Flat soft magnetic metal powder and composite magnetic material including the soft magnetic metal powder

An Fe—Ni—(Nb, V, Ta)-based soft magnetic metal powder (hereinafter, referred to as an Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder), comprising:

• a component composition which includes Ni in the range of 60 to 90 mass %, at least one of Nb, V, and Ta in the range of 5.4 to 20 mass % in total, at least one of Al and Mn in the range of 0.01 to 1 mass % in total, and the balance including Fe and inevitable impurities;
• an average grain size in the range of 30 to 150 μm;
• an aspect ratio (average grain size/average thickness) in the range of 5 to 500;
• and a flat face,
• wherein a peak intensity ratio I220/I111 of the Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder is in the range of 0.1 to 10, when it is assumed that a peak intensity of a face index (220) in an X-ray diffraction pattern is I220 and a peak intensity of a face index (111) in the X-ray diffraction pattern is I111, the X-ray diffraction pattern being measured in a state where a plane including an incidence direction and a diffraction direction of an X ray is perpendicular to the flat face of the Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder, and an angle formed by the incidence direction and the flat face is equal to an angle formed by the diffraction direction and the flat face.

An oxide-coated Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder, comprising:

• an Fe—Ni—(Nb, V, Ta)-based soft magnetic metal powder (hereinafter, referred to as an Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder);
• and
• an oxide film having a thickness in the range of 5 to 100 nm which is formed on the surface of the Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder,
• wherein the Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder includes a component composition which includes Ni in the range of 60 to 90 mass %, at least one of Nb, V, and Ta in the range of 5.4 to 20 mass % in total, and the balance including Fe and inevitable impurities;
• an average grain size in the range of 30 to 150 μm;
• an aspect ratio (average grain size/average thickness) in the range of 5 to 500;
• and a flat face,
• wherein a peak intensity ratio I220/I111 of the oxide-coated Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder is in the range of 0.1 to 10, when it is assumed that a peak intensity of a face index (220) in an X-ray diffraction pattern is I220 and a peak intensity of a face index (111) in the X-ray diffraction pattern is I111, the X-ray diffraction pattern being measured in a state where a plane including an incidence direction and a diffraction direction of an X ray is perpendicular to the flat face of the oxide-coated Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder, and an angle formed by the incidence direction and the flat face is equal to an angle formed by the diffraction direction and the flat face.

An oxide-coated Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder, comprising:

• an Fe—Ni—(Nb, V, Ta)-based soft magnetic metal powder (hereinafter, referred to as an Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder);
• and
• an oxide film having a thickness in the range of 5 to 100 μm which is formed on the surface of the Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder,
• wherein the Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder includes a component composition which includes Ni in the range of 60 to 90 mass %, at least one of Nb, V, and Ta in the range of 5.4 to 20 mass % in total, least one of Al and Mn in the range of 0.01 to 1 mass % in total, and the balance including Fe and inevitable impurities;
• an average grain size in the range of 30 to 150 μm;
• an aspect ratio (average grain size/average thickness) in the range of 5 to 500;
• and a flat face,
• wherein a peak intensity ratio I220/I111 of the oxide-coated Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder is in the range of 0.1 to 10, when it is assumed that a peak intensity of a face index (220) in an X-ray diffraction pattern is I220 and a peak intensity of a face index (111) in the X-ray diffraction pattern is I111, the X-ray diffraction pattern being measured in a state where a plane including an incidence direction and a diffraction direction of an X ray is perpendicular to the flat face of the oxide-coated Fe—Ni—(Nb, V, Ta)-based flat soft magnetic metal powder, and an angle formed by the incidence direction and the flat face is equal to an angle formed by the diffraction direction and the flat face.

An Fe—Ni—Mo—(Nb, V, Ta)-based soft magnetic metal powder (hereinafter, referred to as an Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder), comprising:

• a component composition which includes Ni in the range of 60 to 90 mass %, Mo in the range of 0.05 to 10 mass %, at least one of Nb, V, and Ta in the range of 5.4 to 19.95 mass % in total, and the balance including Fe and inevitable impurities;
• an average grain size in the range of 30 to 150 μm;
• an aspect ratio (average grain size/average thickness) in the range of 5 to 500;
• and
• a flat face,
• wherein a peak intensity ratio I220/I111, of the Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder is in the range of 0.1 to 10, when it is assumed that a peak intensity of a face index (220) in an X-ray diffraction pattern is I220 and a peak intensity of a face index (111) in the X-ray diffraction pattern is I111, the X-ray diffraction pattern being measured in a state where a plane including an incidence direction and a diffraction direction of an X ray is perpendicular to the flat face of the Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder, and an angle formed by the incidence direction and the flat face is equal to an angle formed by the diffraction direction and the flat face.

An Fe—Ni—Mo—(Nb, V, Ta)-based soft magnetic metal powder (hereinafter, referred to as an Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder), comprising:

• a component composition which includes Ni in the range of 60 to 90 mass %, Mo in the range of 0.05 to 10 mass %, at least one of Nb, V, and Ta in the range of 5.4 to 19.95 mass % in total, at least one of Al and Mn in the range of 0.01 to 1 mass % in total, and the balance including Fe and inevitable impurities;
• an average grain size in the range of 30 to 150 μm;
• an aspect ratio (average grain size/average thickness) in the range of 5 to 500;
• and
• a flat face,
• wherein a peak intensity ratio I220/I111 of the Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder is in the range of 0.1 to 10, when it is assumed that a peak intensity of a face index (220) in an X-ray diffraction pattern is I220 and a peak intensity of a face index (111) in the X-ray diffraction pattern is I111, the X-ray diffraction pattern being measured in a state where a plane including an incidence direction and a diffraction direction of an X ray is perpendicular to the flat face of the Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder, and an angle formed by the incidence direction and the flat face is equal to an angle formed by the diffraction direction and the flat face.

An oxide-coated Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder, comprising:

• an Fe—Ni—Mo—(Nb, V, Ta)-based soft magnetic metal powder (hereinafter, referred to as an Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder);
• and
• an oxide film having a thickness in the range of 5 to 100 μm which is formed on the surface of the Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder,
• wherein the Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder includes a component composition which includes Ni in the range of 60 to 90 mass %, Mo in the range of 0.05 to 10 mass %, at least one of Nb, V, and Ta in the range of 5.4 to 19.95 mass % in total, and the balance including Fe and inevitable impurities;
• an average grain size in the range of 30 to 150 μm;
• an aspect ratio (average grain size/average thickness) in the range of 5 to 500;
• and a flat face,
• wherein a peak intensity ratio I220/I111 of the oxide-coated Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder is in the range of 0.1 to 10, when it is assumed that a peak intensity of a face index (220) in an X-ray diffraction pattern is I220 and a peak intensity of a face index (111) in the X-ray diffraction pattern is I111, the X-ray diffraction pattern being measured in a state where a plane including an incidence direction and a diffraction direction of an X ray is perpendicular to the flat face of the oxide-coated Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder, and an angle formed by the incidence direction and the flat face is equal to an angle formed by the diffraction direction and the flat face.

An oxide-coated Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder, comprising:

• an Fe—Ni—Mo—(Nb, V, Ta)-based soft magnetic metal powder (hereinafter, referred to as an Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder);
• and
• an oxide film having a thickness in the range of 5 to 100 μm which is formed on the surface of the Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder,
• wherein the Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder includes a component composition which includes Ni in the range of 60 to 90 mass %, Mo in the range of 0.05 to 10 mass %, at least one of Nb, V, and Ta in the range of 5.4 to 19.95 mass % in total, at least one of Al and Mn in the range of 0.01 to 1 mass % in total, and the balance including Fe and inevitable impurities;
• an average grain size in the range of 30 to 150 μm;
• an aspect ratio (average grain size/average thickness) in the range of 5 to 500;
• and a flat face,
• wherein a peak intensity ratio I220/111 of the oxide-coated Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder is in the range of 0.1 to 10, when it is assumed that a peak intensity of a face index (220) in an X-ray diffraction pattern is I220 and a peak intensity of a face index (111) in the X-ray diffraction pattern is I111, the X-ray diffraction pattern being measured in a state where a plane including an incidence direction and a diffraction direction of an X ray is perpendicular to the flat face of the oxide-coated Fe—Ni—Mo—(Nb, V, Ta)-based flat soft magnetic metal powder, and an angle formed by the incidence direction and the flat face is equal to an angle formed by the diffraction direction and the flat face.