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Received: 2017-01-19

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Journal of Zhejiang University SCIENCE A 2017 Vol.18 No.3 P.163-166

10.1631/jzus.A17NT001


Soft magnetic composites with enhanced performance and their key production technologies


Author(s):  Mi Yan, Chen Wu

Affiliation(s):  State Key Laboratory of Silicon Materials, School of Materials Science and Engineering, Zhejiang University, Hangzhou 310027, China

Corresponding email(s):   mse_yanmi@zju.edu.cn

Key Words:  Soft magnetic, Composite, Power


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Mi Yan, Chen Wu. Soft magnetic composites with enhanced performance and their key production technologies[J]. Journal of Zhejiang University Science A, 2017, 18(1): 163-166.

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Abstract: 
soft magnetic composites (SMCs) contain metallic magnetic powders embedded in an insulation matrix, and are usually prepared by procedures including powder production, insulation coating, binding, compaction, and annealing. They have attracted extensive interest as fundamental electric and electronic components in the fields of energy, information, transportation, and national defense. With the development of electric and electronic devices with properties suitable for high frequency, large power, energy saving, and being electromagnetically compatible, the demand and requirements for SMCs become significantly higher. The SMC industry in China used to lag far behind overseas competitors with a huge technological gap. The main domestic products were Fe SMCs with only a small amount of alloy SMCs. Such SMCs exhibited low magnetization and unsatisfactory DC-bias properties with double the loss compared to the overseas products. Since 2002, Prof. Mi YAN’s team at Zhejiang University, China has carried out long-term cooperation with related enterprises, achieved key breakthroughs, and invented a series of new SMCs with enhanced performance and low loss. The team has also achieved large-scale production and wide application of the new SMCs, pushing the domestic industry into a world-leading position.

低功耗高性能软磁复合材料及关键制备技术

概要:软磁复合材料是软磁金属经制粉、绝缘处理、粘结、压制和热处理而制备的磁性复合材料,广泛应用于能源、信息、交通和国防等重要领域,是国民经济和国防建设的关键基础材料。随着电力和电子装备向高频、高功率密度、节能和电磁兼容方向发展,软磁复合材料的需求量越来越大,要求也越来越高。我国软磁复合材料过去长期存在功率损耗大、磁通密度低、直流叠加性能差等严重问题,技术水平与国外差距巨大。2002年以来,浙江大学严密教授团队与相关企业进行了长期的合作研究,原创性提出了制备多软磁相核壳结构复合材料的技术思路,创新了绝缘包覆技术,大幅消除了颗粒间涡流损耗;建立了软磁合金新体系,显著提高了复合材料软磁性能;创新和集成核心生产技术,实现了规模化生产和广泛的实际应用。
创新点:1. 发明多软磁相核壳结构复合材料和磁粉绝缘包覆新技术。降低以涡流损耗为主的功率损耗,是软磁复合材料的世界性难题。本项目提出了在软磁粉末基体上原位生成高电阻率软磁壳层,制备多软磁相核壳结构复合材料以降低涡流损耗的新思路,发明了Fe基软磁合金基体与Fe4N/Fe3O4、Fe3O4等高电阻率软磁壳层组成的核壳结构材料。创新了磁粉绝缘包覆技术,发明了分别适用于不同合金磁粉的非均匀形核、溶胶-凝胶和复合绝缘包覆技术。以上发明在保持高磁性能的同时,大幅度抑制了颗粒间涡流,显著降低了功率损耗。2. 发明系列新型高性能软磁合金。创新设计了Fe-Si-M、Fe-Ni-M(M为Mo、Ni、Al或Co)新型晶态软磁合金和Fe-Cu-Nb-Ti-Si-B、Fe-Ni-Al-Si-B纳米晶/非晶软磁新合金,掌握了成分配方对合金相结构、显微组织和磁性能的作用规律及机理,发明了系列新型高性能软磁合金,制备出具有高磁通密度、高直流叠加等不同特性的高性能软磁复合材料产品。3. 创新和集成核心生产与应用技术。发明了新型耐高温粘结剂和有机-无机复合粘结技术,创新和改进了针对不同合金的磁粉制备技术,系统集成相关发明与关键技术,建立了低功耗高性能软磁复合材料成套生产工艺。
成果:项目创新成果已在合作企业全面应用,为新能源汽车、高铁、计算机及国防领域做出了重要贡献,并获得了2016年度国家技术发明奖二等奖。值得一提的是,这已是严密教授团队获得的第二个国家技术发明奖二等奖。2013年度,严密教授团队完成的"钕铁硼晶界组织重构及低成本高性能磁体生产关键技术"项目亦获得国家技术发明奖二等奖。

关键词:功耗;软磁;复合材料

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