Abrading – Machine – Sandblast
Patent
1996-12-20
2000-08-22
Banks, Derris Holt
Abrading
Machine
Sandblast
451 36, 451 38, B24C 300
Patent
active
061063762
DESCRIPTION:
BRIEF SUMMARY
This invention relates to a method of producing bulk objects from thin ribbons of metallic glass including a means to cut the desired shape of the bulk object as well as a method of making and annealing uniquely shaped parts from the bulk object. The parts so manufactured are suitable for the manufacture of electric motors, transformers and other machines which can advantageously use the ferromagnetic properties of metallic glass.
BACKGROUND
"Metallic glass" is an amorphous ferromagnetic material. Such material can be used in the construction of electrical equipment to reduce core losses. The problems associated with forming bulk objects from thin metallic glass ribbons (sometimes referred to as amorphous ribbons) are described in U.S. Pat. No. 4,529,458 which teaches stacking the ribbon and consolidating the alloy under a pressure of at least 5895 kPa at a temperature of between 70% and 90% of the crystallisation temperature of the ribbon material for a time sufficient to facilitate bonding of the ribbons into a bulk object.
U.S. Pat. No. 4,529,458 also discloses other methods of forming bulk objects such as the method revealed in U.S. Pat. No. 4,298,382 involving hot pressing finely dimensioned bodies with forces of at least 6895 kPa in a non-oxidising environment at temperatures ranging from about 25.degree. C. below the glass transition temperature to about 15% above the glass transition temperature for a period of time sufficient to cause the bodies to flow and fuse together into an integral unit.
The methods described have the following common steps:
Preheating the ribbons; bringing the ribbons into contact; compacting the block of ribbons and heat treating the bulk object to be formed.
Preheating the ribbons makes them brittle and very prone to damage, consequently material losses and production delays are common.
Even the finished bulk product of the process described above is relatively brittle, consequently breakages and imperfections are common.
Metallic glass blocks and ribbons are so hard that their shape cannot be easily or reliably changed by conventional cutting methods, even though a ribbon is flexible. Guillotine or blank die cutting methods stress and crack the blocks, laser and EDM cutting methods melt the metallic glass and create undesirable crystallisation which reduces the ferromagnetic properties of the material. Furthermore, some of these cutting methods create undesirable magnetic and electrical connections between laminated ribbons in the block which propagate undesirable eddy currents. Thus these cutting methods further reduce the ferromagnetic properties of laminated metallic glass blocks.
In some applications, the individual ribbon portions are heated to pre-anneal the material so that it will have good ferromagnetic properties when one or more strategically located strips of material are required in an electrical device. However, pre-annealing makes the ribbons very brittle.
The use of metallic glass (amorphous magnetic) ribbons annealed or un-annealed on stators and other parts of electric motors, either singly or in laminations, is common. For example, rotary electric machines like those described in Canadian Patent No 1136199 are made by adhering amorphous magnetic material ribbons to the stator core coil. Alternatively, a magnetic wedge can be fitted into the stator slot of the motor where the magnetic wedge consists of an amorphous magnetic ribbon adhered onto a non-magnetic, insulating sheet of the type described in U.S. Pat. No. 5,252,877.
However the methods described above for producing cores for rotors and stators is time consuming. Furthermore, the brittleness of the typically pre-annealed amorphous magnetic material results in high production losses.
Other ways of producing parts of electric and even servo-electric motors include winding wire shaped amorphous magnetic material around a cylindrical coil or producing a stator from one or two edge wound helices of amorphous magnetic ribbon as described in U.S. Pat. No. 4,392,073. These types of construction are n
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Conroy Andrew
Georgopolos Peter
Rybak Tadeusz
Banks Derris Holt
Glassy Metal Technologies Limited
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