Time [hr]

6 MAGFINE MagFine Magnet Lineup The mechanism of anisotropy has been clarified, the dhddr process has advanced and the performance of the magnet powder has been increased. In 21, Aichi Steel developed a new series of heat resistant MagFine powders without the use of Dy. These are known as MF15P and MF18P. Magnets made by compression molding of these powders are MF14C, MF16C and MF18C. MF18C is a heat resistant MagFine able to be used up to Lineup Residual Flux Density /kg Sintered Nd Magnet Sintered Ferrite Dy Added New MagFine powder without Dy addition Isotropic NdFeB Powder Coercivity/kA/m (BH)max (MGOe) 25 2 MF14C MF16C MF18C ihc (koe) MagFine Lineup MAGFINE Isotropic Powder MF1 5 P MF18P MF1 4 C Compression MF1 6 C MF18C Compresー sion ( BH) max MGOe Br kg ihc koe Α % / Β % /

7 21. Powder Magnetic Characteristics A. Specifications Product name MF15P MF18P Isotropy Br (T) B. Demagnetization Curve (kg) Typical 13.2 kg 12.5 kg H CJ (ka/m) (koe) Typical 14. koe 17. koe (BH)max (kj/m 3 ) MGOe Typical Measurement method Capsule: φ5 mm x 7.5mm Particle size: 212 μm Weight of magnet powder: 15 ±5 mg Alignment field: 1.8T at 1 deg.c, Magnetization field : 45kOe Device: VSM (BHV525H, Riken Denshi Co., Tokyo, Japan) Magnet powder was fixed with paraffin. Magnet Properties were calculated using.17 as demagnetizing factor. MF18P MF15P Isotropy Temp Magnetic Polarization J / T Magnetic Field μ H / T Typical Demagnetization Curve 7

8 22. Powder Particle Distribution and Shape A. Particle Distribution Product name MF15P MF18P Distribution <212μm <212μm X1/μm 256μm 256μm X5/μm 913μm 913μm X9/μm 1722μm 1722μm VMD/μm 914μm 914μm Cumulative frequency, Q3 / % < 212 micron meter sieving Mean diameter (volumetric) 11 micron meter Average particle size 1μm Frequency, Q Particle size / m measurement instrument: Laser diffraction particle size analysis B. Shape MF15P, MF18P 5μm 5μm Reference) Isotropic power shape : granular shape : flake *measurement method :HRSEM 8

9 31. Injection molding Magnetic properties Resin Powder Br kg bhc koe ihc koe ( BH) max MGOe Flow ability Q value cm 3 /s Vending strength MPa density g/ cm 3 1 PA1 2 MF18 P METE MF15 P PPS MF18 P MF15 P PA1 2 MF1 8 P+SmFeN SMM MF1 5 P+SmFeN MF1 8 P+SmFeN NICHIA MF1 5 P+SmFeN PPS MF1 8 P+SmFeN SMM MF1 5 P+SmFeN Injection molding Characteristics 1 MAGFINE+PA12 Demagnetization Curve Flux loss at 12, 15 1 MF18P+PA12 12 MF18P+PA12 15 MF15P+PA12 12 MF15P+PA12 15 MF18P+PA12 MF15P+PA B [kg] Flux loss [%] H [koe] Time [Hr] 1

10 2 MAGFINE+PPS Demagnetization Curve Flux loss at 12, 15 1 MF18P+PPS 12 MF18P+PPS 15 MF15P+PPS 12 MF15P+PPS 15 MF18P+PPS B [kg] Flux loss [%] 1 2 MF15P+PPS H [koe] Time [Hr] 1 3 MAGFINE+SmFeN+PA12 Demagnetization Curve MF18P+SmFeN+PA12 MF15P+SmFeN+PA12 SSM MF18P+SmFeN+PA12 MF15P+SmFeN+PA12 NICHIA 1 Flux loss at B [kg] Flux loss [%] H [koe] Time [Hr] 1 1

11 4 MAGFINE+SmFeN+PPS Demagnetization Curve Flux loss at 15 1 MF15P+SmFeN+PPS B [kg] Flux loss [%] 1 2 MF18P+SmFeN+PPS MF15P+SmFeN+PPS MF18P+SmFeN+PPS H [koe] Time [Hr] 1 11

12 41. Compression molding Magnetic properties A. Specifications Product name MF14C MF16C MF18C Block Ring Block Ring Block Ring Isotropic B r [kg] ih c [koe] bh c [koe] (BH) max [MGOe] Temperature coefficient of B r [%/deg.c].11 (RT12 deg.c).11 (RT15 deg.c).11 (RT15 deg.c).12 (RT12 deg.c) Temperature coefficient of i H c [%/deg.c].56 (RT12 deg.c).47 (RT15 deg.c).46 (RT15 deg.c).35 (RT12 deg.c) Recoil permeability [%] Density [g/cm 3 ] Coefficient of thermal expansion [deg.c 1 ] (JIS K7197) Parallel to alignment direction Perpendicular to alignment direction 8.2 x x 1 6 Modulus of elasticity [MPa] 15, Compression strength [MPa] 12 Electronic resistivity [mωcm] Typical magnet shape Block magnet:7mm x 7mm x 7mm Ring magnet:o.d 26mmThickness 1.mmLength 16mm B. Demagnetization Curve Pc=.5 Pc=1. Pc=2. 1. MF14C MF16C MF18C Isotropic Magnetic Polarization J / T Magnetic Field μ H / T 12

13 42. Compression molding Characteristics 1 MF14C A. Magnetic Properties B r i H c b H c (BH) max T kg ka/m koe ka/m koe kj/cm 3 MGOe Block magnet Ring magnet Typical magnet shape Block magnet:7mm x 7mm x 7mm Ring magnet:o.d 26mmThickness 1.mmLength 16mm B. Demagnetization Curve R.T Magnetic Polarization J / T Magnetic Field μ H / T 13

14 C. Recoil 1 D. Irreversible Loss 5 3 H / koe B / kg Flux Loss / % in Air 4 noncoated Holding time : 5min Temperature / deg.c E. Aging Test F. Humidity Test 1 1 Flux Loss / % deg.C 15deg.C Flux Loss / % Exposure time / hr 5 8deg.C x 95%RH Exposure time / hr Br/Br(4.5T) / % G. Magnetization Magnetization field / T 14

15 2 MF16C A. Magnetic Properties B r i H c b H c (BH) max T kg ka/m koe ka/m koe kj/cm 3 MGOe Block magnet Ring magnet Typical magnet shape Block magnet:7mm x 7mm x 7mm Ring magnet:o.d 26mmThickness 1.mmLength 16mm B. Demagnetization Curve R.T Magnetic Polarization J / T Magnetic Field μ H / T 15

16 C. Recoil D. Irreversible Loss H / koe B / kg Flux Loss / % in Air noncoated Holding time : 5min Temperature / deg.c E. Aging Test F. Humidity Test 1 1 Flux Loss / % deg.C 15deg.C Flux Loss / % Exposure time / hr 5 6 8deg.C x 95%RH Exposure time / hr G. Magnetization Br/Br(4.5T) / % Magnetization field / T 16

17 3 MF18C A. Magnetic Properties B r i H c b H c (BH) max T kg ka/m koe ka/m koe kj/cm 3 MGOe Block magnet Ring magnet Typical magnet shape Block magnet:7mm x 7mm x 7mm Ring magnet:o.d 26mmThickness 1.mmLength 16mm B. Demagnetization Curve R.T Magnetic Polarization J / T Magnetic Field μ H / T 17

18 C. Recoil 1 D. Irreversible Loss 5 3 H / koe B / kg Flux Loss / % in Air noncoated Holding time : 5min Temperature / deg.c E. Aging Test F. Humidity Test 1 1 Flux Loss / % deg.C 15deg.C Flux Loss / % Exposure time / hr 5 8deg.C x 95%RH Exposure time / hr G. Magnetization Br/Br(4.5T) / % Magnetization field / T 18

19 5. Mechanical / Physical Properties Type Compression molding Injection molding Binder resin Epoxy Nylon 12 PPS Tensile strength MPa 12 * 3 55 Modulus of elasticity GPa 21 * Poisson's ratio Tensile strain at breaking %.1.96 Compressive strength MPa 1 * Compression strain at breaking % 1.1 * Hoop stress MPa ( 27) Radial crushing strength MPa 2 Coefficient of thermal expansion %/ ** ** Molded density g/ cm * Measurement temperature :1 5 * * Measurement temperature : 4 ~1 5 19

20 USA Inquiries MagnetoDynamics LLC. TEL FAX: January 215Technical Data 1 Wanowari, Araomachi, Aichiken, JAPAN Inquiries Electromagnetic Products, Sales Div. TEL: FAX: magfine@he.aichisteel.co.jp 2