Nano-crystalline, magnetic alloy, its production method, alloy ribbon and magnetic part
View Patent ↗A magnetic alloy having a composition represented by the general formula of Fe 100-x-y Cu x B y (atomic %), wherein x and y are numbers meeting the conditions of 0.1≦x≦3, and 10≦y≦20, or the general formula of Fe 100-x-y-z Cu x B y X z (atomic %), wherein X is at least one element selected from the group consisting of Si, S, C, P, Al, Ge, Ga and Be, and x, y and z are numbers meeting the conditions of 0.1≦x≦3, 10≦y≦20, 0<z≦10, and 10<y+z≦24), the magnetic alloy having a structure containing crystal grains having an average diameter of 60 nm or less in an amorphous matrix, and a saturation magnetic flux density of 1.7 T or more.
1. A magnetic alloy having a composition represented by the following general formula (1):
Fe 100-x-y Cu x B y (atomic %) (1),
wherein x and y are numbers meeting the conditions of 1.2≦x≦1.6, and 10≦y≦20, said magnetic alloy having a structure containing crystal grains having an average diameter of 60 nm or less which is dispersed in a proportion of 30% or more by volume in an amorphous matrix, and a saturation magnetic flux density of 1.7 T or more, and a coercivity of 24 A/m or less.
2. The magnetic alloy according to claim 1 , which has maximum permeability of 20,000 or more.
3. The magnetic alloy according to claim 1 , wherein a part of Fe is substituted by Ni and/or Co in a proportion of 10 atomic % or less based on Fe.
4. The magnetic alloy according to claim 1 , wherein a part of Fe is substituted by at least one element selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, platinum-group elements, Au, Ag, Zn, In, Sn, As, Sb, Bi, Y, N, O and rare earth elements in a proportion of 5 atomic % or less based on Fe.
5. The magnetic alloy according to claim 1 , which is in a powder or flake shape.
6. A magnetic alloy having a composition represented by the following general formula (2):
Fe 100-x-y-z Cu x B y X z (atomic %) (2),
wherein X is at least one element selected from the group consisting of Si, S, C, P, Al, Ge, Ga and Be, and x, y and z are numbers meeting the conditions of 1.2≦x≦1.6, 10≦y≦20, 0<z≦10, and 10<y+z≦24, said magnetic alloy having a structure containing crystal grains having an average diameter of 60 nm or less which is dispersed in a proportion of 30% or more by volume in an amorphous matrix, and a saturation magnetic flux density of 1.7 T or more, and a coercivity of 24 A/m or less.
7. The magnetic alloy according to claim 6 , wherein said X is Si and/or P.
8. The magnetic alloy according to claim 6 , which has maximum permeability of 20,000 or more.
9. The magnetic alloy according to claim 6 , wherein a part of Fe is substituted by Ni and/or Co in a proportion of 10 atomic % or less based on Fe.
10. The magnetic alloy according to claim 6 , wherein a part of Fe is substituted by at least one element selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, platinum-group elements, Au, Ag, Zn, In, Sn, As, Sb, Bi, Y, N, O and rare earth elements in a proportion of 5 atomic % or less based on Fe.
11. The magnetic alloy according to claim 6 , which is in a powder or flake shape.
12. An alloy ribbon having a composition represented by the following general formula (1).
Fe 100-x-y Cu x B y (atomic %) (1),
wherein x and y are numbers meeting the conditions of 1.2≦x≦1.6, and 10≦y≦20, said alloy ribbon having a structure containing fine crystal grains having an average diameter of 30 nm or less which is dispersed in a proportion of more than 0% by volume and 30% by volume or less in an amorphous matrix.
13. The alloy ribbon according to claim 12 , wherein a part of Fe is substituted by Ni and/or Co in a proportion of 10 atomic % or less based on Fe.
14. The alloy ribbon according to claim 12 , wherein a part of Fe is substituted by at least one element selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, platinum-group elements, Au, Ag, Zn, In, Sn, As, Sb, Bi, Y, N, O and rare earth elements in a proportion of 5 atomic % or less based on Fe.
15. An alloy ribbon having a composition represented by the following general formula (2):
Fe 100-x-y-z Cu x B y X z (atomic %) (2),
wherein X is at least one element selected from the group consisting of Si, S, C, P, Al, Ge, Ga and Be, and x, y and z are numbers meeting the conditions of 1.2≦x≦1.6, 10≦y≦20, 0<z≦10, and 10<y+z≦24, said alloy ribbon having a structure containing fine crystal grains having an average diameter of 30 nm or less which is dispersed in a proportion of more than 0% by volume 30% by volume or less in an amorphous matrix.
16. The alloy ribbon according to claim 15 , wherein said X is Si and/or P.
17. The alloy ribbon according to claim 15 , wherein a part of Fe is substituted by Ni and/or Co in a proportion of 10 atomic % or less based on Fe.
18. The alloy ribbon according to claim 15 , wherein a part of Fe is substituted by at least one element selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, platinum-group elements, Au, Ag, Zn, In, Sn, As, Sb, Bi, Y, N, O and rare earth elements in a proportion of 5 atomic % or less based on Fe.
19. A magnetic part made of the magnetic alloy according to claim 1 .
20. A magnetic part made of the magnetic alloy according to claim 6 .
21. The magnetic alloy according to claim 1 , wherein a part of Fe is substituted by Ni and/or Co in a proportion of 10 atomic % or less based on Fe, and at least one element selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, platinum-group elements, Au, Ag, Zn, In, Sn, As, Sb, Bi, Y, N, O and rare earth elements in a proportion of 5 atomic % or less based on Fe.
22. The magnetic alloy according to claim 1 , wherein 1.2≦x≦1.6 and 12≦y≦17.
23. The magnetic alloy according to claim 1 , wherein 1.2≦x≦1.6 and 12≦y≦15.
24. The magnetic alloy according to claim 6 , wherein a part of Fe is substituted by Ni and/or Co in a proportion of 10 atomic % or less based on Fe, and at least one element selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, platinum-group elements, Au, Ag, Zn, In, Sn, As, Sb, Bi, Y, N, O and rare earth elements in a proportion of 5 atomic % or less based on Fe.
25. The magnetic alloy according to claim 6 , wherein 1.2≦x≦1.6, 12≦y ≦17, 0<z≦7, and 13≦y+z≦20.
26. The magnetic alloy according to claim 6 , wherein 1.2≦x≦1.6, 12≦y ≦15, 0<z≦5, and 14≦y+z≦19.
27. The magnetic alloy according to claim 6 , wherein 1.2≦x≦1.6, 12≦y≦15, 0<z≦4, and 14≦y+z≦17.
28. The alloy ribbon according to claim 12 , wherein a part of Fe is substituted by Ni and/or Co in a proportion of 10 atomic % or less based on Fe, and at least one element selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, platinum-group elements, Au, Ag, Zn, In, Sn, As, Sb, Bi, Y, N, O and rare earth elements in a proportion of 5 atomic % or less based on Fe.
29. The alloy ribbon according to claim 12 , wherein 1.2≦x≦1.6 and 12≦y ≦17.
30. The alloy ribbon according to claim 12 , wherein 1.2≦x≦1.6 and 12≦y ≦15.
31. The alloy ribbon according to claim 12 , wherein an average diameter of said crystal grains is 0.5 to 20 nm.
32. The alloy ribbon according to claim 12 , wherein an average distance between said crystal grains is 50 nm or less.
33. The alloy ribbon according to claim 15 , wherein a part of Fe is substituted by Ni and/or Co in a proportion of 10 atomic % or less based on Fe, and at least one element selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, platinum-group elements, Au, Ag, Zn, In, Sn, As, Sb, Bi, Y, N, O and rare earth elements in a proportion of 5 atomic % or less based on Fe.
34. The alloy ribbon according to claim 15 , wherein 1.2≦x≦1.6, 12≦y≦17, 0<z≦7, and 13≦y+z≦20.
35. The alloy ribbon according to claim 15 , wherein 1.2≦x≦1.6, 12≦y≦15, 0<z≦5, and 14≦y+z≦19.
36. The alloy ribbon according to claim 15 , wherein 1.2≦x≦1.6, 12≦y≦15, 0<z≦4, and 14≦y+z≦17.
37. The alloy ribbon according to claim 15 , wherein an average diameter of said crystal grains is 0.5 to 20 nm.
38. The alloy ribbon according to claim 15 , wherein an average distance between said crystal grains is 50 nm or less.
39. The alloy ribbon according to claim 1 , wherein said magnetic alloy has a coercivity of 12 A/m or less.
40. The alloy ribbon according to claim 6 , wherein said magnetic alloy has a coercivity of 12 A/m or less.
41. The alloy ribbon according to claim 12 , wherein said alloy ribbon having a structure in which fine crystal grains having an average diameter of 30 nm or less are dispersed in an amorphous phase in proportion of 3% by volume or more and 30% by volume or less.
42. The alloy ribbon according to claim 15 , wherein said alloy ribbon having a structure in which fine crystal grains having an average diameter of 30 nm or less are dispersed in an amorphous phase in proportion of 3% by volume or more and 30% by volume or less.