European Research and Training Network ”Ductile BMG Composites” Magnetic Properties of Bulk Metallic Glasses Paola Tiberto INRIM, Torino Outline • Magnetic Materials Overview Applications • Bulk Metallic Glasses • Hard and soft compositions • Nanocomposite Magnets • Recent Experimental data • Conclusions Magnetic Effects of Electrons -- Domains • Permanent magnetism is an atomic effect due to electron spin. In atoms with two or more electrons, the electrons are usually arranged in pairs with their spins oppositely aligned → NOT MAGNETIC • If the spin does not pair → ferromagnetic materials m = −( e / 2me )⋅ L m =i⋅A -e v i i L me Domains • Large groups of atoms in which the spins are aligned are called domains • When an external field is applied, the domains that are aligned with the field tend to grow at the expense of the others. material becomes magnetized Domains • (a) Random alignment shows an unmagnetized material • (b) When an external magnetic field is applied, the domains aligned parallel to external magnetic field grow Ferromagnetic materials Hysteresis loop H=0 H = Hmax B= µ0(H + M) = µ0H + J H=0 Types of Ferromagnetic Materials •Two categories: a)Soft magnetic materials •i.e. Fe: easily magnetized If the external field is removed, magnetism disappears Hc < 10 A/m b) Hard magnetic materials • Co and Ni: difficult to magnetize –They tend to retain their magnetism Permanent magnets Hc > 100 A/m Hysteresis Loops SOFT magnetic materials A small amount of dissipated energy in repeated Reversing magnetisation HARD magnetic materials Retains a large fraction of the saturation field when H is removed M Transformers Motor cores permanent magnets, memory devices Magnetic recording Ferromagnetic Materials Magnetic materials are widely used in modern devices for their ability to produce or to amplify a magnetic field in the outer space. •SOFT magnetic •HARD magnetic easy to magnetise difficult to demagnetise provide great amplification of magnetic field produced by electric current in a coil provide a source of magnetic field without power supply Ferromagnetic materials Soft Magnetic materials • Shape of the M,H (or B,H) curve affected by magnetic anisotropy K: K magnetic properties depend on the direction in which they are measured. • K is exploited in the design of most magnetic materials of commercial importance. Soft and extra-soft magnetic properties: low values of the magnetic anisotropy (K in the range of few ten J/m3 and less, i.e. Fe-Ni alloys). Vanishing anisotropy can be obtained in amorphous and nanocrystalline alloys, because the structural order in these materials is extended over limited distances, from few atomic spacings to few nanometers. Soft Magnetic materials High saturation magnetisation Low magnetocrystalline anisotropy Low coercive field High magnetic response Easy and fast attain of saturation Easy magnetic domain wall movement (homogeneous material without difects, inclusions, stress …) High Curie Temperature High electrical resistance Magnetic stability at higher temperatures Minimise magnetic losses due to Eddy currents Non-expensive For application in devices on large scale Soft Magnetic materials Composition: values of saturation magnetization Ms, the magnetic anisotropy constants K and the magnetostriction constants magnetization process related to the material structure (e.g. crystallographic texture, grain size,lattice defects, etc.). Proper choice of composition and suitable metallurgical and thermal treatments allow to obtain extra soft magnets (Hc≈ 0.1 A/m and µ0 ≈ 106). A number of additional properties, like thermal and structural stability, stress sensitivity of the magnetic parameters, mechanical properties and machinability, thermal conductivity have to be considered. The final acceptance of a material in applications will result from a cost-benefit evaluation of all these properties. Soft Magnetic materials Composition µmax Hc (A/m) Js (T) ----------------------------------------------------------------------------------------------------------Fe100 3-50⋅⋅103 1-100 2.16 Fe NO Fe-Si Fe(>96)-Si(<4) 3-10⋅⋅103 30-80 1.98-2.12 GO Fe-Si Fe97-Si3 20-80⋅⋅103 4-15 2.03 Fe-Si 6.5% Fe93.5-Si6.5 5-30⋅⋅103 10-40 1.80 Sintered powders Permalloy Fe99.5-P0.5 0.2-2⋅⋅103 100-500 1.65-1.95 Fe16-Ni79-Mo5 5⋅⋅105 0.4 0.80 Permendur Fe49-Co49-V2 2⋅⋅103 100 2.4 Ferrites (Mn,Zn)O⋅⋅Fe2O3 3⋅⋅103 20-80 0.2-0.5 Sendust Fe85-Si9.5-Al5.5 50⋅⋅103 5 1.70 Amorphous (Fe-based) Fe78B13Si9 105 2 1.56 Amorphous (Co-based) Co71Fe4B15Si10 5⋅⋅105 0.5 0.86 1 1.2 NanocrystallineFe73.5Cu1Nb3Si13.5B9 105 Hard magnetic materials Hard magnets are used for their ability to produce a static magnetic field in the outer space without need of electric power and without heat dissipation. Three relevant quantities are used to describe their performances: • Coercive field, Hc • Remanent magnetisation, Mr • Maximum Energy Product, (BH)max B= µ0H + µ0M Coercivity Expresses the ability of the magnetic material to retain its magnetised state The magnetisation reversal occurring in the 2nd quadrant of the M:H loop may be strongly hindered by: the magnetic phase intrinsic ANISOTROPY AND/OR Fe14Nd2B M M the material MICROSTRUCTURE (grain size, defects, precipitates...) Original magnetisation Reversed magnetisation Domain wall Pinning centre Materials for permanent magnets (BH)max has doubled every 12 years in XX century Increase in (BH)max = decrease in size and weight of devices Now reached a plateau value with NdFeB magnets based on the intermetallic compound: Fe14Nd2B Intrinsic limitation: (BH)max≤ µ0Ms2/4 magnetite ferrite NdFeB Applications: Hard Magnets • 60% of NdFeB magnet production goes into disc-drive applications, primarily voice-coil-motors (VCMs). • very wide range of applications for RE-magnets: 1. Automotive: modern cars ≈ 100 permanent magnet motors. Currently these are almost exclusively based on Sr-ferrite (SrFe12019) and the penetration of NdFeB magnets into this area requires a significant cost reduction, an increase in the maximum operating temperature and improvement in corrosion resistance. 2.“white goods”: washing machines, refrigerators to improve energy efficiency and hence reduce CO2 emissions using NdFeB magnets would be a significant reduction in volume and weight and an improved efficiency. Ferromagnetic BMG • Non-optimal properties and uses of electromagnetic materials in various devices and appliances. • Improved energy efficiency: 1% total electrical energy produced in the US lost as heat dissipated by distribution transformers that use ferromagnetic cores made from amorphous glassy materials (20 -40 µm thick) • Limitation of efficiency: post-anneal brittleness, stress sensitivity • Quest for materials having simultaneously high glass forming ability, superhigh strength and excellent magnetic properties. Bulk Metallic Glasses • 1951: Amorphous metallic materials unique electronic and mechanical properties arising from a lack of long-range crystallographic order. Produced by means of rapid solidification techniques (melt-spinning and splat-cooling) with extreme quenching conditions, typically exceeding 106 K/s. • 1974: BMG certain metallic alloys can be vitrified into a completely amorphous state from the liquid at cooling rate of 10 K/s . •Late eighties: BMG alloys may be cast into rods up to 2 cm or more in diameter and have technological potential due to netshape forming. forming Ferromagnetic BMG: chronology • Before 1993: no room-temperature ferromagnetic BMG • 1995: Inoue containing a compositions (P,B,Si). et al. Produced ferromagnetic BMG alloys very large number of elements. Typical Fe–(Al,Ga)–(P,C,B,Si) and Co–Cr–(Al,Ga)– •1996 Inoue et al. developed BMG rods (1–12mm diameter) of composition RE60Fe30Al10 (RE=Nd or Pr) with appreciable coercivities at room temperature (HARD). • Relatively difficult to cast: critical cooling rate of 102 ÷103 K/s, K/s higher than 1 ÷ 10 K/s characteristic for alloys with very good GFA, limiting the maximum achievable diameter to a few millimeters. •Other Hindrance: presence of impurities in the melt, or of crystalline inclusions that can form upon solidification of the melt. Ferromagnetic BMG Ferromagnetic BMG Ferromagnetic BMG • Amorphous Fe-Al-Ga-P-C-B cast cylinders: Hc ≈ 10 A/m and a Js ≈ 1.1 T compare with those of conventional FeSi-B-based amorphous ribbons without the appreciable degradation observed for thick samples (i.e. . A. Inoue, Acta Mater. 48 (2000) 279) • Ultrahigh strength (5 GPa) Co43Fe20Ta5.5B31.5 bulk glassy alloy. Ring (thick 1 mm, d = 7 and 3 mm): Hc = 0.25 A/m and µm = 5.5 105 Js = 0. 49 T. Softness related to glassy structure with high homogeneity level and absence of crystalline nuclei (A. Inoue at al., Nat. Mat. 2 (2003) 661) • Nd,Pr-Fe-based BMG’s, containing ultra-fine dispersions of nanocrystals, have moderately high Hc (2.5 105 A/m). Ferromagnetic BMG Fe- and Co-based glassy alloys have similar combination of lower coercivity and higher electrical resistivity among all soft magnetic metallic alloys. The lower coercivity is presumably due to the smaller magnetic anisotropy and lower internal stress. Soft magnetic BMG Soft magnetic BMG (Fe0.6Co0.4)72Si4B20Nb4 glassy plates used for the magnetic yoke of linear actuator (devices which transform an input signal). Js = 1.15 T and µmax= 73000. Soft magnetic BMG Hard magnetic BMG • BMG rods (1–12mm diameter) of composition RE60Fe30Al10 (RE=Nd or Pr) with appreciable coercivities (about 0.4 T) at room temperature nanocomposite structures nanocrystallites embedded in the amorphous matrix • These microstructures have been shown to improve the soft or hard magnetic properties in ribbons, respectively by controlled crystallisation of an initially amorphous alloy or by casting under controlled conditions (i.e. FINEMET, Exchange Spring). • A major hindrance: inherent brittleness induced during the development of a nanocrystalline phase. • The use of BMG precursors facilitates the direct casting not only of toroidal but also more complex shapes which can then be annealed to nanocomposite structures with exchange enhanced properties Nanocomposite Magnets • Uniform mixture of exchange coupled magnetically hard and soft phases : High energy products and relatively high coercivities •Advantages: high reduced remanence, mr (= Mr/Ms) and low material cost due to the reduction in the content of the expensive hard magnetic phase. •A small grain size (10-20 nm) and a uniform mixture of the two phases is a prerequisite for exchange coupling. This coupling leads to a smooth hysteresis loop in which the individual character of the constituent phases is concealed. •Suitable microstructure is most conveniently handled through non-equilibrium metallurgical techniques such as melt-spinning, mechanical alloying, and sputter deposition. The ternary system Nd-Fe-Al This ternary alloy system: • Exhibits amorphous formation in a wide composition range: • Shows good hard magnetic properties (i.e. high coercivity) at RT in the amorphous state • Has a low critical cooling rate for glass formation, suitable for Bulk Metallic Glasses (BMG) preparation Origin of coercivity in NdFeAl BMG Observation: Hard behaviour associated with a nominally amorphous (at XRD) phase developed under moderate cooling conditions Proposed explanations: • RANDOM ANISOTROPY MODEL: exchange coupling among magnetically ordered (Fe-rich) clusters with large random magnetic anisotropy • PINNING MODEL: impediment to domain wall motion due to non-magnetic (Nd-rich) nanoparticles acting as pinning centres • PRESENCE OF ANISOTROPIC PHASES : ternary equilibrium µ phase or the binary Fe-Nd metastable A1 Hard magnetic BMG The high coercivity can arise from impediments to domain wall motion, caused by grains boundaries, surfaces, or magnetic inhomogeneities. Research Objectives evaluate the effects of different quenching rates on magnetic properties of the alloy: Nd70Fe20Al10 and relate microstructural features with magnetic hysteresis ? Production techniques Nd70Fe20Al10 ARC MELTING AM bulk ingot COPPER MOULD CASTING PLANAR FLOW CASTING CM cone Ribbon Studied samples Arc melted master alloy AM sample CM sample 1 CM sample 2 2 Copper mould cones 2 Rapidly solidified ribbons RS ribbon 1 RS ribbon 2 Sample A 2 Crystalline samples Sample E (master alloy annealed at 580°C) (prealloy solidified under equilibrium conditions) - despite the claimed large GFA crystallisation cannot be avoided - hcp-Nd + additional reflections: (1 1 4) (1 1 0) (1 0 3) (1 0 6) hcp-Nd calc. (1 0 1) (0 0 4) Intensity (arbitrary units) (1 0 2) Structural characterisation @ Nd3Al, for AM and CM samples; # ternary δ phase (Nd6Fe13-xAl1+x) for AM master alloy - broad amorphous halo in RS ribbons @ @# @ @ AM sample @ CM sample 2 CM sample 1 RS ribbon 2 RS ribbon 1 2.0 2.5 3.0 3.5 4.0 -1 Wavevector S [Å ] 4.5 - grain size for Nd crystals: RS ribbons CM cones AM master alloy ~10 nm ~30 nm ~40 nm Residual amorphous phases with different elemental composition: quenching Nd70Fe20Al10 → x Nd + (1-x) Am Thermal behaviour Temperature [K] - An amorphous phase is formed in all samples regardless of the quenching rate; - no evidence of Tg but additional exothermic signal present at T< Tx due to the growth of Nd precipitates. 650 700 750 800 850 EXO 100 mW/g Tx = 531°C AM master alloy Tx = 505°C CM 2 Heat flow - Onset crystallisation temperatures (Tx) increase with the decrease of the quenching rate; 600 Tx = 486°C CM 1 Tx = 475°C RS 2 Tx = 453°C RS 1 300 350 400 450 500 550 Temperature [°C] An amorphous phase can be easily developed under moderate cooling rates, such as in the arc melting equipment. Its composition is determined by the amount and stoichiometry of crystalline phases precipitated during the solidification process. Magnetic behaviour • All samples are ferromagnetic at RT; • heat treatment above Tx causes collapsing of hysteresis loop into a paramagnetic response -1000 -500 500 1000 0.05 J [T] • Coercive fields increase with the decrease of the quenching rate; 0.10 H [kA/m] 0 annealed 0.00 on RS ribb -0.05 -0.10 -15000 mple CM sa mple AM sa -10000 -5000 0 5000 10000 H [Oe] •HARD PROPERTIES depend on the presence of the AMORPHOUS PHASE; •none of the CRYSTALLINE EQUILIBRIUM PHASES is FERROMAGNETIC at RT 15000 Magnetic behaviour/bulk samples H [kA/m] 0 500 1000 0.10 5 Hc = 87 kA/m 0.05 Hc = 256 kA/m 0 0.00 Hc = 160 kA/m -5 -0.05 AM sample CM sample1 -10 -15000 J [T] •highest coercive field develops in the slowest cooling conditions -500 10 M [emu/g] •Magnetic properties are extremely sensitive to quenching conditions; -1000 CM sample 2 -10000 -5000 0 5000 10000 -0.10 15000 H [Oe] •Absolute values of Mmax and Mr depend on composition of the ferromagnetic phase and not only on its volume fraction •All hysteresis loops don’t reach saturation at the maximum applied field Magnetic behaviour/bulk samples No saturation is reached at the maximum applied field 0.10 -1500 -1000 -1000 -500 -500 H (kA/m) (kA/m) H 500 00 500 1500 2 magnetic contributions: aa 10 0.10 10 b 0.05 0.05 5 5 b c 0 0 0.00 0.00 M M (emu/g) (emu/g) JJ (T) (T) 1000 1000 -5 -5 -0.05 -0.05 -10 -0.10 -10 -0.10 -20000 -15000-10000-5000 -15000 -10000 -5000 00 H (Oe) (Oe) H 5000 20000 5000 10000 1000015000 15000 •FERROMAGNETIC contribution due to the amorphous phase •PARAMAGNETIC contribution due to the precipitated phases Magnetisation is saturated after subtraction Hard behaviour isn’t related to high anisotropy Origin of coercivity in bulk samples •No evidence of definite hard magnetic phases like A1 or µ phase •first magnetisation curve: PINNING type BEHAVIOUR of the magnetisation process •coercivity independent on the formation of Nd crystals evidenced by SEM and XRD -500 0 500 0.08 5 0.04 0 0.00 -5 -0.04 -10 -10 mple AM sa -5 J (T) 10 M (emu/g) •coercivity due to paramagnetic nanoparticles, embedded in the ferromagnetic amorphous matrix, which act as pinning centres H (kA/m) -0.08 0 5 10 H (kOe) CRITICAL SIZE FOR PINNING PROCESS IS RELATED TO THE DOMAIN WALL WIDTH (δ) Condition: d > δ Conclusions • Magnetic properties similar to the one achieved in materials conventionally exploited in applications • preparation geometries; in one-step process in different • miniaturization opportunities for magnetic cores or inductive components and could be used successfully in making transformers, dc-dc and dc-ac converters, magnetic heads, etc. • have more degrees of freedom to tailor magnetic properties due to the flexibility in composition, shape, and dimensions. Heat flow EXO DSC: as-prepared •Significant amount of an amorphous phase is formed in both samples regardless of the quenching rate: strong exothermic signal (around 500 °C) due to a crystallisation process (see Fig. 1) 100 mW/g AM master alloy Tx = 531°C CM Cone 300 350 Tx = 500°C 400 450 500 Temperature [°C] 550 •An additional exothermic signal is observed at lower temperature ⇒ growth of Nd precipitates? DSC traces of the Nd70Fe20Al10 as cast samples. AM samples: master alloy ingots, through arc melting CM samples: cone-shaped ingots (diameter from 1 to 4 mm ), by copper mould casting Effect of annealing H e a t in g r a t e : 4 0 K / m in 150 EXO A ) C o p p e r M o u ld C o n e a s q u e n c h e d s a m p le s a m p le p r e t r e a t e d u p t o 4 9 0 ° C 100 Heat flux (mW/g) 50 Heat treatments: performed in the DSC cell at temperatures increasing from 200 to 500 °C (heating rate 40 K/min) with each step of 50°C. 0 Tx = 461°C 150 B ) A r c m e lt e ld M a s t e r a llo y a s c a s t s a m p le 100 s a m p le p r e t r e a t e d 1) as-quenched: subjected to a DSC run up to (Tx-10)°C and then allowed to cool to room temperature. u p to 5 2 0 °C 2) the same specimen was heated again up to 580°C to complete crystallisation. 50 0 Tx = 491°C 250 300 350 400 450 500 550 T e m p e ra t u re (° C ) Dashed line: first DSC run stopped at (Tx-10)°C; Continuous line second DSC run up to 580°C. Magnetic behaviour : effect of annealing 300 • A reduction of Hc is observed in both samples, especially in the AM master alloy (relative decrease ≈ 24%). Hc (kA/m) 250 200 150 • An increase of magnetisation particularly evident in the CM sample is observed. This effect can be related to variation in composition of the residual amorphous matrix induced by the thermal treatments and resulting from the segregation of Nd atoms in nanocrystalline form. form AM master alloy CM sample 100 13,0 12,0 AM master alloy CM sample 11,5 0,110 0,105 0,100 11,0 0,095 10,5 0,090 10,0 J (T) M (emu/g) 12,5 • Hc reduction ⇒ size increase of the Nd precipitates responsible for the pinning mechanism of the domain walls and segregated from the matrix during the alloy solidification. Optimal dimensions of a nonnon-magnetic precipitate to obtain maximum hardening effect ≈ domain wall width [3]. A further increase beyond this size will cause a decrease in the pinning effect. 0,085 9,5 0 50 100 150 200 250 300 350 400 450 500 Annealing temperature (°C) Annealing treatment induces a growth of the pre-existing Nd nanocrystals and a reduction of their effectiveness as pinning centres, being their size already above the optimal one. Room-Temperature magnetic behaviour H (kOe) 0 5 B) 10 0,10 AM master alloy CM sample pure Nd 5 0,05 0 0,00 -5 -0,05 -500 0 H (kA/m) 500 -0,10 1000 0 5000 10000 0,10 AM master alloy CM sample 0,05 5 0,00 0 -5 -10 -10 -1000 -10000 -5000 10 M (emu/g) M (emu/g) 10 -5 -1000 J (T) -10 J (T) A) H (Oe) -0,05 Annealing temperature = 350 °C -500 0 500 -0,10 1000 H (kA/m) Hc increases with the decrease of quenching rate • No saturation at Hmax ⇒ hysteresis loop can be decomposed into 2 terms: a) ferromagnetic contribution due to the amorphous phase and b) paramagnetic contribution due to the precipitated Nd. • Production techniques: ARC MELTING • 99.9% pure elements • Water-cooled copper plate • Ar atmosphere COPPER MOULDING • Crushed portion of master alloy • melted in a quartz tube • ejected in a conical copper mould • Ar atmosphere Nd70Fe20Al10 Planar Flow Casting Ferromagnetic BMG • The optimization of soft or hard magnetic properties (e.g. by increasing the Fe content for increasing the saturation magnetization) also affects the mechanical properties of the material • the use of such glasses as magnetic parts in various devices is strongly related to their elastic and/or plastic response. • For practical use, it is desirable to exactly evaluate both the magnetic and the mechanical behavior, the modifications induced by (nano)crystalline inclusions, in order to finally reach a suitable compromise between magnetic and mechanical properties. • Mechanical properties of ferromagnetic BMGs and nanocomposites preliminarily investigated: fracture strength ≥ 3 GPa and the Young’s modulus moduli of up to 268 GPa n attained materials very attractive for applications. Soft Magnetic materials Magnetic behaviour/ RS ribbons •Faint coercivity: 4 kA/m •high initial susceptibility •No saturation H [kA/m] [kA/m] H -1500 -1000 -1000 -500 -500 00 500 500 10001000 1500 0.06 0.06 RS ribbon ribbon 11 RS RS ribbon ribbon 22 RS 0.04 0.04 M [emu/g] 44 22 0.02 0.02 Langevin fit function of RS 1 anhysteretic curve 00 0.00 0.00 -2 -2 -0.02 -0.02 Langevin fit function of -4 -4 RS 2 anhysteretic curve 00 -0.04 -0.04 30% µ1 ~ 1·10-16 emu -0.06 -0.06 70% µ2 ~ 5·10-18 emu -6 -6 -15000 -10000 -20000 -15000 -10000 -5000 -5000 µ ⋅H M ∝ L kB ⋅T J [T] 66 5000 10000 1000015000 15000 5000 20000 H [Oe] [Oe] H SUPERPARAMAGNET: •A collection of non-interacting magnetic moments disordered by thermal energy •Described by the Langevin Function (L) Amorphous hard magnets ? Hard magnetic behaviour in the as-cast state for bulk amorphous samples; Hard magnetic behaviour for partially amorphous ribbons obtained at low speeds; Soft magnetic behaviour for fully amorphous ribbons spun at high speeds; Paramagnetic behaviour after heat treatment up to complete crystallisation STRONG DEPENDENCE OF COERCIVE FIELD ON QUENCHING CONDITIONS Soft Magnetic materials Efficient flux multiplier in a large variety of devices, including transformers, generators, motors, to be used in the generation and distribution of electrical energy, and a wide array of apparatus, from household appliances to scientific equipment. High initial magnetic permeability and/or maximum • magnetic fast switching • electronics • magnetic recording and sensors • magnetic shielding