铁基非晶磁粉芯的低压成型及性能研究

磁粉芯是一种采用绝缘物质将磁性金属粉末包覆后，在压力作用下成型，具有软磁特性的复合材料。磁粉芯作为一体成型电感的主要部件，广泛应用于高精密电子设备中。铁基非晶合金由于不存在晶界缺陷，且具有高电阻率、高磁导率和低矫顽力的优点，是制备磁粉芯的理想材料。然而，铁基非晶合金硬度大且变形能力差，压制成型过程通常需要施加很高的压力，易引起非晶磁粉芯的绝缘层破损、内应力过大等问题。因此，降低成型压力是制备高性能非晶磁粉芯的关键。本论文旨在开发低压成型技术制备新型铁基非晶磁粉芯，并对制备工艺及磁性能进行系统研究。

首先采用热压成型法制备铁基非晶磁粉芯。通过提高压制温度至近Fe₇₃Si₁₁B₁₁C₃Cr₂粉末的玻璃态转变温度，提高粉末塑性，以降低磁粉芯成型压力。并且，在此温度下进行退火时，“软化”的粉末可充分释放应力，减小磁畴壁移动的阻碍，使磁粉芯磁性能提高。试验中，通过150 °C、15小时的水热处理在Fe₇₃Si₁₁B₁₁C₃Cr₂粉末表面原位生成Fe₃O₄绝缘层后，在600 MPa压力、430 °C温度下成型，之后在430 °C 进行真空热处理1小时以消除残余应力。所制备的非晶磁粉芯，具有最优磁性能：100 kHz、50 mT下损耗498 kW/m³，有效磁导率43。与传统的冷压成型法相比，本文采用的热压成型将非晶磁粉芯成型压力降低了400 MPa以上。

为了进一步降低磁粉芯的成型压力，提高制备效率， 采用了注射成型法制备非晶磁粉芯。高分子粘结剂在熔融状态下与非晶粉末混合均匀形成喂料后，注射成型为磁粉芯。其中，粘结剂既提高了粉末流动速度，又在粉末表面形成绝缘包覆。首先研究了粘接剂的种类和含量对磁粉芯磁性能和力学性能的影响规律。结果表明，具有极性键的骨架粘结剂尼龙66能够与包覆在粉末表面的耦合剂硬脂酸形成强有力的氢键，使磁粉芯粉末颗粒表面绝缘包覆更加充分，内部结构更加均匀，磁粉芯具有最佳的磁性能和力学性能；在确保喂料具有足够流动性的前提下，提高粉末装载量可有效提高磁粉芯性能，对于D₅₀~20 μm的非晶粉末，最大的粉末装载量为93 wt%，此时的磁粉芯在100 kHz、30 mT下损耗为251 kW/m³，有效磁导率为26。和热压法相比，注射成型制备磁粉芯的成型压力显著降低，仅为80 MPa。

在优化粘结剂的基础上，进一步研究了磁粉芯中粉体的组成对非晶磁粉芯磁性能的影响。第一部分，研究了非晶粉末粒径(D₅₀分别为6和18 μm)对喂料流动性以及磁性能的影响。结果表明，随着细粉质量占比增加，喂料的黏度先降低，后增加，50 wt%时达到最小。细粉的引入会增大磁粉芯退磁场，导致磁导率下降，但是，由于细粉可抑制磁粉芯的涡流损耗，同时喂料黏度降低带来的较小残余应力有利于减小磁滞损耗。当细粉占比为50 wt%时，磁粉芯具有最低损耗250 kW/m³(100 kHz, 30 mT)，因此最佳的细粉引入量为50 wt%。第二部分，通过Fe₅₀Co₅₀细粉替代铁基非晶细粉进一步改善磁粉芯的性能。随着Fe₅₀Co₅₀细粉含量的增加，磁粉芯的饱和磁感应强度和直流偏置性能不断提高，但当Fe₅₀Co₅₀细粉比例为50 wt%时，粉末的松装密度最大，且具有最大的流动性，此时喂料黏度最小，残余应力最小，因此磁粉芯损耗最低，为210 kW/m³(100 kHz, 30 mT)。第三部分，研究了纳米锰锌铁氧体的添加对磁粉芯磁性能的影响。结果表明，在超交换作用下，化学成分为Mn_0.5Zn_0.5Fe₂O₄的纳米锰锌铁氧体粉末具有最大的饱和磁化强度。当纳米铁氧体添加比例为0.1 wt%时，纳米粉末破环了粗非晶粉的“搭桥”现象，增大了粉末流动性，磁粉芯的磁性能明显提升，损耗为262 kW/m³(100 kHz, 30 mT)，磁导率为25。因此粉体的粒度和成分配比是影响磁粉芯综合磁性能的关键因素。

论文还研究了注射成型制备磁粉芯中后处理对磁粉芯性能的影响，后处理可有效释放残余应力，减少磁畴壁在外磁场作用下移动的阻碍。结果表明，非晶粉末在450°C条件下真空退火3小时，能够改善非晶磁粉芯的磁性能，100 kHz下，磁导率提高约7%、损耗降低约8%。此外，非晶磁粉芯成型件经过一年老化可消除由喂料黏度引入的残余应力，显著提高磁性能，在100 kHz下，磁导率提高约16%、损耗降低约17%；将温度由室温提高至60 °C可加速老化过程，提高磁性能，并使非晶磁粉芯在短时间内达到性能稳定状态。

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