# US 2013/0278366 A1 · Alloy composition, fe-based nano-crystalline alloy and forming method of the same and magnetic component

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- Number: US 2013/0278366 A1
- Document ID: US20130278366A1
- Status: Published application
- Kind: A1
- Application number: 13/921,370
- Filed: 2013-06-19
- Published: 2013-10-24
- Earliest claimed: 2008-08-22
- Inventors: Akihiro MAKINO
- Web page: https://patentgrep.com/patent/US20130278366A1

## CPC

- H01F 1/01: of inorganic materials (H01F1/44 takes precedence)
- C21D 5/00: Heat treatments of cast-iron
- C21D 6/00: Heat treatment of ferrous alloys
- C22C 33/0264: {the maximum content of each alloying element not exceeding 5%}
- C22C 38/02: containing silicon
- C22C 38/06: containing aluminium
- C22C 38/08: containing nickel {(C22C38/105 takes precedence)}
- C22C 38/10: containing cobalt
- C22C 38/12: containing tungsten, tantalum, molybdenum, vanadium, or niobium
- C22C 38/16: containing copper
- C22C 38/20: with copper
- C22C 38/32: with boron
- C22C 45/02: with iron as the major constituent
- H01F 1/15333: {containing nanocrystallites, e.g. obtained by annealing}
- C22C 2202/02: Magnetic
- H01F 41/0246: {Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36)}
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- C21D: MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING (surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by this subclass C23F17/00; unidirectional solidification of eutectic materials or unidirectional demixing of eutectoid materials C30B)
- C22C: ALLOYS (treatment of alloys C21D, C22F)

## Abstract

An alloy composition of the formula FeaBbSicPxCuz. Parameters meet the following conditions: 79≦a≦86 atomic %; 5≦b≦13 atomic %; 0<c≦1 atomic %; 1≦x≦8 atomic %; 0.4≦z≦1.4 atomic %; and 0.08≦z/x≦0.8.

## Claims

### Claim 1

An alloy composition consisting of the formula FeaBbSicPxCuz, wherein 79≦a≦86 atomic %, 5≦b≦13 atomic %, 0<c≦1 atomic %, 1≦x≦8 atomic %, 0.4≦z≦1.4 atomic %, and 0.08≦z/x≦0.8.

### Claim 2 (depends on 1)

The alloy composition according to claim 1, where 0.4≦z≦1.1 atomic %, and 0.08≦z/x≦0.55.

### Claim 3 (depends on 1)

The alloy composition according to claim 1, the alloy composition having a continuous strip shape.

### Claim 4 (depends on 3)

The alloy composition according to claim 3, the alloy composition being capable of being flat on itself when being subjected to a 180 degree bend test.

### Claim 5 (depends on 3)

The alloy composition according to claim 3, the alloy composition being formed in a powder form.

### Claim 6 (depends on 1)

The alloy composition according to claim 1, the alloy composition having a first crystallization start temperature (Tx1) and a second crystallization start temperature (Tx2) which have a difference (ΔT=Tx2−Tx1) of 100° C. to 200° C.

### Claim 7 (depends on 1)

The alloy composition according to claim 1, the alloy composition having a nano-hetero structure which comprises amorphous phase and microcrystals existing in the amorphous, wherein the initial microcrystals have an average diameter of 0.3 to 10 nm.

### Claim 8 (depends on 1)

A magnetic component formed from the alloy composition according to claim 1.

### Claim 9 (depends on 1)

A method of forming an Fe-based nano-crystalline alloy, the method comprising:
preparing the alloy composition according to claim 1; and
exposing the alloy composition to a heat treatment under a condition that a temperature increase rate is 100° C. or more per minute and a condition that a process temperature is not lower than a crystallization start temperature of the alloy composition.

### Claim 10 (depends on 9)

An Fe-based nano-crystalline alloy formed by the method according to claim 9, the Fe-based nano-crystalline alloy having magnetic permeability of 10,000 or more and saturation magnetic flux density of 1.65 T or more.

### Claim 11 (depends on 10)

The Fe-based nano-crystalline alloy according to claim 10, wherein the nano-crystals have an average diameter of 10 to 25 nm.

### Claim 12 (depends on 10)

The Fe-based nano-crystalline alloy according to claim 10, the Fe-based nano-crystalline alloy having saturation magnetostriction of 10×10−6 or less.

### Claim 13 (depends on 10)

A magnetic component formed from the Fe-based nano-crystalline alloy according to claim 10.

### Claim 14 (depends on 1)

The alloy composition according to claim 1, wherein an amorphous phase is obtained by a rapid cooling process.

### Claim 15 (depends on 1)

The alloy composition according to claim 1, wherein the alloy composition has a saturation magnetic flux density of 1.77 T or 2.01.