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1 Journal of Achievements in Materials and Manufacturing Engineering

1 2010

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Arc-plasma spraying and suction-casting methods in magnetic materials manufacturing

Wysłocki J. J., Pawlik P.

Journal of Achievements in Materials and Manufacturing Engineering

2010

Vol. 43, nr 1

463--468

Purpose: The paper discusses two new technologies for producing magnetic materials which have been successfully developed in recent years at the Institute of Physics of the Czestochowa University of Technology and discusses properties of the materials obtained with the use of these methods. Design/methodology/approach: In this research the arc-plasma deposition of Nd2Fe14B powders onto a substrate either cooled with water or heated up to a temperature in the range from 773 to1023 K was applied. In the second method the suction of an arc-melted alloy to a water-cooled copper mould (the suction-casting method) was introduced. Moreover, microstructure, magnetic properties and domain structure of the produced samples were determined. Findings: It has been found that thin Nd2Fe14B strips obtained by the plasma method possess magnetic properties. It has also been demonstrated that the suction-casting method makes it possible to obtain both amorphous magnetically soft materials (e.g. Fe-Co-W-Zr-B), as well as magnetically hard nanocomposites (e.g. (Fe-Co)-(Pr-Dy)-B-Zr). Research limitations/implications: The main problem in the suction-casting method is to reduce the critical cooling rate required for the production of amorphous alloys and to increase the geometrical dimensions of amorphous specimens. Practical implications: Thin-layered Nd-Fe-B magnets produced by means of arc-plasma deposition can be applied directly onto the surface of electromagnetic equipment parts. Magnets with isotropic magnetic properties were obtained by applying layers onto the water-cooled copper substrate. Whereas, anisotropic magnets were obtained as a result of the arc-plasma deposition of powders onto the copper substrate heated up to 873 K. The most advantageous properties were achieved for the microcrystalline structure of a grain size close to the single-domain particle size (approx. 0.3 μm). Moreover, it has been demonstrated that the suction-casting method makes it possible to obtain bulk amorphous alloys of considerable sizes, such as rods of magnetically soft Fe-Co-W-Zr-B alloys of a diameter up to 2 mm, as well as Fe-Co-Pr-Zr-B tubes of a diameter up to 3 mm. It is also possible to produce magnetically hard nanocomposite materials of the (Fe-Co)-(Pr,Dy)-B-Zr type by annealing of metallic glasses. Originality/value: Successfully introduced new methods of magnetic materials manufacturing.