Specification
FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]
RARE EARTH SINTERED MAGNET, METHOD FOR PRODUCING RARE EARTH
SINTERED MAGNET, ROTOR, AND ROTARY MACHINE
MITSUBISHI ELECTRIC CORPORATION A CORPORATION ORGANISED AND
EXISTING UNDER THE LAWS OF JAPAN, WHOSE ADDRESS IS 7-3,
MARUNOUCHI 2-CHOME, CHIYODA-KU, TOKYO 1008310, JAPAN
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE
INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.
2
DESCRIPTION
Field
[0001] The present disclosure relates to a rare earth
sintered magnet which is a permanent magnet obtained by5
sintering a material containing a rare earth element, a
method for producing a rare earth sintered magnet, a rotor,
and a rotary machine.
Background10
[0002] R-T-B-based permanent magnets having a tetragonal
R2T14B intermetallic compound as a main phase are known. Here,
R is a rare earth element, T is a transition metal element
such as Fe (iron) or Fe that is partially replaced by cobalt
(Co), and B is boron. R-T-B-based permanent magnets are15
used for various components having a high added value,
including for example industrial motors. In particular, Nd-
Fe-B-based sintered magnets in which R is neodymium (Nd) are
used for various components due to excellent magnetic
properties. In addition, because industrial motors are often20
used in a high temperature environment exceeding 100°C,
attempts have been made to improve coercive force by adding
heavy rare earth elements such as dysprosium (Dy) to Nd-T-
B-based sintered magnets.
[0003] In recent years, the production of Nd-Fe-B-based25
sintered magnets has been expanded, and the consumption of
Nd and heavy rare earth elements such as Dy and terbium (Tb)
has been increased. However, Nd and heavy rare earth
elements are expensive and also have a procurement risk due
to high distribution unevenness. In view of this, a possible30
measure for reducing the consumption of Nd and heavy rare
earth elements is to use a magnet that forms a main phase
including a low heavy rare earth phase, to use other rare
3
earth elements as R, such as praseodymium (Pr), cerium (Ce),
lanthanum (La), samarium (Sm), scandium (Sc), gadolinium
(Gd), yttrium (Y), and lutetium (Lu), or to use a special
production method such as subjecting a sintered body to hot
plastic working. Hereinafter, hot plastic working applied5
to a sintered body is referred to as hot working. However,
adding a heavy rare earth element to the main phase to no
small extent contributes to improvement of the coercive force,
but significantly degrades the residual magnetic flux
density. In addition, replacing all or a part of Nd with10
elements such as Pr, Ce, La, Sm, Sc, Gd, Y, and Lu
significantly degrades the magnetic properties of the
residual magnetic flux density and the coercive force.
Furthermore, subjecting the sintered body to hot working
significantly degrades the magnetization of the magnet due15
to the refinement of the crystal grains. From the above, it
has been difficult to achieve both saving of heavy rare earth
elements and excellent magnetic properties and magnetization.
Therefore, attempts have been conventionally made to develop
technology that allows for improvement of magnetic20
properties at room temperature and prevention of degradation
of magnetic properties associated with temperature rise in
the case of using these elements for producing Nd-Fe-B-based
sintered magnets. In particular, at present, a rare earth
magnet that allows for both further reduction of heavy rare25
earth elements and excellent magnetic properties and
magnetization is required.
[0004] Patent Literature 1 discloses an R-T-B-based
sintered magnet containing main phase grains consisting of
an R2T14B crystal, where R is one or more kinds of rare earth30
elements including a heavy rare earth element RH as an
essential element, T is one or more kinds of transition metal
elements including Fe or including Fe and Co as an essential
4
element, B is boron. A part of the main phase grains of the
R-T-B-based sintered magnet includes a plurality of low heavy
rare earth element crystal phases therein, and the low heavy
rare earth element crystal phase is a phase consisting of an
R2T14B crystal and having a relatively low concentration of5
the heavy rare earth element with respect to the
concentration of the heavy rare earth element in the entire
main phase grains. According to the technique described in
Patent Literature 1, it is possible to obtain an R-T-B-based
sintered magnet having improved magnetic properties at low10
cost.
[0005] Patent Literature 2 discloses a method for
producing a rare earth magnet consisting of: a first step of
producing a sintered body represented by a composition
formula of (R11-xR2x)aTMbBcMd and having a structure consisting15
of a main phase and a grain boundary phase; a second step of
producing a rare earth magnet precursor by subjecting the
sintered body to hot working; and a third step of producing
a rare earth magnet from the rare earth magnet precursor by
causing a melt of an R3-M modified alloy to be diffused and20
permeating through the grain boundary phase of the rare earth
magnet precursor. Here, R1 is one or more rare earth
elements including Y, R2 is a rare earth element different
from R1, TM is a transition metal including one or more of
Fe, nickel (Ni), and Co, B is boron, and M is one or more of25
titanium (Ti), gallium (Ga), zinc (Zn), silicon (Si),
aluminum (Al), niobium (Nb), zirconium (Zr), Ni, Co,
manganese (Mn), vanadium (V), tungsten (W), tantalum (Ta),
germanium (Ge), copper (Cu), chromium (Cr), hafnium (Hf),
molybdenum (Mo), phosphorus (P), carbon (C), magnesium (Mg),30
mercury (Hg), silver (Ag), and gold (Au). Further, x, a, b,
c, and d satisfy 0.01≤x≤1, 12≤a≤20, b=100−a−c−d, 5≤c≤20, and
0≤d≤3, all by at%. R3 is a rare earth element including R1
5
and R2. According to the technique described in Patent
Literature 2, it is possible to produce a rare earth magnet
excellent in not only magnetization but also coercive force
performance even when the main phase ratio is high.
5
Citation List
Patent Literature
[0006] Patent Literature 1: Japanese Patent Application
Laid-open No. 2018-174313
Patent Literature 2: Japanese Patent Application10
Laid-open No. 2015-153813
Summary of Invention
Problem to be solved by the Invention
[0007] However, in the R-T-B-based sintered magnet15
described in Patent Literature 1, a phase including a heavy
rare earth element is present in the main phase, which
improves coercive force but cannot yield the residual
magnetic flux density required for industrial motors or the
like, which may lead to degradation of magnetic properties.20
Furthermore, since heavy rare earth elements are used, there
is a problem that the procurement risk and cost cannot be
reduced. Even if the rare earth magnet produced with the
production method described in Patent Literature 2 can reduce
heavy rare earth elements and improve the coercive force,25
the production method includes hot working. For this reason,
there is a possibility of lowering the residual magnetic
flux density and magnetization of the rare earth magnet to
be produced.
[0008] The present disclosure has been made in view of30
the above, and an object thereof is to obtain a rare earth
sintered magnet capable of improving magnetic properties and
magnetization as compared with the related art, while
6
reducing use of Nd and heavy rare earth elements as compared
with the related art.
Means to Solve the Problem
[0009] In order to solve the above-described problems and5
achieve the object, a rare earth sintered magnet according
to the present disclosure includes a main phase that
satisfies a general formula (Nd, Pr, R)-Fe-B, where R is one
or more rare earth elements selected excluding Nd and Pr,
the main phase containing crystal grains based on an Nd2Fe14B10
crystal structure. The main phase includes a core portion
and a shell portion covering the core portion. The main
phase includes a first main phase that satisfies CNd>CPr and
a second main phase that satisfies CNdCPr and a second main phase25
12 that satisfies CNdCPr is satisfied in
the core portion 11c of the first main phase 11, and CNdCPr and the second main phase 12 that
satisfies CNdC2Nd and C1PrCPr is present more than the second main phase5
12 each of which satisfies CNdSNd and CPrSPr, where SNd is the
concentration of Nd in the shell portions 11s and 12s and25
SPr is the concentration of Pr in the shell portions 11s and
12s. Specifically, the shell portion 11s of the first main
phase 11 has a higher concentration of Pr than the core
portion 11c instead of having a lower concentration of Nd,
and the shell portion 12s of the second main phase 12 has a30
higher concentration of Nd than the core portion 12c instead
of having a lower concentration of Pr. By forming the first
main phase 11 including the shell portion 11s having a high
12
concentration of Pr in the main phase 10, the coercive force
can be improved. Furthermore, by forming the second main
phase 12 including the shell portion 12s having a high
concentration of Nd in the main phase 10, it is possible to
prevent degradation of the residual magnetic flux density5
while maintaining the coercive force. Through selective
control to achieve such a structure form, the rare earth
sintered magnet 1 can exhibit excellent magnetic properties
as compared with the related art.
[0019] Further, the average grain size of the crystal10
grains of the main phase 10 is preferably 100 μm or less,
and more preferably 0.5 μm to 50 μm for improving magnetic
properties. Furthermore, setting the average grain size to
about 1 μm to 10 μm results in a grain size different from
the microstructure produced by hot working, leading to the15
rare earth sintered magnet 1 that maintains good magnetizing
ability and has excellent magnetic properties as compared
with the related art.
[0020] The rare earth sintered magnet 1 according to the
first embodiment may contain an additive element M that20
further improves magnetic properties. The additive element
M is one or more elements selected from the group consisting
of Ga, Cu, Al, Co, Zr, Ti, Nb, Dy, Tb, Mn, Gd, and Ho
(holmium). Therefore, the rare earth sintered magnet 1
according to the first embodiment is expressed by the general25
formula (NdaPrbRc)FedBeMf, where the additive element M is one
or more elements selected from the group consisting of Ga,
Cu, Al, Co, Zr, Ti, Nb, Dy, Tb, Mn, Gd, and Ho. It is
desirable that a, b, c, d, e, and f satisfy the following
relational expressions.30
[0021] 5≤a+b≤20
0CPr and the second main phase 12 that satisfies CNdC2Nd and20
C1PrSNd and CPrSPr. This also makes it possible to obtain the rare
earth sintered magnet 1 in which magnetic properties and
magnetization are improved, while reducing use of Nd and
heavy rare earth elements.
[0024] Second Embodiment.30
FIG. 2 is a diagram schematically illustrating an
exemplary sintered structure of a rare earth sintered magnet
according to the second embodiment. The rare earth sintered
14
magnet 1 according to the second embodiment includes the
main phase 10 and the subphase 20. The main phase 10 includes
the first main phase 11 and the second main phase 12 as
described in the first embodiment, but in FIG. 2, the first
main phase 11 and the second main phase 12 are collectively5
denoted by the main phase 10. The subphase 20 is present
between the main phases 10.
[0025] In the rare earth sintered magnet 1 according to
the second embodiment, a case where La and Sm are selected
as the element R will be described. In a case where La and10
Sm are selected as the element R, the effect of improving
the magnetic properties and having excellent magnetization
as compared with the related art, while reducing use of Nd
and heavy rare earth elements, is further enhanced. In this
example, the main phase 10 has the composition formula15
(Nd,Pr,La,Sm)2Fe14B. The reason why the element R of the
rare earth sintered magnet 1 having a tetragonal R2Fe14B
crystal structure is rare earth elements including La and Sm
is that the calculation of magnetic interaction energy with
the use of a molecular orbital method shows that a20
composition in which La and Sm are added can produce the
rare earth sintered magnet 1 which is suitable for practical
use in that degradation of magnetic properties associated
with temperature rise can be significantly prevented. In
addition, by intentionally segregating La and Sm also in the25
grain boundary, which is an example of the subphase 20, it
is possible to cause Nd and Pr to be relatively diffused
throughout the main phase 10, resulting in enhanced
magnetocrystalline anisotropy of the main phase 10. As a
result, a core-shell structure in which a portion having30
high magnetic anisotropy and a portion having low magnetic
anisotropy exist in the main phase 10 is formed, and a state
in which the rare earth sintered magnet 1 in which the first
15
main phase 11 that satisfies CNd>CPr and the second main
phase 12 that satisfies CNd(C+D) is
preferably satisfied, where A, B, C, and D are the
composition ratios of Nd, Pr, La, and Sm, respectively.10
[0027] In the rare earth sintered magnet 1 according to
the second embodiment, given R=La and/or Sm, the rare earth
sintered magnet 1 includes the subphase 20 in addition to
the first main phase 11 and the second main phase 12 in the
first embodiment. The subphase 20 includes a crystalline15
first subphase 21 based on an oxide phase having a main
component represented by (Nd, Pr, La, Sm)-O, and a
crystalline second subphase 22 having a main component
represented by (Nd, Pr, La)-O. The concentration of Sm in
the subphase 20 is higher in the first subphase 21 than in20
the second subphase 22. This achieves the effect of
preventing not only degradation of the magnetic properties
at room temperature but also degradation of the magnetic
properties associated with temperature rise.
[0028] Here, “the concentration of Sm is higher in the25
first subphase 21 than in the second subphase 22” means that
the detection intensity of Sm is higher on average in the
first subphase 21 than in the second subphase 22 by mapping
analysis using EPMA.
[0029] The crystalline subphase 20 is a generic name for30
the crystalline first subphase 21 and the crystalline second
subphase 22, and is present between the main phases 10. The
crystalline first subphase 21 is represented by (Nd, Pr, La,
16
Sm)-O, and the crystalline second subphase 22 is represented
by (Nd, Pr, La)-O. Here, (Nd, Pr, La, Sm) means that a part
of Nd and Pr is replaced by La and Sm. Note that the elements
of the main components are described in parentheses;
therefore, the first subphase 21 and the second subphase 225
may contain a small amount of another component, in addition
to the elements indicated in parentheses. In one example,
the second subphase 22 represented by (Nd,Pr,La)-O contains
an extremely small amount of Sm.
[0030] In the rare earth sintered magnet 1 according to10
the second embodiment, there is a concentration difference
of La and Sm between the main phase 10 and the subphase 20,
and La and Sm are segregated in the subphase 20 more than in
the main phase 10. That is, the sum of the concentrations
of La in the first subphase 21 and the second subphase 22 is15
equal to or greater than the concentration of La in the main
phase 10, and the sum of the concentrations of Sm in the
first subphase 21 and the second subphase 22 is equal to or
greater than the concentration of Sm in the main phase 10.
Specifically, the concentrations of La and Sm in the subphase20
20 are equal to or higher than the concentrations of La and
Sm in the main phase 10. Here, the concentration of La of
the main phase 10 is the sum of the concentration of La of
the first main phase 11 and the concentration of La of the
second main phase 12. That is, the sum of the concentrations25
of La in the first subphase 21 and the second subphase 22 is
higher than the sum of the concentrations of La in the first
main phase 11 and the second main phase 12. Here, the
concentration of Sm of the main phase 10 is the sum of the
concentration of Sm of the first main phase 11 and the30
concentration of Sm of the second main phase 12. That is,
the sum of the concentrations of Sm in the first subphase 21
and the second subphase 22 is higher than the sum of the
17
concentrations of Sm in the first main phase 11 and the
second main phase 12.
[0031] Here, given that X represents the concentration of
La contained in the main phase 10, X1 represents the
concentration of La contained in the first subphase 21, X25
represents the concentration of La contained in the second
subphase 22, Y represents the concentration of Sm contained
in the main phase 10, Y1 represents the concentration of Sm
contained in the first subphase 21, and Y2 represents the
concentration of Sm contained in the second subphase 22, the10
relationship of Formula (1) below is satisfied.
[0032] 1<(Y1+Y2)/Y<(X1+X2)/X •••• (1)
[0033] Furthermore, from the viewpoint of improving the
magnetic properties, the relationships of Formulas (2) and
(3) below are satisfied with respect to the concentrations15
of Nd and Pr contained in the main phase 10.
[0034] (CNd+SNd)>(X+Y) •••• (2)
(CPr+SPr)>(X+Y) •••• (3)
[0035] In the above description, the concentration of La
in the main phase 10 is the sum of the concentrations of La20
in the first main phase 11 and the second main phase 12, and
the concentration of Sm in the main phase 10 is the sum of
the concentrations of Sm in the first main phase 11 and the
second main phase 12. This indicates that both La and Sm
are segregated in the subphase 20 more than in the main phase25
10. However, when viewed locally, each of the sum of the
concentrations of La and Sm in the first main phase 11 and
the second main phase 12 and each of the sum of the
concentrations of La and Sm in the first subphase 21 and the
second subphase 22 may not satisfy the above relationship.30
Therefore, more specifically, the concentration of La in the
main phase 10 indicates the average of the concentrations of
La in the first main phase 11 and the second main phase 12,
18
and the concentration of Sm in the main phase 10 indicates
the average of the concentrations of Sm in the first main
phase 11 and the second main phase 12. In this case, the
concentration of La of the subphase 20, that is, the sum of
the concentrations of La in the first subphase 21 and the5
second subphase 22 means the average of the concentrations
of La in the first subphase 21 and the second subphase 22,
and the concentration of Sm of the subphase 20, that is, the
sum of the concentrations of Sm in the first subphase 21 and
the second subphase 22 means the average of the10
concentrations of Sm in the first subphase 21 and the second
subphase 22.
[0036] La is present at a high concentration in the grain
boundary in the process of production, particularly in the
heat treatment, whereby Nd and Pr are relatively diffused15
throughout the main phase 10. As a result, in the rare earth
sintered magnet 1 according to the second embodiment, Nd and
Pr in the main phase 10 are not consumed at the grain boundary,
leading to improved magnetocrystalline anisotropy. Sm is
also present at a higher concentration in the subphase 20,20
particularly in the first subphase 21, than in the main phase
10, whereby Nd is relatively diffused throughout the main
phase 10 as in the case of La, resulting in improved
magnetocrystalline anisotropy.
[0037] Next, at which atomic sites of the tetragonal25
R2Fe14B crystal structure La and Sm are substituted will be
described. FIG. 3 is a diagram illustrating atomic sites in
a tetragonal Nd2Fe14B crystal structure. Note that the
crystal structure illustrated in FIG. 3 is described, in one
example, in FIG. 1 of Reference Literature 1 shown below.30
The sites of substitution are determined from the numerical
value of the stabilization energy associated with
substitution computed using band calculation and molecular
19
field approximation based on the Heisenberg model.
(Reference Literature 1): J. F. Herbst et al., “Relationships
between crystal structure and magnetic properties in
Nd2Fe14B”, PHYSICAL REVIEW B. 1984, Vol. 29, No. 7, p. 4176–
4178.5
[0038] First, a method for calculating stabilization
energy in La will be described. The stabilization energy in
La can be computed as the energy difference between
(Nd7La1)Fe56B4+Nd and Nd8(Fe55La1)B4+Fe using Nd8Fe56B4 crystal
cells. The smaller the energy value, the more stable it is10
when the atom is substituted at that site. That is, La is
likely to be substituted at an atomic site having the
smallest energy among the atomic sites. This calculation
assumes that substituting La for the original atom does not
change the lattice constant in the tetragonal R2Fe14B crystal15
structure due to the difference in atomic radius. Table 1
shows the stabilization energy of La at each substitution
site at various environmental temperatures.
[0039] [Table 1]
20
20
[0040] Table 1 indicates that stable substitution sites
for La are Nd (f) sites at temperatures of 1000K and higher,
and Fe (c) sites at temperatures of 293K and 500K. As will
be described later, the raw material of the rare earth
sintered magnet 1 according to the second embodiment is5
heated and melted at a temperature of 1000K or higher and
then rapidly cooled. Therefore, it is considered that the
raw material of the rare earth sintered magnet 1 is
maintained in a state of 1000K or higher, that is, 727°C or
higher, and more preferably about 1300K, that is, 1027°C.10
In this case, La is considered to be substituted at Nd (f)
sites or Nd (g) sites. Here, La is considered to be
preferentially substituted at energetically stable Nd (f)
sites, but may be substituted at Nd (g) sites having a small
energy difference among the substitution sites for La. This15
is why Nd (g) sites are also mentioned as a candidate for
the substitution sites for La.
[0041] Furthermore, when the rare earth sintered magnet
1 is produced with the production method described later,
the temperature is 1000K or higher at the time of sintering,20
but the Fe (c) sites described in Table 1 are held in an
energetically stable temperature zone repeatedly through the
primary aging step, the secondary aging step, the tertiary
aging step, the quaternary aging step, and the cooling step.
In other words, the substitution of La at Nd sites of the25
main phase 10 is maintained in an unstable energy state.
That is, La is mainly substituted at Nd sites of the main
phase 10 in the raw material stage of the rare earth sintered
magnet 1; however, in the rare earth sintered magnet 1
produced with the production method described later, by30
intentionally holding the Nd sites of the main phase 10
repeatedly in a temperature range in an unstable energy state,
a certain amount of La is selectively released from the Nd
21
sites of the main phase 10, and as a result, La is segregated
in the subphase 20. As a result, the main phase 10 promotes
the formation of the characteristic structure, namely the
core-shell structure.
[0042] Next, a method for calculating stabilization5
energy in Sm will be described. The stabilization energy of
Sm can be computed as the energy difference between
(Nd7Sm1)Fe56B4+Nd and Nd8(Fe55Sm1)B4+Fe. Similarly to the case
of La, atomic substitution does not change the lattice
constant in the tetragonal R2Fe14B crystal structure. Table10
2 shows the stabilization energy of Sm at each substitution
site at various environmental temperatures.
[0043] [Table 2]
[0044] Table 2 indicates that stable substitution sites15
for Sm are Nd (g) sites at any temperature, unlike in the
case of La. Sm is also considered to be preferentially
substituted at energetically stable Nd (g) sites, but may be
substituted at Nd (f) sites having a small energy difference
22
among the substitution sites for Sm.
[0045] When the rare earth sintered magnet 1 is produced
with the production method described later, substitution at
Nd (g) sites of the main phase 10 is most stable in terms of
energy. However, as described above, holding in a5
temperature range where the substitution of La at Nd sites
of the main phase 10 is unstable causes a part of Sm to be
released from the Nd sites of the main phase 10 together
with La and segregated in the subphase 20. As a result, the
concentrations of La and Sm differ between the main phase 1010
and the subphase 20: the sum of the concentrations of La in
the first subphase 21 and the second subphase 22 is equal to
or greater than the concentration of La in the main phase
10, and the sum of the concentrations of Sm in the first
subphase 21 and the second subphase 22 is equal to or greater15
than the concentration of Sm in the main phase 10. More
specifically, the average of the concentrations of La in the
first subphase 21 and the second subphase 22 is equal to or
greater than the average of the concentrations of La in the
first main phase 11 and the second main phase 12, and the20
average of the concentrations of Sm in the first subphase 21
and the second subphase 22 is equal to or greater than the
average of the concentrations of Sm in the first main phase
11 and the second main phase 12. That is, La and Sm can be
said to be segregated in the subphase 20.25
[0046] Comparing La and Sm, La held in a temperature range
in an unstable energy state is overwhelmingly more likely to
be segregated in the subphase 20 from the viewpoint of energy.
As a result, in the case of the rare earth sintered magnet
1 prepared with almost the same concentrations of La and Sm,30
comparing La and Sm present in the rare earth sintered magnet
1, La has a larger segregation ratio to the subphase 20. By
being held repeatedly in this temperature region, the
23
subphase 20 produces a concentration difference in Sm that
has a small segregation ratio, and the first subphase 21 and
the second subphase 22 are formed. This promotes the
formation of the core-shell structure in the main phase 10.
[0047] Here, Nd is representatively described as5
illustrated in FIG. 3, but Nd and Pr are produced as a
mixture as represented by didymium (Di), and thus it is
considered that the energy levels of Nd and Pr are close to
each other. Therefore, the same applies to a case where Nd
is replaced with Pr. As the two types of Nd and Pr are10
present, the main phase 10 having two types of core-shell
structures can be formed.
[0048] As described above, the rare earth sintered magnet
1 according to the second embodiment includes the main phase
10 that satisfies a general formula (Nd, Pr, R)-Fe-B, where15
R is one or more rare earth elements selected excluding Nd
and Pr, the main phase 10 containing crystal grains based on
an Nd2Fe14B crystal structure, wherein the main phase 10
includes a core portion and a shell portion covering the
core portion, and given R=La and/or Sm, the rare earth20
sintered magnet 1 includes the subphase 20 in addition to
the first main phase 11 and the second main phase 12
described in the first embodiment. The subphase 20 includes
the crystalline first subphase 21 having a main component
based on an oxide phase represented by (Nd, Pr, La, Sm)-O25
and the crystalline second subphase 22 having a main
component represented by (Nd, Pr, La)-O, and the
concentration of Sm is higher in the first subphase 21 than
in the second subphase 22. That is, the two types of main
phases 10 and the two types of subphases 20 exist. As a30
result, it is possible to provide the rare earth sintered
magnet 1 having excellent magnetic properties, such as
temperature properties of magnetic properties, as compared
24
with the related art. In addition, by setting R to La and
Sm, the main phase 10 is in a state in which the first main
phase 11 that satisfies CNd>CPr and the second main phase 12
that satisfies CNdCPr and the second5
main phase 12 consisting of CNdCPr and the second main phase 12 consisting of CNdCPr and the second25
main phase 12 that satisfies CNdCPr and the
second main phase 12 that satisfies CNdCPr and the second main phase 12 that satisfies
CNdCPr is larger than the number of second main phases 125
that are CNdSNd and
CPrSPr.10
[0096] Next, the results of measurement of the magnetic
properties in each sample according to Examples 1 to 8 and
Comparative Examples 1 to 12 will be described. The shape
of each sample that is the subject of magnetic measurement
is a block shape having a length, a width, and a height of15
7 mm. The first measurement temperature T1 is 23°C, and the
second measurement temperature T2 is 200°C. 23°C is room
temperature. 200°C of the second measurement temperature T2
is a temperature that can occur as an environment in which
automobile motors and industrial motors operate.20
[0097] First, the residual magnetic flux density and the
coercive force in each sample according to Examples 1 to 8
and Comparative Examples 2 to 12 are determined in comparison
with Comparative Example 1. When the values of the residual
magnetic flux density and the coercive force of each sample25
at 23°C are within an allowable measurement error of 1%
compared with the values of Comparative Example 1, the values
are rated as “equivalent”. Values of 1% or more higher are
rated as “good”, and values of 1% or more lower are rated as
“poor”.30
[0098] Next, the temperature coefficient α of residual
magnetic flux density is calculated using the residual
magnetic flux density at the first measurement temperature
44
T1 of 23°C and the residual magnetic flux density at the
second measurement temperature T2 of 200°C. The temperature
coefficient β of coercive force is calculated using the
coercive force at the first measurement temperature T1 of
23°C and the coercive force at the second measurement5
temperature T2 of 200°C. The temperature coefficient of
residual magnetic flux density and the temperature
coefficient of coercive force in each sample according to
Examples 1 to 8 and Comparative Examples 2 to 12 are
determined in comparison with Comparative Example 1. When10
the values of each sample are within an allowable measurement
error of ±1% compared with the absolute value |α| of the
temperature coefficient of residual magnetic flux density
and the absolute value |β| of the temperature coefficient of
coercive force in the sample of Comparative Example 1, the15
values are rated as “equivalent”. Values of −1% or more
lower are rated as “good”, and values of +1% or more higher
are rated as “poor”. Because the samples determined to be
“good” have a smaller temperature coefficient, it is possible
to provide the rare earth sintered magnet 1 having stable20
magnetic properties even in a high temperature environment
while preventing degradation of magnetic properties
associated with temperature rise.
[0099] Next, regarding the magnetizing ability, the
magnetization rate is calculated from the ratio of the25
magnetic flux density, which is one intersection of the
magnetic hysteresis of the applied magnetic field of 20kOe
and the permeance coefficient Pc, and the magnetic flux
density, which is one intersection of the magnetic hysteresis
of the applied magnetic field of 80kOe in the saturation30
magnetization state and the permeance coefficient Pc. The
magnetizing ability in each sample according to Examples 1
to 8 and Comparative Examples 2 to 12 is determined in
45
comparison with Comparative Example 1. That is, for each
sample, compared with the magnetization rate in the sample
according to Comparative Example 1, values of −1% or more
higher, being considered as a measurement error, are rated
as “equivalent or better”, and values of −1% or more lower5
are rated as “poor”. It is possible to provide the rare
earth sintered magnet 1 having high magnetizing ability for
samples rated as “equivalent or better”.
[0100] The results of determination of the residual
magnetic flux density, the coercive force, the temperature10
coefficient of residual magnetic flux density, the
temperature coefficient of coercive force, and the
magnetizing ability are shown in Table 3.
[0101] Comparative Example 1 is a sample of the rare earth
sintered magnet 1 prepared in the form of Nd-Fe-B with the15
production method described in Patent Literature 1 using Nd,
Fe, and FeB as raw materials. From the observation of the
structure form of this sample with the method described above,
due to the absence of Pr, La, and Sm, no core-shell structure
is confirmed in the main phase 10, and it is not confirmed20
that the concentration of Sm in the subphase 20 is higher in
the first subphase 21 than in the second subphase 22. The
evaluation of the magnetic properties of this sample with
the method described above shows that the residual magnetic
flux density is 1.3 T and the coercive force is 1000 kA/m.25
The temperature coefficients of residual magnetic flux
density and coercive force are |α|=0.191 %/°C and
|β|=0.460 %/°C, respectively. The magnetization rate is
98.6%. These values of Comparative Example 1 are used as a
reference.30
[0102] Comparative Example 2 is a sample of the rare earth
sintered magnet 1 prepared in the form of (Nd, Dy)-Fe-B with
the production method described in Patent Literature 1 using
46
Nd, Dy, Fe, and FeB as raw materials. From the observation
of the structure form of this sample with the method
described above, due to the absence of Pr, La, and Sm, no
core-shell structure is confirmed in the main phase 10, and
it is not confirmed that the concentration of Sm in the5
subphase 20 is higher in the first subphase 21 than in the
second subphase 22. The evaluation of the magnetic
properties of this sample with the method described above
shows that the residual magnetic flux density is “poor”, the
coercive force is “good”, the temperature coefficient of10
residual magnetic flux density is “equivalent”, the
temperature coefficient of coercive force is “equivalent”,
and the magnetizing ability is “equivalent or better”. This
result reflects the fact that the coercive force is improved
by substituting Dy having high magnetocrystalline anisotropy15
for a part of Nd.
[0103] Comparative Example 3 is a sample of the rare earth
sintered magnet 1 prepared in the form of (Nd, Pr)-Fe-B with
the production method described in Patent Literature 1 using
Nd, Pr, Fe, and FeB as raw materials. From the observation20
of the structure form of this sample with the method
described above, the main phase 10 in which Nd and Pr are
provided mixedly is confirmed due to the addition of Pr, but
a core-shell structure is not formed. In addition, due to
the absence of La and Sm, it is also not confirmed that the25
concentration of Sm in the subphase 20 is higher in the first
subphase 21 than in the second subphase 22. The evaluation
of the magnetic properties of this sample with the method
described above shows that the residual magnetic flux density
is “equivalent”, the coercive force is “good”, the30
temperature coefficient of residual magnetic flux density is
“equivalent”, the temperature coefficient of coercive force
is “poor”, and the magnetizing ability is “equivalent or
47
better”. This result reflects the fact that the magnetic
anisotropy of the main phase 10 is increased and the coercive
force is improved by the addition of Pr, but the structure
form is not optimal in the main phase 10 and the subphase
20.5
[0104] Comparative Example 4 is a sample of the rare earth
sintered magnet 1 prepared in the form of (Nd, La, Sm)-Fe-B
with the production method described in Patent Literature 1
using Nd, La, Sm, Fe, and FeB as raw materials. From the
observation of the structure form of this sample with the10
method described above, no core-shell structure is confirmed
in the main phase 10 due to the absence of Pr. In addition,
due to the addition of La and Sm, the concentration of Sm is
segregated in one subphase 20 along with the segregation of
La, but the second subphase 22 does not exist. Furthermore,15
it is also not confirmed that the concentration of Sm is
higher in the first subphase 21 than in the second subphase
22. The evaluation of the magnetic properties of this sample
with the method described above shows that the residual
magnetic flux density is “equivalent”, the coercive force is20
“equivalent”, the temperature coefficient of residual
magnetic flux density is “good”, the temperature coefficient
of coercive force is “good”, and the magnetizing ability is
“equivalent or better”. This result reflects the fact that
the presence of La and Sm in the main phase 10 or the subphase25
20 gives a good result in the temperature coefficient of the
magnetic properties, but the magnetic properties at room
temperature are not improved, and the structure form is not
optimal in the main phase 10 and the subphase 20.
[0105] Comparative Example 5 is a sample of the rare earth30
sintered magnet 1 prepared in the form of (Nd, La, Sm)-Fe-B
with the production method described in Patent Literature 1
using Nd, La, Sm, Fe, and FeB as raw materials. The
48
composition ratio of Nd, La, and Sm is different from that
of Comparative Example 4. From the observation of the
structure form of this sample with the method described above,
no core-shell structure is confirmed in the main phase 10
due to the absence of Pr. In addition, due to the addition5
of La and Sm, the concentration of Sm is segregated in one
subphase 20 along with the segregation of La, but the second
subphase 22 does not exist. Furthermore, it is also not
confirmed that the concentration of Sm is higher in the first
subphase 21 than in the second subphase 22. The evaluation10
of the magnetic properties of this sample with the method
described above shows that the residual magnetic flux density
is “equivalent”, the coercive force is “equivalent”, the
temperature coefficient of residual magnetic flux density is
“good”, the temperature coefficient of coercive force is15
“good”, and the magnetizing ability is “equivalent or better”.
This result reflects the fact that the presence of La and Sm
in the main phase 10 or the subphase 20 gives a good result
in the temperature coefficient of the magnetic properties,
but the magnetic properties at room temperature are not20
improved, and the structure form is not optimal in the main
phase 10 and the subphase 20: the change in the composition
ratio of Nd, La, Sm results in almost the same result as in
Comparative Example 4.
[0106] Comparative Example 6 is a sample of the rare earth25
sintered magnet 1 prepared in the form of (Nd, Pr, La, Sm)-
Fe-B with the production method described in Patent
Literature 1 using Nd, Pr, La, Sm, Fe, and FeB as raw
materials. From the observation of the structure form of
this sample with the method described above, the main phase30
10 in which Nd and Pr are provided mixedly is confirmed due
to the addition of Pr, but a core-shell structure is not
formed. In addition, due to the addition of La and Sm, the
49
concentration of Sm is segregated in one subphase 20 along
with the segregation of La, but the second subphase 22 does
not exist. Furthermore, it is also not confirmed that the
concentration of Sm is higher in the first subphase 21 than
in the second subphase 22. The evaluation of the magnetic5
properties of this sample with the method described above
shows that the residual magnetic flux density is “equivalent”,
the coercive force is “good”, the temperature coefficient of
residual magnetic flux density is “good”, the temperature
coefficient of coercive force is “equivalent”, and the10
magnetizing ability is “equivalent or better”. This result
reflects the fact that that the addition of Pr increases the
magnetic anisotropy of the main phase 10 to improve the
coercive force, and the presence of La and Sm in the main
phase 10 or the subphase 20 improves the temperature15
coefficient of the magnetic properties, particularly the
temperature coefficient of the coercive force, but the
structure form is not optimal in the main phase 10 and the
subphase 20.
[0107] Comparative Example 7 is a sample of the rare earth20
sintered magnet 1 prepared in the form of Nd-Fe-B with the
production method including the hot working method described
in Patent Literature 2 using Nd, Fe, and FeB as raw materials.
From the observation of the structure form of this sample
with the method described above, due to the absence of Pr,25
La, and Sm, no core-shell structure is confirmed in the main
phase 10, and it is not confirmed that the concentration of
Sm in the subphase 20 is higher in the first subphase 21
than in the second subphase 22. However, the refinement of
the structure, which is a characteristic of a magnet produced30
with the hot working method, is confirmed. The evaluation
of the magnetic properties of this sample with the method
described above shows that the residual magnetic flux density
50
is “poor”, the coercive force is “good”, the temperature
coefficient of residual magnetic flux density is
“equivalent”, the temperature coefficient of coercive force
is “equivalent”, and the magnetizing ability is “poor”. This
result reflects the decrease in residual magnetic flux5
density and deterioration in magnetizing ability despite the
improvement of the coercive force associated with the
refinement of the structure through the hot working method.
[0108] Comparative Example 8 is a sample of the rare earth
sintered magnet 1 prepared in the form of (Nd, Dy)-Fe-B with10
the production method including the hot working method
described in Patent Literature 2 using Nd, Dy, Fe, and FeB
as raw materials. From the observation of the structure
form of this sample with the method described above, due to
the absence of Pr, La, and Sm, no core-shell structure is15
confirmed in the main phase 10, and it is not confirmed that
the concentration of Sm in the subphase 20 is higher in the
first subphase 21 than in the second subphase 22. The
evaluation of the magnetic properties of this sample with
the method described above shows that the residual magnetic20
flux density is “poor”, the coercive force is “good”, the
temperature coefficient of residual magnetic flux density is
“equivalent”, the temperature coefficient of coercive force
is “equivalent”, and the magnetizing ability is “poor”. This
indicates that the coercive force is significantly improved25
by the substitution of Dy having high magnetocrystalline
anisotropy for a part of Nd in addition to the manufacture
with hot working, but the other properties reflect the
structure refinement.
[0109] Comparative Example 9 is a sample of the rare earth30
sintered magnet 1 prepared in the form of (Nd, Pr)-Fe-B with
the production method including the hot working method
described in Patent Literature 2 using Nd, Pr, Fe, and FeB
51
as raw materials. From the observation of the structure
form of this sample with the method described above, the
core-shell structure is confirmed through hot working in
addition to the addition of Pr, but there is only one type
of main phase 10 having a high Pr concentration in the core5
portion. In addition, due to the absence of La and Sm, it
is also not confirmed that the concentration of Sm in the
subphase 20 is higher in the first subphase 21 than in the
second subphase 22. The evaluation of the magnetic
properties of this sample with the method described above10
shows that the residual magnetic flux density is “poor”, the
coercive force is “good”, the temperature coefficient of
residual magnetic flux density is “equivalent”, the
temperature coefficient of coercive force is “equivalent”,
and the magnetizing ability is “poor”. This indicates that15
the coercive force is significantly improved to the level of
the rare earth sintered magnet 1 containing Dy due to the
formation of the core-shell structure having a high Pr
concentration in the core portion, but the other properties
reflect the structure refinement.20
[0110] Comparative Example 10 is a sample of the rare
earth sintered magnet 1 prepared in the form of (Nd, La,
Sm)-Fe-B with the production method including the hot working
method described in Patent Literature 2 using Nd, La, Sm,
Fe, and FeB as raw materials. From the observation of the25
structure form of this sample with the method described above,
no core-shell structure is confirmed in the main phase 10
due to the absence of Pr. In addition, due to the addition
of La and Sm, the concentration of Sm is segregated in one
subphase 20 along with the segregation of La, but the second30
subphase 22 does not exist. Furthermore, it is also not
confirmed that the concentration of Sm is higher in the first
subphase 21 than in the second subphase 22. The evaluation
52
of the magnetic properties of this sample with the method
described above shows that the residual magnetic flux density
is “poor”, the coercive force is “good”, the temperature
coefficient of residual magnetic flux density is “good”, the
temperature coefficient of coercive force is “good”, and the5
magnetizing ability is “poor”. This result reflects the
fact that the presence of La and Sm in the main phase 10 or
the subphase 20 gives a good result in the temperature
coefficient of the magnetic properties, but the residual
magnetic flux density and the magnetizing ability at room10
temperature are not improved, and the structure form is not
optimal in the main phase 10 and the subphase 20.
[0111] Comparative Example 11 is a sample of the rare
earth sintered magnet 1 prepared in the form of (Nd, La,
Sm)-Fe-B with the production method including the hot working15
method described in Patent Literature 2 using Nd, La, Sm,
Fe, and FeB as raw materials. The composition ratio of Nd,
La, and Sm is different from that of Comparative Example 10.
From the observation of the structure form of this sample
with the method described above, no core-shell structure is20
confirmed in the main phase 10 due to the absence of Pr. In
addition, due to the addition of La and Sm, the concentration
of Sm is segregated in one subphase 20 along with the
segregation of La, but the second subphase 22 does not exist.
Furthermore, it is also not confirmed that the concentration25
of Sm is higher in the first subphase 21 than in the second
subphase 22. The evaluation of the magnetic properties of
this sample with the method described above shows that the
residual magnetic flux density is “poor”, the coercive force
is “good”, the temperature coefficient of residual magnetic30
flux density is “good”, the temperature coefficient of
coercive force is “good”, and the magnetizing ability is
“poor”. This result reflects the fact that the presence of
53
La and Sm in the main phase 10 or the subphase 20 gives a
good result in the temperature coefficient of the magnetic
properties, but the residual magnetic flux density and the
magnetizing ability at room temperature are not improved,
and the structure form is not optimal in the main phase 105
and the subphase 20. The change in the composition ratio of
Nd, La, Sm results in almost the same result as in
Comparative Example 10.
[0112] Comparative Example 12 is a sample of the rare
earth sintered magnet 1 prepared in the form of (Nd, Pr, La,10
Sm)-Fe-B with the production method including the hot working
method described in Patent Literature 2 using Nd, Pr, La,
Sm, Fe, and FeB as raw materials. From the observation of
the structure form of this sample with the method described
above, the core-shell structure is confirmed through hot15
working in addition to the addition of Pr, but there is only
one type of main phase 10 having a high Pr concentration in
the core portion. In addition, due to the addition of La
and Sm, the concentration of Sm is segregated in one subphase
20 along with the segregation of La, but the second subphase20
22 does not exist. Furthermore, it is also not confirmed
that the concentration of Sm is higher in the first subphase
21 than in the second subphase 22. The evaluation of the
magnetic properties of this sample with the method described
above shows that the residual magnetic flux density is “poor”,25
the coercive force is “good”, the temperature coefficient of
residual magnetic flux density is “good”, the temperature
coefficient of coercive force is “good”, and the magnetizing
ability is “poor”. This indicates that the coercive force
is significantly improved to the level of the rare earth30
sintered magnet 1 containing Dy due to the formation of the
core-shell structure having a high Pr concentration in the
core portion, and the presence of La and Sm in the main phase
54
10 or the subphase 20 improves the temperature coefficient
of the magnetic properties, particularly the temperature
coefficient of the coercive force. However, the result also
reflects the fact that the residual magnetic flux density
and the magnetizing ability at room temperature are not5
improved, and the structure form is not optimal in the main
phase 10 and the subphase 20.
[0113] The samples of Examples 1 to 8 are the rare earth
sintered magnet 1 including the main phase 10 that satisfies
a general formula (Nd, Pr, R)-Fe-B, where R is one or more10
rare earth elements selected excluding Nd and Pr, the main
phase 10 containing crystal grains based on an Nd2Fe14B
crystal structure, wherein the main phase 10 includes a core
portion and a shell portion covering the core portion, the
main phase 10 includes the first main phase 11 that satisfies15
CNd>CPr and the second main phase 12 that satisfies CNdCPr and a second main phase that satisfies10
CNdC2Nd and C1PrSNd and CPrSPr,
where SNd is concentration of Nd in the shell portion and
57
SPr is concentration of Pr in the shell portion.
[Claim 5] The rare earth sintered magnet according to claim
1, further comprising, given R=La and/or Sm, a first subphase
that is crystalline and has a main component based on an5
oxide phase represented by (Nd, Pr, La, Sm)-O, and a second
subphase that is crystalline and has a main component
represented by (Nd, Pr, La)-O, wherein
concentration of Sm is higher in the first subphase
than in the second subphase.10
[Claim 6] The rare earth sintered magnet according to claim
5, wherein 1<(Y1+Y2)/Y<(X1+X2)/X is satisfied, where X
represents concentration of La contained in the main phase,
X1 represents concentration of La contained in the first15
subphase, X2 represents concentration of La contained in the
second subphase, Y represents concentration of Sm contained
in the main phase, Y1 represents concentration of Sm
contained in the first subphase, and Y2 represents
concentration of Sm contained in the second subphase.20
[Claim 7] The rare earth sintered magnet according to claim
4, wherein
concentrations of Nd and Pr contained in the first main
phase satisfy a relational expression of (CNd+SNd)>(X+Y),25
and
concentrations of Nd and Pr contained in the second
main phase satisfy a relational expression of
(CPr+SPr)>(X+Y).
30
[Claim 8] A method for producing the rare earth sintered
magnet according to any one of claims 1 to 7, the method
comprising:
58
a melting step of melting a raw material of a rare earth
sintered magnet alloy containing an element constituting the
rare earth sintered magnet;
a primary cooling step of cooling the raw material
molten in the melting step to obtain a solidified alloy;5
a secondary cooling step of further cooling the
solidified alloy to obtain a rare earth sintered magnet
alloy;
a pulverizing step of pulverizing the rare earth
sintered magnet alloy satisfying (Nd, Pr, R)-Fe-B;10
a molding step of preparing a molded body by molding
powder of the rare earth sintered magnet alloy pulverized in
the pulverizing step;
a sintering step of obtaining a sintered body by
sintering the molded body at a sintering temperature that is15
a predetermined temperature;
a primary aging step of holding the sintered body at a
primary aging temperature that is a temperature lower than
the sintering temperature;
a secondary aging step of holding the sintered body20
held in the primary aging step at a secondary aging
temperature that is a temperature lower than the primary
aging temperature;
a tertiary aging step of holding the sintered body held
in the secondary aging step again at the primary aging25
temperature;
a quaternary aging step of holding the sintered body
held in the tertiary aging step again at the secondary aging
temperature; and
a cooling step of cooling the sintered body held in the30
quaternary aging step.
59
[Claim 9] A rotor comprising:
a rotor core; and
the rare earth sintered magnet according to any one of
claims 1 to 7 provided in the rotor core.
5
[Claim 10] A rotary machine comprising:
the rotor according to claim 9; and
an annular stator facing the rotor and including, on an
inner surface on a side where the rotor is placed, windings
provided on teeth protruding toward the rotor.10