Fe-based amorphous magnetic powder, magnetic powder core with excellent high frequency properties and method of making them

Abstract

The present invention provides an amorphous alloy powder and magnetic powder cores exhibiting excellent high frequency properties and a method for making themof. The composition of said alloy powder by atomic percentage satisfies the following formula: (Fe 1-x M x ) 100-a-b-c P a T b D c , wherein M represents at least one element of Co and Ni; T is over three elements selected from Al, C, B and Si, D is at least one element of Sn, Cr, Mn, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd and Au; the subscripts x, a, b, and c satisfy the relationships 0.01≦x≦0.16, 8≦a≦15, 10≦b≦25 and 0.5≦c≦6. The said amorphous alloy powder is made by atomization method and a magnetic powder core comprises a molded article of mixture of the said alloy powder and an insulating material. A method of making the amorphous alloy powder core includes the steps of screening, insulating, compacting, annealing and spray painting.

1 . A method for making amorphous alloy powder exhibiting excellent soft magnetic properties in high frequency characterized in that the alloy powder with composition in atomic percent of the following formula: (Fe 1-x M x ) 100-a-b-c P a T b D c , wherein M represents at least one element of Co and Ni; T is over three elements selected from Al, C, B and Si, D is at least one element selected from Sn, Cr, Mn, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd and Au, the subscripts x, a, b, and c satisfy the relationships of 0.0≦x≦0.16, 8≦a≦15, 10≦b≦25 and 0.5≦c≦6 is made by atomization method, wherein said atomization maybe water atomization and/or gas atomization, while said gas atomization may be vacuum gas atomization, non-vacuum gas atomization, adjustable gas atomization or their combination. 
     
     
         2 . The method for making amorphous alloy powder according to  claim 1 , characterized in that the loose packed density of the powder ρ satisfies the relation: ρ≧2.4 g/cm 3 .