Fe-based amorphous alloy powder, dust core using the same, and coil-embedded dust core
View Patent ↗An Fe-based amorphous alloy powder of the present invention has a composition represented by (Fe 100-a-b-c-x-y-z-t Ni a Sn b Cr c P x C y B z Si t ) 100-α M α . In this composition, 0 at %≦a≦10 at %, 0 at %≦b≦3 at %, 0 at %≦c≦6 at %, 6.8 at %≦x≦10.8 at %, 2.2 at %≦y≦9.8 at %, 0 at %≦z≦4.2 at %, and 0 at %≦t≦3.9 at % hold, a metal element M is at least one selected from the group consisting of Ti, Al, Mn, Zr, Hf, V, Nb, Ta, Mo, and W, and the addition amount α of the metal element M satisfies 0.04 wt %≦α≦0.6 wt %. Accordingly, besides a decrease of a glass transition temperature (Tg), an excellent corrosion resistance and high magnetic characteristics can be obtained.
1. An Fe-based amorphous alloy powder having a composition represented by a formula: (Fe 100-a-b-c-x-y-z-t Ni a Sn b Cr c P x C y B z Si t ) 100-α M α , wherein
an addition amount a of Ni satisfies 0 at %≦a≦10 at %,
an addition amount b of Sn satisfies 0 at %≦b≦3 at %,
an addition amount c of Cr satisfies 0 at %≦c≦6 at %,
an addition amount x of P satisfies 6.8 at %≦x≦10.8 at %,
an addition amount y of C satisfies 2.2 at %≦y≦9.8 at %,
an addition amount z of B satisfies 0 at %≦z≦4.2 at %, and
an addition amount t of Si satisfies 0 at %≦t≦3.9 at %,
wherein a metal element M is at least one selected from the group consisting of Ti, Al, Mn, Zr, Hf, V, Nb, Ta, Mo, and W, and an addition amount a of the metal element M satisfies 0.04 wt %≦α≦0.6 wt %,
and wherein a concentration of the metal element M is higher in a powder surface layer than that inside the powder.
2. The Fe-based amorphous alloy powder according to claim 1 , wherein the addition amount z of B satisfies 0 at %≦z≦2 at %, the addition amount t of Si satisfies 0 at %≦t≦1 at %, and a sum of the addition amount z of B and the addition amount t of Si satisfies 0 at %≦z+t≦2 at %.
3. The Fe-based amorphous alloy powder according to claim 1 , wherein the alloy powder includes non-zero addition amounts of B and Si, and the addition amount z of B is greater than the addition amount t of Si.
4. The Fe-based amorphous alloy powder according to claim 1 , wherein the addition amount a of the metal element M satisfies 0.1 wt %≦α≦0.6 wt %.
5. The Fe-based amorphous alloy powder according to claim 1 , wherein the metal element M includes Ti.
6. The Fe-based amorphous alloy powder according to claim 1 , wherein the metal element M includes Ti, Al, and Mn.
7. The Fe-based amorphous alloy powder according to claim 1 , wherein the alloy powder includes Ni or Sn.
8. The Fe-based amorphous alloy powder according to claim 1 , wherein the addition amount a of Ni satisfies 0 at %≦a≦6 at %.
9. The Fe-based amorphous alloy powder according to claim 1 , wherein the addition amount b of Sn satisfies 0 at %≦b≦2 at %.
10. The Fe-based amorphous alloy powder according to claim 1 , wherein the addition amount c of Cr satisfies 0 at %≦c≦2 at %.
11. The Fe-based amorphous alloy powder according to claim 1 , wherein the addition amount x of P satisfies 8.8 at %≦x≦10.8 at %.
12. The Fe-based amorphous alloy powder according to claim 1 , wherein
the addition amount a of Ni satisfies 0 at %≦a≦6 at %,
the addition amount b of Sn satisfies 0 at %≦b≦2 at %,
the addition amount c of Cr satisfies 0 at %≦c≦2 at %,
the addition amount x of P satisfies 8.8 at %≦x≦10.8 at %,
the addition amount y of C satisfies 2.2 at %≦y≦9.8 at %,
the addition amount z of B satisfies 0 at %≦z≦2 at %,
the addition amount t of Si satisfies 0 at %≦t≦1 at %,
the sum of the addition amount z of B and the addition amount t of Si satisfies 0 at %≦z+t≦2 at %, and
the addition amount a of the metal element M satisfies 0.1 wt %≦α≦0.6 wt %.
13. The Fe-based amorphous alloy powder according to claim 1 , wherein the alloy powder has an aspect ratio of greater than 1 to 1.4.
14. The Fe-based amorphous alloy powder according to claim 13 , wherein the alloy powder has an aspect ratio of 1.2 to 1.4.
15. The Fe-based amorphous alloy powder according to claim 1 , wherein the alloy powder includes a non-zero addition amount of Si as a composition element, and the concentration of the metal element M in the powder surface layer is higher than a concentration of Si.
16. A dust core comprising:
the Fe-based amorphous alloy powder according to claim 1 ; and
a binding material solidifying the Fe-based amorphous alloy powder.
17. A coil-embedded dust core comprising:
a dust core including the Fe-based amorphous alloy powder according to claim 1 and a binding material solidifying the Fe-based amorphous alloy powder; and
a coil encapsulated in the dust core.
18. The coil-embedded dust core according to claim 17 , wherein the coil is an edgewise coil.