JPH0610282B2 - Amorphous metal forming method - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing an amorphous metal compact mainly composed of an iron-based element. Since the amorphous metal has an amorphous structure, it has a large mechanical strength, a small coefficient of thermal expansion, a small radiation damage, and excellent chemical corrosion resistance and abrasion resistance. In particular, an amorphous material as a magnetic material has no structural defects such as crystal grain boundaries, no crystalline magnetic anisotropy, significant improvement in coercive force and relative permeability, and high It has excellent properties such as having electrical resistivity. Therefore, amorphous metal is also called a dream material, and is expected to have an extremely wide range of applications such as electromagnetic cores, various sensors, and electromagnetic clutches. According to the manufacturing method of the present invention, it is possible to manufacture a bulk (lump) -shaped amorphous metal compact having a small number of voids. Therefore, it can be used to manufacture motor cores (Fig. 3), transformer cores (Fig. 4), electromagnetic coil cores (Fig. 5), electromagnetic pickups (Fig. 6), electromagnetic cores, electromagnetic clutches, and various sensors. Available.

[Prior Art] Since the above-mentioned amorphous metal is formed by a liquid quenching method of cooling at about 10 ⁷ ° C / sec, a sputtering method, and a vapor deposition method, only a ribbon shape, a powder shape, a thin wire shape, and a thin film shape can be manufactured. Further, the amorphous metal is extremely weak against heat, and when heated to 300 to 400 degrees, the amorphous property is impaired, and processing such as welding cannot be performed. Therefore, it could not be manufactured in bulk. Therefore, although the amorphous metal has the above-mentioned excellent properties and is said to be a dream material, it can be applied only to a member having a special shape, and its use is narrowly limited. Therefore, the present inventors have recently discovered that if an amorphous metal powder is subjected to explosion molding, a bulk (lump) shaped body can be obtained without impairing the amorphous property. However, although only the explosive molding can form a bulk (lump) shaped body, a small amount of voids remain inside the molded body, and this small amount of voids adversely affects the magnetic properties, mechanical properties, etc. Exert.

[Object of the Invention] The present invention has been made in view of the above-mentioned conventional circumstances. Therefore, an object of the first invention and the second invention is to provide a method for producing an amorphous metal compact which can reduce voids.

[Summary of the Invention] The present inventor has conducted extensive research on amorphous metal based on the above object, and as a result, mixed amorphous metal powder and amorphous metal ultrafine powder to form a mixed powder, or amorphous metal powder and metal ultrafine powder. When mixed with powder to form mixed powder, or mixed with amorphous metal powders having different particle diameters to form mixed powder, and subjecting this mixed powder to high energy velocity processing such as explosion molding, it becomes a void. It has been found that the molded body can be formed with significantly reduced or almost no. It was also discovered that the voids can be considerably reduced even when high energy velocity processing is performed on amorphous metal powder having a grain size with a close ratio of the longitudinal cross-sectional area to the cross-sectional area. The present invention is based on such findings.

[Structure of First Invention] A method for manufacturing an amorphous metal compact according to a first invention comprises an amorphous metal powder mainly composed of iron-based elements and having a particle size of 10 to 200 μm, and a particle size mainly composed of iron-based elements. 50-
The present invention is characterized in that a mixed powder is formed by mixing with 1000 angstrom ultrafine amorphous metal powder to form a mixed powder, and the mixed powder is solidified by high energy speed processing to form a compact.

[Detailed Description of the Configuration of the First Invention] Hereinafter, (amorphous metal powder) (amorphous metal ultrafine powder) (metal ultrafine powder) (step) will be described in detail.

(Amorphous Metal Powder) The amorphous metal powder used in the first invention is a powder mainly composed of iron-based elements. Here, the iron-based element is iron (F
e), cobalt (Co) and nickel (Ni) are meant. Amorphous metal powders mainly composed of iron-based elements are alloys of iron-based elements and semimetals (phosphorus (P), carbon (C), boron (B), silicon (Si), etc.), or iron-based elements and rare earths. An alloy with a metal (Gd, Tb, Dy, etc.) can be used. Typical amorphous metal powders include Fe ₇₀ Co ₁₅ B ₁₅ and Fe ₈₀ B ₁₅ S.
i ₅ , Fe ₄₀ Ni ₄₀ P ₁₄ B ₆ , Fe ₇₀ Co ₁₅
B ₁₅ , Co ₈₀ B ₁₅ C ₁₅ , Ni ₇₈ B ₂ Si ₁₀
and so on. (Numerical values such as 70, 15, and 5 indicate atomic%.) The particle shape of the amorphous metal powder is preferably spherical or elongated gourd shape with excellent symmetry, but may be flaky or ribbon shape in some cases. Alternatively, a linear product may be crushed.

In the present invention, the granularity of the amorphous metal powder is 10 to 200.
A material with a size of about μm is used. The reason why the numerical value is limited to 10 to 200 μm is as follows. That is, if it is less than 10 μm, the volume of the powder particles becomes smaller than the surface area of the powder particles. Therefore, it becomes insufficient to remove the heat generated on the surface of the particles of the amorphous metal powder to the inside of the particles when performing high energy velocity processing such as explosion molding.
As a result, the amorphous property of the ultrafine amorphous metal powder existing on the surface of the particles is likely to be lost. Again 2
This is because if it exceeds 00 μm, the powder packing density becomes low and the bondability of the powder particles deteriorates.

Amorphous metal powder having a particle size of 10 to 200 μm can be produced by a commonly used method. For example, a rotating roll method, an atomizing method, a spray method, a spark method, a cavitation method or the like can be used. Amorphous metal powder having spherical particles can be produced by a spark method or an atomizing method.

A typical example of producing an amorphous metal powder by the rotating roll method will be described more specifically. That is, Fe65
Parts, Co15 parts, B15 parts, Si5 parts and powder having a particle size of 1 to 1000 μm are mixed in a ball mill,
It is melted at a high temperature of 13.56 MHz at 1400 ° C. or higher, and then this molten metal is formed into a rod shape having a diameter of 5 to 30 mm. Next, this rod-shaped molded body is heated and melted at a temperature of 1350 ° C. to 1400 ° C. in a container made of quartz or ceramics. High frequency melting is preferable for heat melting. Next, the molten metal formed as described above is jetted from the nozzle of the container toward the underwater rotating roll, thereby producing an amorphous metal powder having a particle size of 10 to 200 μm. The shape of the amorphous metal powder produced in this way is often a gourd shape.

(Amorphous metal ultrafine powder) The amorphous metal ultrafine powder used in the first invention means an ultrafine amorphous metal powder having an amorphous property and a particle size of 50 to 1000 angstrom. This amorphous metal ultrafine powder has a very large specific surface area and is therefore very active. If this amorphous metal ultrafine powder is added, the bondability between the particles forming the compact can be improved.

As a typical amorphous metal ultrafine powder, silicon, Fe ₈₀ B ₁₅ Si ₅ , Fe ₇₀ Co ₁₅ B ₁₅ ,
It can be used as the _{Co 75 B 15 Si 10, Ni} 75 B 15 Si 70. Amorphous metal ultrafine powder with a particle size of 50 to 1000 angstrom is plasma CV
It can be manufactured by the D method or the sputtering method. Plasma CVD
In the case of the method, an amorphous metal producing gas is introduced between the electrodes, and high-frequency power is applied between the electrodes to cause glow discharge between the electrodes, whereby the produced gas is made into plasma and the amorphous metal super-imposed on the substrate. This produces a fine powder. For example, in the case of producing amorphous silicon ultrafine powder which is a typical example of amorphous metal ultrafine powder, silane (S
iH4) gas by plasma CVD method from 0.001
Decomposes in the range of 10 W / cm ³ and deposits ultrafine amorphous metal powder on the substrate. The substrate is preferably kept at room temperature or cooled with water. The particle size of the amorphous silicon ultrafine powder produced by the plasma CVD method as described above is usually
It is 50 to 800 angstroms.

Iron-based, cobalt-based, and nickel-based ultrafine amorphous metal powders can be similarly produced by plasma CVD or sputtering. For example, when producing ultrafine powder of FeBSi alloy, which is a typical example of amorphous metal ultrafine powder, a mixed gas of silane (SiH4) gas and BCl3 gas (or B2H6 gas) and FeCl3 solid are heated and vaporized. And the gas is sent into the reaction vessel 10 ^-2 ~
0.001 to 10 w / cm under vacuum at 5 Torr
It is made to react under the plasma of ^{3 and} the particle size is 50-10.
FeBS with an amorphous property of 00 angstrom
Ultrafine powder of i alloy can be manufactured.

(Ultrafine metal powder) Ultrafine metal powder can be added to the mixed powder. The ultrafine metal powder is a fine metal powder having a particle size of 50 to 1000 angstrom and does not have an amorphous property. The ultrafine metal powder has a very large specific surface area and is therefore very active. Therefore, if this ultrafine metal powder is added, the bondability between the particles constituting the compact can be improved.

Fe, Co, Ni, S are typical metal ultrafine powders.
i or the like can be used. The ultrafine metal powder can be generally produced by a vacuum evaporation method, an electron beam evaporation method, a sputtering method, or the like. For example, it can be manufactured by putting a few to several hundreds Torr of an inert gas in a vacuum evaporator having a vacuum of 10 ⁻⁴ Torr or less, and melting and evaporating a metal therein. As the ultrafine metal powder, a commercially available product can be used.

(Step) In the manufacturing method of the first invention, the amorphous metal powder and the amorphous metal ultrafine powder are mixed to form a mixed powder. When mixing, use a pot mill mixing method, a reiki mixing method, a vibration mill mixing method, etc. Specifically, first fill a large powder, and then, while vibrating, fill and mix ultrafine powder between the large powders. It is carried out by a method, that is, a vibration filling mixing method. Since the amorphous metal ultrafine powder has a very large specific surface area and is highly active, it is necessary to take care so that it does not deteriorate. In order to suppress alteration, the prepared powder should be adsorbed on the surface in an inert gas such as N ₂ or Ar in a vacuum, and then taken out into the atmosphere to quickly remove N ₂ or
It is recommended to store in a room kept in Ar atmosphere. In the mixed powder, the addition amount of the amorphous metal ultrafine powder is 0.
01 to 20 Vol% or less is preferable. The reasons are, firstly, that the bondability does not change even if it is further added, and secondly, the magnetic properties of the molded body deteriorate. The magnetic properties are deteriorated because the surfaces of the ultrafine metal particles are often oxidized or deteriorated.

In the manufacturing method according to the first aspect of the present invention, the mixed powder described above is subjected to high-energy speed processing to consolidate and form a compact. FIG. 1 is a schematic view of the mixed powder in a microscopic state, and FIG. 2 is a schematic view of a molded body obtained by processing the mixed powder at a high energy velocity in a microscopic view. As is apparent from FIG. 2, the powder particles are solidified in the state of high energy speed processing. Here, high energy speed machining means
This means a processing method of instantaneously releasing energy in an extremely short time (generally, an extremely short time of about 10 ⁻³ to 10 ⁻⁶ seconds) to perform molding. When the high energy speed processing is used, the energy per unit time, that is, the energy speed is extremely large, and therefore the solidification can be performed without generating much heat. Therefore, it can be solidified without impairing the amorphous property. Molding pressure by high energy speed machining is 0.7-1
0 GPa is good. Here, when the molding pressure is less than 0.7 GPa, the pressure of the powder particles is low and the powder particles have poor pressure-bonding properties, making it difficult to perform integral molding. However, when the molding pressure is 0.7 GPa or more, integral molding is possible, and more preferably 1. If it exceeds 5 GPa, a better and uniform molded product can be obtained. Depending on the case, for example, when the powder particles are large, 50 GPa
May be close to.

Explosive molding processing is a typical high energy speed processing. The explosive molding process is a method in which pressure is momentarily applied by a shock wave or gas expansion generated by the explosion of TNT explosive or dynamite. Explosive molding is generally performed by exploding explosive powder in water. The pressure of explosion molding can be adjusted by the depth from the water surface to the explosive, the distance from the explosive to the object to be molded, and the amount of explosive. Pressure when using explosive molding is 0.7-10
GPa is desirable. If a higher pressure than that is applied, the amount of heat at the time of joining becomes too large, and part of the amorphous is crystallized, so that the amorphous property tends to be lost, and if the pressure is lower than that, the particles do not sufficiently join. is there.

In the explosive molding, specifically, the above-mentioned mixed powder is loaded into a molding die (for example, a molding die for molding an iron core for a motor), and this and T
It is installed in a container filled with NT powder.

In a special case, an electric discharge forming method using electric energy can be used as the high energy speed machining.
In the electric discharge molding method, the electric charge accumulated in the capacitor is spark-discharged in water, and the shock wave generated at that time is used to instantaneously consolidate the mixed powder. According to the electric discharge molding method, the magnitude of pressure can be easily adjusted electrically.

The mechanism by which the amorphous metal compact is consolidated is presumed to be as follows. That is, the mixed powder adheres strongly by high energy velocity processing such as explosive molding, which causes consolidation. High energy speed machining is usually 10 ⁻³
Since the energy is instantaneously released in an extremely short time in the range of -10 to ⁶ seconds, even if the amorphous metal powder easily loses the amorphous property by heating, the amorphous property is not impaired, or almost no Can be solidified without damage. In this case, the amorphous metal ultrafine powder of the first invention is located around the particles of the amorphous metal powder forming the compact and functions as a binder. Here, the heat generated in the amorphous metal ultrafine powder is taken to the inside of the amorphous metal powder that is the base. Therefore, the amorphous metal ultrafine powder can be solidified without impairing the amorphous property or almost impairing it.

(Structure) The structure of the amorphous metal compact manufactured by the manufacturing method of the first invention is shown in FIG. The sample shown in FIG.
e ₈₀ B ₂₀ 90 vol% powder having a particle size of 10 to 200 μ,
10 vol% amorphous metal ultrafine powder Fe ₈₀ B ₂₀
Was added and the mixture was molded by explosion molding (about 1.5 MPa). In this sample, a halo pattern was obtained in the X-ray diffraction pattern regardless of which part was seen.

In FIG. 8, the ultrafine amorphous metal powder functions as a binder for binding the amorphous metal powder as the base material.

It has been clarified that the amorphous metal molded body manufactured by the method as described above secures the amorphous property. That is, in the structure of the amorphous metal formed body according to the first invention shown in FIG. 8, the Vickers hardness is 700 to 1
It is as high as 300, which is clear from the fact that a halo pattern was observed by X-ray diffraction and a halo ring was observed by electron beam diffraction using an electron microscope.

[Effect of the first invention] According to the manufacturing method of the first invention described above, the number of voids is reduced as compared with the conventional case. This is also apparent from the fact that the Vickers hardness of the first invention product is larger than that of the comparative example, as shown by the test values of Examples described later.

[Examples of First Invention] Table 1 shows examples of amorphous metal compacts produced by the production methods of the first invention and comparative examples. In this case, the amorphous metal powder has an average particle size of 5
Those having a particle size of 0 to 70 μ and a particle size of 10 to 200 μ were used. Further, as shown in Table 1, as the amorphous metal ultrafine powder,
Fe ₈₀ B ₁₅ Si ₅ , Fe ₇₀ Co ₁₅ B ₁₅ , Co
₇₅ B ₁₅ Si ₁₀ and Ni ₇₅ B ₁₅ Si ₁₀ were used. Further, as the metal ultrafine powder, Fe, Si, Co,
A crystal powder of Ni was used. As the amorphous metal ultrafine powder and the metal ultrafine powder, those having a particle size of 50 to 500 angstrom were used. The addition amount of the amorphous metal ultrafine powder and the metal ultrafine powder was set to 0.01 to 20 Vol%. To mix amorphous metal powder and ultrafine amorphous metal powder, or mix amorphous metal powder and ultrafine metal powder, first fill a large powder of 80 to 99.9 vol%, and then apply vibration to the gap between the particles. Fine powder 0.01-2
It was carried out by a method of mixing 0 vol%. In the above embodiment, explosion molding was performed as high energy speed machining.
Specifically, the explosion molding is performed as follows. That is, the powder is loaded into a container having a predetermined shape so as to have a theoretical density of about 50 to 60%, and the container is sealed after vacuum deaeration. Next, pretreatment by sheet explosion is performed. Then take it out and store it in an inner container made of copper, brass, or stainless steel, and then install an outer container outside the inner container. Make a point explosion by. Next, the main explosive, causemite explosive, is exploded by a plane explosive wave by the explosive lens due to the shape effect of the outer container, and explosion molding is performed. This explosion molding has a water depth of about 1
It goes under ~ 2m and absorbs sound and energy at the time of explosion.
The manufactured molded body is housed in an inner container, and the inner container contacting the molded body is removed by grinding or etching with an acid / alkali. The molding pressure was 0.7 to 10 GPa, although it varied depending on the mixing ratio.

Table 1 shows the magnetic characteristics (saturation magnetic flux density, magnetic permeability, coercive force) and Vickers hardness of the amorphous metal compacts of the respective examples manufactured as described above. The Vickers hardness is compared in Table 1. First, No. 1 to No. 3 (first invention) having the same composition of amorphous metal powder and No. 8 (comparative example) are compared. Vickers hardness is No.1 to No.3
(Molded product of the first invention) was as high as 1030. On the other hand, in No. 8 (comparative example), it was as low as 990. Also, No. 6
When comparing No. 7 and No. 8 with No. 8 (comparative example), No. 6
And Vickers hardness of No. 7 is 1030, and No. 8
It was higher than (comparative example). This also shows that the molded article of the first invention has few voids.

The saturation magnetic flux density is 14.5 to 16.2 in No. 1 to No. 3 and No. 6 (molded product of the first invention). On the other hand, N
It was as low as 14.0 in o.8 (Comparative Example). This also shows that the product of the present invention has few voids.

[Structure of Second Invention] A method for manufacturing an amorphous metal compact according to a second invention comprises: an amorphous metal powder mainly composed of an iron-based element and having a particle size of 75 to 125 μm; and a particle size mainly composed of an iron-based element. 10 to
The present invention is characterized in that a mixed powder containing 50 μm of amorphous metal powder is formed, and the mixed powder is consolidated by high-energy speed processing to form a compact.

A feature of the second invention is that amorphous metal powders having a large particle size and a small particle size are used. Therefore, the packing density of the powder can be increased, and the voids of the molded body can be reduced.
Incidentally, those having a small particle size mainly function as a binder.

[Detailed Description of Configuration of Second Invention] The amorphous metal powder used in the second invention is a powder mainly containing an iron-based element. Here, the iron-based element means iron, cobalt, and nickel. As in the case of the first invention, the amorphous metal powder is an alloy of the iron-based element and a semimetal (P, C, B, Si, etc.) or an iron-based element and a rare earth metal (Gd, Tb, Dy, etc.). ) And an alloy with can be used.

The particle size of the amorphous metal powder is 75 to 125 μ.
m, 10 to 50 μm, but powders having other particle sizes may be added to the mixed powder.
For example, ultrafine powder having a particle size of 50 to 1000 angstrom may be added separately. The ultrafine powder to be added should have excellent heat resistance and corrosion resistance, such as Fe, Co, Ni, and C.
r, Si, B, W, Ti, Mo, V, Ge and Pd are preferable.

As a typical amorphous metal powder having a particle size of 75 to 125 μ, MaYbZc (wherein M is Fe, Co and Ni, Y is phosphorus (P), carbon (C) and boron (B) and Z is Z). Al, Si, etc. a, b, c are atomic%
Where a is 60 to 90, b is 10 to 30, and c is 0.1 to 1.
5) can be used. For example, Fe ₆₅ Co ₁₅ B
₁₅ and Si ₅ can be used.

Further, as typical amorphous metal powders of 10 to 30 μm, Fe _{75 to 85} B _{15 to 25} and Ni _{75 to 85} B are used.
_15-25 , Ni _65-75 B _10-20 P _5-25 ,
Fe _75-85 B _5-15 C _5-15 , Fe _75-80
B _10-25 Co _1-3 Mo _0.1-2 . The shape of the amorphous metal powder is preferably spherical or elongated gourd with excellent symmetry, but may be non-spherical, for example, flaky, ribbon or linear.

When the amorphous metal powder of 75 to 125 μm having the above composition of MaYbZc is used, the particle size is 10 to 5
The shape of the particles of the amorphous metal powder of 0 μ is preferably spherical. The reason is that although the amorphous metal powder of 75 to 125 μ represented by the above-mentioned composition of MaYbZc has excellent magnetization characteristics, most of them are not spherical, and therefore spherical particles are added to improve the packing density. is there. In particular, an amorphous metal powder having a particle size of 10 to 50 μ is added to Fe ₈₀ B ₂₀ (or Fe _{75 to 85} B).
_{15 to 25} ) is preferable because the particle shape is close to a spherical shape and the saturation magnetic characteristic is 18 KG.

Amorphous metal powder with a particle size of 75-125μ and a particle size of 1
When mixing 0-50 μm of the amorphous metal powder, a powder having a composition shown in Table 2 may be used, and the addition amount may also be shown in Table 2. Where 1
Amorphous metal powder of 0 to 50μ is 7 to 25 VoL
% Is desirable. Here, an amorphous metal powder having a particle size of 75 to 125 μ (Fe65 Co15 B15
Si5) is 75% by weight or less, and the particle size is 10 to 50 μ.
When the amount of the amorphous metal powder (Fe80 B20) is 25% by weight or more, the number of voids in the molded body increases. Therefore, the density is as low as 6.5 g / cc (theoretical density is 6.87 g.
/ Cc) and the saturated velocity density is 16 KG or less, which is not preferable. The reason is that there are many particles having a small particle size (10 to 50 μm), so that a shock wave during explosion molding is difficult to be transmitted to the inside. Therefore, there are some areas where particles do not solidify, it is difficult to obtain a tight one, and there are many voids with a small volume, so the packing density is much smaller than the theoretical density, and as a result, the magnetization characteristics are also poor. Because it will be.

When 93% by weight or more of the amorphous metal powder having a particle size of 75 to 125 μ and 7% by weight or less of the amorphous metal powder having a particle size of 10 to 50 μ, voids are easily formed because many particles have a large particle size. As a result, the packing density becomes 6.5 g / cc or less, and it is difficult to obtain preferable magnetization characteristics.

In order to improve the packing density and the moldability of explosion molding, ultrafine powder may be mixed in the mixed powder. As the ultrafine powder, those having a particle size of 50 to 1000 angstrom are usually used. The ultrafine powder may be a crystalline metal powder or an amorphous metal powder.

High energy speed machining can be performed in the same manner as in the invention described above, and explosive molding is preferably performed in the same manner as described above. The molding pressure is preferably 10 to 50 GPa. If the molding pressure is low, for example, 5G
If it is less than Pa, the pressure-bonding property of the powder particles deteriorates.

[Effects of the Second Invention] According to the manufacturing method of the second invention described above, it is possible to manufacture an amorphous metal molded body with reduced voids or no voids. It should be noted that, while the density of the molded body obtained by explosive molding of amorphous metal powder (composition of Fe ₈₀ B ₂₀ ) of 75 to 125 μ is 6.4 to 6.5 g / cc, that of the product of this example. It is also clear from the fact that the density is as high as 6.75 g / cc as shown in Table 3.

[First embodiment of the second invention] (Production of amorphous metal powder having a particle size of 75 to 125 µm) Powder having a particle size of 1 to 1000 µ having a composition of 65 parts of Fe, 15 parts of Co, 15 parts of B, and 5 parts of Si is ball milled. After mixing, it is melted at 1400 ° C. or higher by high frequency heating at 13.56 MHz. After that, the molten metal is formed into a rod shape having a diameter of 5 to 30 μ. In this case, the molten metal is poured into a mold or sucked into a pipe-shaped container to be solidified and molded into a rod shape.

Next, this rod-shaped molded body is heated and melted at a temperature of 1350 to 1400 ° C. in a rod-shaped container made of quartz or ceramics.
High frequency heating was used for melting.

Next, the molten metal formed as described above is ejected from the nozzle of the rod-shaped container toward the rotating roll, whereby the particle size of 75-
125μ amorphous metal powder (Fe ₆₅ Co ₁₅ B
₁₅ Si ₅ ) is produced. The shape of the amorphous metal powder was mostly gourd type. In this example, the material of the rotating roll capable of holding water is copper or brass, aluminum, aluminum alloy, the diameter of the rotating roll is 30 to 60 cm, the rotating speed of the rotating roll is 3000 to 10000 rpm, the melting temperature is 1200 to 1600 ° C, and the nozzle is Diameter of spouting part of 0.05 ~
It was 0.5 mm.

(Production of Amorphous Metal Powder of 10 to 50 μm) Amorphous metal powder (Fe ₈₀ B ₂₀ ) having a particle size of 10 to 50 μ was also produced by the same rotating roll method.

(Step) Next, the amorphous metal powder (Fe ₈₀ B ₂₀ ) having a particle size of 10 to ₅₀ μm manufactured as described above and the particle size of 75 to 125 are used.
μ amorphous metal powder (Fe ₆₅ Co ₁₅ B ₁₅ S
i ₅ ) was mixed with a ball mill or a liqui machine to form a mixed powder. In this example, the additive amount of Fe80 B20 amorphous metal powder was 12 wt% as shown in Table 3.

Next, the above-mentioned mixed powder was loaded into a predetermined molding die, and this was placed in a container filled with TNT explosive, and the TNT explosive was ignited to perform explosion molding. Thereby, the mixed powder was solidified to produce an amorphous metal compact. The size of the compact is φ15 × H40 mm. In this example, the molded body is specifically shown in FIG. The explosion molding of this example was specifically carried out by the same method as described above.

(Test Value) The amorphous metal compact thus produced has a maximum saturated velocity density of 17.5 KG, as shown in Table 3.
The magnetic permeability is 5 × 10 ⁴ μe, and the maximum molding density is (Theoretical density is )Met. Incidentally, the molding density of the conventional product such as the powdered ribbon-shaped product or the flat-shaped product is 5.8 g / cc. This conventional product is manufactured by cutting an amorphous ribbon-shaped product or a flat product prepared by making a roll with a cavity when making amorphous powder into a flat product and then rapidly cooling it with the next roll. It was done.

The amorphous metal molded body of this example manufactured as described above was cut to a thickness of 0.2 to 0.7 mm by a diamond slicer, electric discharge machining, etc., and one piece was insulated from the other for a motor. It is used as an iron core material and laminated and molded. The characteristic of the motor manufactured as described above is that the saturation magnetic flux density is 16 to 1
8 KG, which is about 18 to 2 of the conventional grain-oriented silicon steel.
Although lower than 0 KG, the iron loss of the current product (45 W rating) is 2.4 W when viewed from the whole motor, and the iron loss of the product of the present invention is as low as (45 W rating) 1.2 W.

(Test Values of Other Embodiments) In Table 3, the test results of the maximum magnetic flux density and the maximum compacting density when the composition of the amorphous metal powder of 10 to 50 μ is variously changed to Fe65Co15B15Si5 of 75 to 125 μ of the amorphous metal powder. It is shown.

As shown in Table 3, the maximum saturation magnetic flux density is 16.0 to 1.
It is about 7.5 KG, and the maximum molding density is 6.55-6.
It was 81 g / cc.

[Second embodiment of the second invention] This embodiment is characterized in that particles of amorphous metal powder having a nearly spherical shape are used. That is Fe75-85B
An amorphous metal powder having a composition of 15 to 25 was used, which had a nearly spherical shape and good magnetic properties. That is, particle size 75 to 12
75-94% by weight of powder of 5μ and 6-25% by weight of powder of particle size 10-30μ were mixed. Then, it was molded by explosive molding (molding at a pressure of about 3 GPa). In the case of a spherical shape, molding can be performed even with a relatively low pressure of about 3 GPa. However, even in this case, it is more preferable that the molding pressure is about 8 GPa or more.

When the core for a transformer shown in FIG. 4 is formed by using the amorphous metal powder manufactured by the above manufacturing method,
The iron loss characteristics of the transformer (conventional one is grain oriented silicon steel, maximum 20KW, 45W iron loss) is 12W at maximum 20KW, which is about 1/3 or less compared to the conventional one. The weight was good, and since the organic binder was not used for the size and shape, the weight could be reduced by about 5% as compared with the conventional product.

[Third Embodiment of the Second Invention] This embodiment is characterized in that the mixed powder contains ultrafine metal powder. This ultrafine metal powder functions as a binder for amorphous metal powder. 88 parts of amorphous metal powder (Fe80B20) with a particle size of 75-125μ, particle size 1
Amorphous metal powder of 0 to 30 μm (Fe80B2
0) 12 parts of crystalline ultrafine Fe powder (average particle size 0.03 to 0.05 μm, particle size distribution 0.005 to
0.1 μm) was added. The method of mixing ultrafine powder is
Powder of 75 to 125 μ and powder of 10 to 30 μ are mixed by a ball mill or the like, and the mixed powder is filled in a mold for explosion molding. Then, ultrafine powder is added from the upper surface of the mold, and vibration is applied to the mold. The vibration was 50 to 100 KHz. Then 7
Ultra-fine powder is filled in the particles of 5 to 125 μ and the space generated between the particles of 10 to 30 μ. When the desired amount is filled, the addition of ultrafine powder is stopped. In this way, the ultrafine powder can be uniformly filled in the gaps between the particles.
The relationship between molding density and explosive molding pressure at this time
Shown in the figure. As shown in FIG. 7, the molding density increases as the amount of ultrafine Fe powder added increases, but the increase of the molding density reaches a ceiling even when about 5 parts or more is added. On the other hand, the pressure at which explosive molding is possible can be reduced as the amount of the ultrafine Fe powder added is increased, but a significant effect cannot be obtained at approximately 12 parts or more. Therefore, it is not preferable to mix the ultrafine powder, which is costly, unnecessarily, and the range of about 0.1 to 12 parts is preferable.

Here, the ultrafine Fe powder is present as a binder between the particles of the amorphous metal powder. A magnetic core material for an automobile ignition coil (core for an electromagnetic coil) shown in FIG. 6 was formed using the molded body manufactured as described above.
In this case, the magnetic permeability could be increased and the iron loss characteristics could be reduced by about 5 to 7% as compared with the conventional one. As the amorphous metal powder used in the method of the present invention, a nearly spherical particle powder having a ratio of vertical cross-sectional area to cross-sectional area of 5: 1 or less can be adopted. This is advantageous for producing an amorphous metal molded body that has no voids or has a considerably reduced number of voids. here,
The vertical cross-sectional area means a cross-sectional area cut at a portion having the largest cross-sectional area. The cross-sectional area means a cross-sectional area cut in a direction perpendicular to a cross section having a vertical cross-sectional area.

[Brief description of drawings]

FIG. 1 is an enlarged schematic view showing the state of the mixed powder before the explosion molding. FIG. 2 is an enlarged schematic view showing the inside of the molded body after the explosion molding. 3 to 5 show a molded body manufactured by applying the manufacturing method of the present invention. FIG. 3 is a perspective view of a motor iron core, FIG. 4 is a perspective view of a transformer iron core, and FIG. FIG. 5 is a perspective view of an iron core for an electromagnetic coil, and FIG. 6 is a perspective view of an electromagnetic pickup. FIG. 7 shows the relationship between the addition amount of ultrafine powder and the molding density,
3 is a graph showing the relationship between the amount of ultrafine powder added and the explosive moldable pressure. And FIG. 8 is a micrograph of the metal structure of the sample according to the first invention.

Claims (15)

[Claims] 1. A particle size of 10 to 200 .mu.
m of the amorphous metal powder and an amorphous metal ultrafine powder of iron-based element having a particle size of 50 to 1000 angstrom are mixed to form a mixed powder, and the mixed powder is consolidated by high energy speed processing. 1. A method for producing an amorphous metal compact, which comprises forming a compact. 2. The method for producing an amorphous metal compact according to claim 1, wherein the high energy speed machining is explosion molding. 3. The molding pressure for explosion molding is 0.7 to 50 G.
The method for producing an amorphous metal molded body according to claim 2, wherein the method is Pa. 4. Amorphous metal powder is iron, cobalt,
The method for producing an amorphous metal compact according to claim 1, which is mainly composed of at least one kind of nickel. 5. Amorphous metal ultrafine powder is silicon,
The method for producing an amorphous metal compact according to claim 1, which is mainly composed of at least one of iron, cobalt, and nickel. 6. The method for producing an amorphous metal compact according to claim 1, wherein a ratio of the ultrafine amorphous metal powder in the mixed powder is 0.01 to 20 VOL%. 7. The method for producing an amorphous metal compact according to claim 1, wherein the ratio of the vertical cross-sectional area to the cross-sectional area of the amorphous metal powder is within 5: 1. 8. A particle size of mainly iron-based element of 75 to 125 μm.
m amorphous metal powder and an amorphous metal powder mainly composed of an iron-based element and having a particle size of 10 to 50 μm are formed, and the mixed powder is consolidated at a high energy speed to form a compact. A method for producing an amorphous metal compact, comprising: 9. The production of an amorphous metal compact according to claim 8, wherein the mixed powder contains a metal ultrafine powder having a particle size of 50 to 1000 angstroms or an amorphous metal ultrafine powder having a particle size of 50 to 1000 angstroms. Method. 10. The method for producing an amorphous metal compact according to claim 8, wherein the proportion of the amorphous metal powder of 10 to 50 μm in the mixed powder is 7 to 25 VoL%. 11. The method for producing an amorphous metal compact according to claim 8, wherein the particles of the amorphous metal powder are spherical. 12. The method for producing an amorphous metal compact according to claim 8, wherein the high energy speed machining is explosion molding. 13. The molding pressure for explosion molding is 10 to 50 G.
The method for producing an amorphous metal compact according to claim 12, which is Pa. 14. The method for producing an amorphous metal compact according to claim 8, wherein the amorphous metal powder is mainly composed of at least one of iron, cobalt and nickel. 15. The method for producing an amorphous metal powder according to claim 8, wherein the ratio of the vertical cross-sectional area to the cross-sectional area of the amorphous metal powder is within 5: 1.