Patent Application
20180037965
This disclosure relates to grain-oriented electrical steel sheets used for iron cores of transformers, for example, and to production methods therefor.
Transformers in which grain-oriented electrical steel sheets are used are required to have low iron loss and low noise properties. In order for a transformer to have lower iron loss, it is effective to reduce the iron loss of the grain-oriented electrical steel sheet itself, and as one of the techniques for doing so, it is necessary to irradiate the surface of the steel sheet with laser beams, plasma, electron beams, or the like. JP2012036450A (PTL 1) teaches a technique for reducing iron loss by optimizing the interval between irradiation points and irradiation energy when introducing thermal strain to a surface of a grain-oriented electrical steel sheet in a dot-sequence manner by electron beam irradiation in a direction transverse to a rolling direction. This technique reduces iron loss by not only refining main magnetic domains but also forming an additional magnetic domain structure, called closure domains, inside the steel sheet.
As closure domains increase, however, this technique has a disadvantage in noise performance when incorporated in a transformer. The reason is that since the magnetic moment of closure domains is oriented in a plane orthogonal to the rolling direction, magnetostriction occurs as the orientation changes towards the rolling direction during the excitation process of the grain-oriented electrical steel sheet. The steel sheet also contains other closure domains called “lancet domains”, and magnetostriction also occurs as a result of generation and disappearance of such lancet domains during excitation with alternating magnetic fields. It is known that lancet domains can be reduced by applying tension, for example, and the reduction of lancet domains can yield improved magnetostriction properties. On the other hand, closure domains caused by magnetic domain refinement as described above also cause magnetostriction and deterioration of transformer noise performance. Therefore, there is demand for optimization of not only lancet domains but also closure domains in order to achieve both low iron loss and low noise properties.
Conventional techniques for improving iron loss properties and noise performance with electron beam methods are described below. JP2012172191A (PTL 2) teaches a technique for providing a grain-oriented electrical steel sheet exhibiting excellent iron loss properties and noise performance by adjusting, in the case of performing magnetic domain refining treatment by irradiating with an electron beam in point form, the relationship between holding time t at each irradiation point and interval X between irradiation points in accordance with the output of the electron beam. JP2012036445A (PTL 3) describes a grain-oriented electrical steel sheet in which magnetic domain refining treatment is performed with electron beam irradiation and the relationship between diameter A of a thermal strain introduction region and irradiation pitch B is optimized.
WO2014068962A (PTL 4) describes a technique for optimizing, using an electron beam method, the rolling-direction width and the thickness-direction depth of closure domains as well as the interval at which closure domains are introduced in the rolling direction.
PTL 1: JP2012036450A
PTL 2: JP2012172191A
PTL 3: JP2012036445A
PTL 4: WO2014068962A
However, in PTLs 2 and 3, electron beam irradiation is carried out in a dot-sequence manner, the resulting closure domains are not optimized adequately in terms of shape from the perspective of achieving both low iron loss and low noise properties. Regarding the technique of PTL 4, in view of the fact that the steel sheet has low iron loss and involves closure domains large in volume and large in rolling-direction width, it is estimated that the steel sheet has a small building factor. However, in order for closure domains to be formed to a predetermined depth in the sheet thickness direction, the magnetostriction tends to become significant in the sheet thickness direction. Thus, the technique of PTL 4 is not suitable for use in transformers in which greater importance is placed on noise performance.
It would thus be helpful to provide a grain-oriented electrical steel sheet with low iron loss and low noise when incorporated in a transformer and a production method therefor.
Although the idea of such closure domain formation already exists, we discovered that forming closure domains with a large depth in the sheet thickness direction and with a small volume (which is defined herein as “average closure domain width in the rolling direction Wave*maximum depth D/periodic interval s”) is effective for achieving both low iron loss and low noise properties of a transformer. We also found that the electron beam method is most advantageous as a method of introducing such closure domains. The reason is that the electron beam has high permeability to the interior of a steel sheet, which enables introducing strain and closure domains to a larger depth in the sheet thickness direction from the irradiated surface.
We also revealed that a better balance between iron loss properties and noise performance than in the conventional techniques can be achieved by forming closure domains in a steel sheet surface such that their width periodically varies in the rolling direction and by optimizing the ratio of Wmax/Wmin, where Wmax and Wmin respectively denote a maximum width and a minimum width in the rolling direction, using an electron beam method with extremely high beam controllability and high position controllability.
Finally, we discovered optimum electron beam irradiation conditions for forming closure domains satisfying these conditions. Specifically, we found a technique to make the diameter of a high accelerating voltage beam smaller than was conventionally the case, and to provide high-speed control of beam retention and movement.
The present disclosure was completed based on these discoveries, and primary features thereof are as described below.
(1) A grain-oriented electrical steel sheet with a plurality of strain regions locally present in a surface layer of the steel sheet and formed to extend in a direction transverse to a rolling direction at periodic interval s in millimeters in the rolling direction, wherein each of the strain regions has a closure domain region that is formed continuously over a distance of 200 mm in a width direction and whose width as measured in the rolling direction varies periodically on a surface of the steel sheet, and each of the closure domain regions satisfies a set of conditions including: a ratio of Wmax/Wmin being 1.2 or more and less than 2.5, where Wmax and Wmin respectively denote a maximum width and a minimum width on the surface of the steel sheet as measured in the rolling direction; Wave being 80 μm or more, where Wave denotes an average width on the surface of the steel sheet as measured in the rolling direction; D being 32 μm or more, where D denotes a maximum depth as measured in the sheet thickness direction; and (Wave*D)/s being 0.0007 mm or more and 0.0016 mm or less.
(2) A method for use in producing the grain-oriented electrical steel sheet according to (1), the method comprising: irradiating a surface of the grain-oriented steel sheet with an electron beam while scanning the electron beam in a scanning direction transverse to a rolling direction under a set of electron beam irradiation conditions including: an accelerating voltage being 90 kV or more; d1 being 80 μm or more and 220 μm or less, where d1 denotes a beam diameter as measured in a direction orthogonal to the scanning direction, d2 being (0.8*d1) μm or more and (1.2*d1) μm or less, where d2 denotes a beam diameter as measured in the scanning direction, a beam profile having a Gaussian shape, and the scanning of the electron beam being performed while repeating a process to stop and resume movement by a traveling distance p of the electron beam on the surface, where 1.5*d2≦p≦2.5*d2.
(3) The method according to (2), wherein the movement of the electron beam is stopped for 2 μs or more and the scanning is performed with an average rate of 100 m/s or higher.
(4) The method according to (2), wherein the movement of the electron beam is stopped for 8 μs or more and the scanning is performed with an average rate of 30 m/s or higher.
(5) The method according to any one of (2) to (4), wherein the electron beam is scanned on the surface over a scanning distance as measured in the width direction of 200 mm or more.
(6) The method according to any one of (2) to (4), wherein the electron beam is scanned on the surface over a scanning distance as measured in the width direction of 300 mm or more.
(7) The method according to any one of (2) to (6), wherein the electron beam is sourced from LaB6.
(8) The method according to any one of (2) to (7), wherein the electron beam is converged using at least two coils.
The grain-oriented electrical steel sheet according to the disclosure has low iron loss properties and exhibits low noise performance when incorporated in a transformer. According to the method for use in producing the grain-oriented electrical steel sheet disclosed herein, it is also possible to obtain a grain-oriented electrical steel sheet having low iron loss properties and exhibiting low noise performance when incorporated in a transformer.
In the accompanying drawings:
<Grain-Oriented Electrical Steel Sheet>
First, a grain-oriented electrical steel sheet according to one of the embodiments disclosed herein (hereinafter, also referred to simply as “steel sheet”) will be described.
No limitation is placed on the type (such as the chemical composition or structure) of the grain-oriented electrical steel sheet used in the disclosure, and any type of grain-oriented electrical steel sheets can be used.
The grain-oriented electrical steel sheet of this embodiment has a tension coating formed on a surface thereof. No limitation is placed on the type of tension coating, and one example may be a two-layer coating combining a forsterite coating which is mainly composed of Mg2SiO4 and formed during final annealing and a phosphate-based tension coating formed thereon. It is also possible to form a phosphate-based tension-applying insulating coating directly on the surface of the steel sheet on which no forsterite coating is formed. The phosphate-based tension-applying insulating coating may be formed, for example, by coating a surface of a steel sheet with an aqueous solution containing a metal phosphate and silica as main components, and baking the coating onto the surface.
In the grain-oriented electrical steel sheet of this embodiment, a surface of the grain-oriented electrical steel sheet is irradiated with an electron beam while scanning the electron beam on the surface in a direction transverse to a rolling direction, whereby a plurality of strain regions are caused to locally present in a surface layer of the steel sheet and formed to extend in the direction transverse to the rolling direction at periodic interval s in millimeters in the rolling direction. In each strain region, a closure domain region is formed.
In this embodiment, the tension coating is not damaged by electron beam irradiation. This eliminates the need for recoating for repairing purpose after the electron beam irradiation. There is thus no need to unduly increase the thickness of the coating, and it is thus possible to increase the stacking factor of transformer iron cores assembled from the steel sheets. Moreover, the electron beam is advantageous in that it allows for high-speed and complicated control of positions at which the steel sheet is irradiated with the electron beam.
This embodiment is characterized by the discovery of conditions for closure domains to impart both low iron loss properties and low noise performance to the transformer, and such conditions will be described in detail below.
We first noticed that in the electron beam irradiation method the magnetostrictive harmonic level is one of the magnetostrictive parameters having a good correlation with transformer noise. As used herein, “magnetostrictive harmonic level” refers to a value that is obtained in a range of 0 Hz to 1000 Hz by adding up the results from dividing a magnetostrictive waveform obtained with a laser Doppler-type vibrometer into velocity components at 100 Hz and weighting frequency components using A-scale frequency weighting. At the time of magnetostriction measurement, a maximum magnetic flux density at 1.5 T, which had highest correlation with transformer noise at the maximum magnetic flux density of from 1.3 T to 1.8 T, was used.
As used herein, parameters relating to closure domain structure are defined as:
The width of a closure domain as measured in the rolling direction is determined by observing magnetic domains on the surface of the steel sheet using a magnet viewer containing a magnetic colloidal solution. As used herein, “average width Wave” refers to an arithmetic mean of a maximum width Wmax and a minimum width Wmin. Maximum depth D of closure domain represents the maximum amount of reduction in thickness, when reducing the thickness of the steel sheet in a stepwise manner with chemical polishing, in which the closure domain could be observed following the above-described observation procedure.
[Maximum Depth D as Measured in the Sheet Thickness Direction=32 μm or more]
It is believed that the depth of closure domains affects the iron loss properties. Although a larger depth is more preferable for obtaining an increased magnetic domain refining effect, excessively increasing the depth ends up increasing the volume of the closure domain, causing magnetostriction to increase. Therefore, the maximum depth D in the sheet thickness direction is preferably set to 32 μm or more and 50 μm or less.
[(Wave*D)/s=0.0007 mm or More and 0.0016 mm or Less]
We found that low noise performance can be obtained by reducing the volume of the closure domain.
[Closure Domain's Shape on the Surface of the Steel Sheet]
Subsequently, the closure domain's shape on the surface of the steel sheet was changed by varying the electron beam conditions (beam retention interval and beam current), with maximum depth D of closure domain being set to 36 μm and periodic interval s to 5 mm. As a result, it was found that such a closure domain shape as shown in
Each closure domain region is preferably formed on the surface of the steel sheet continuously over a distance of 200 mm or more in the width direction, and more preferably formed continuously across the entire width. The reason is that a distance of less than 200 mm leads to an increased number of joints of closure domain regions being formed in the width direction, and thus increases in the non-uniformity of the magnetic domain structure of the steel sheet, causing the magnetic properties to deteriorate.
[Average Width Wave on the Surface of the Steel Sheet as Measured in the Rolling Direction=80 μm or More]
Wave of less than 80 μm is too narrow to obtain a sufficient magnetic domain refining effect. Therefore, Wave is set to 80 μm or more in this embodiment. Wave is preferably 250 μm or less. This is because Wave greater than 250 μm tends to increase the magnetostriction.
<Method of Producing the Grain-Oriented Electrical Steel Sheet>
A method for use in producing a grain-oriented electrical steel sheet according to one of the embodiments disclosed herein is a method for use in producing the above-described grain-oriented electrical steel sheet, comprising irradiating a surface of the grain-oriented electrical steel sheet with an electron beam while scanning the electron beam in a direction transverse to a rolling direction to form the strain regions as described above.
As a result of our intensive studies, we discovered electron beam irradiation conditions suitable for satisfying the above-described closure domain conditions.
[Accelerating Voltage Va=90 kV or More and 300 kV or Less]
A higher electron-beam accelerating voltage is more preferable. The reason is that a higher accelerating voltage increases the ability of the electron beam to permeate through substances, which not only enables the electron beam to permeate through the coating more easily so that the damage to the coating is likely to be suppressed, but also allows a closure domain region to be formed in the strain region at a desired depth in the sheet thickness direction. In this embodiment, it is necessary to reduce the beam diameter as much as possible in order to reduce the volume of closure domains formed, as described later. In this respect, a higher accelerating voltage is also advantageous in that it tends to provide a smaller beam diameter.
On the other hand, as the accelerating voltage increases, it becomes difficult to provide a shield from x-rays originating from the irradiated object. Therefore, a preferred upper limit is practically about 300 kV. A preferred lower limit for the accelerating voltage is 150 kV.
[Beam Diameter Dl in a Direction Orthogonal to the Scanning Direction=80 μm or More and 220 μm or Less]
In this embodiment, the diameter of the electron beam is reduced to decrease the volume of closure domains. Specifically, beam diameter d1 is set to 220 μm or less. Excessively decreasing the beam diameter and the width of closure domains is less effective for increasing the magnetic domain refining effect. Therefore, beam diameter d1 is set to 80 μm or more. A more preferable range of beam diameter d1 is from 100 μm to 150 μm.
[Beam Diameter d2 in the Scanning Direction=(0.8*d1) μm or More and (1.2*d1) μm or less]
We also revealed that in the case of scanning a beam while repeating a process to stop and resume its movement, the beam shape should be closer to a perfect circle. The reason is that if the beam assumes an elliptical shape, the beam decreases in energy density and the beam current should be increased to produce higher energy, leading to an increase in beam diameter. From this perspective, beam diameter d2 is set in a range of (0.8*d1) μm to (1.2*d1) μm.
As used herein, for both d1 and d2, “beam diameter” is defined as the half width of the beam profile as measured by the slit method (slit width: 0.03 mm).
[Beam Profile=Gaussian Shape]
We found that the electron beam takes different profile shapes depending on how it is converged, and can be roughly divided into four shape categories as illustrated in
[Line Angle: 60° or More and 120° or Less]
The electron beam is linearly scanned in a direction forming an angle of 60° or more and 120° or less with the rolling direction. As this angle deviates from 90°, the volume of strain-introduced regions increases. Therefore, this angle is desirably set to 90°.
[Electron Beam Irradiation Pattern]
The electron beam is scanned to form strain regions in a manner such that they are continuously distributed in the width direction on the steel sheet being passed. At this time, the electron beam is scanned on the steel sheet with an average scanning rate of preferably 30 m/s or higher. An average scanning rate below 30 m/s cannot yield high productivity. The average scanning rate is desirably 100 m/s or higher. A preferred upper limit for the average scanning rate is 300 m/s in order to enable high-speed repetitive control of stopping and resuming of movement of the beam. It is noted here that the scanning rate is constant during the scanning of the electron beam and that “average scanning rate” refers to an average scanning rate including beam stop time.
When scanning an electron beam at this high rate, it is preferable to keep the electron beam in an irradiation state on a constant basis to avoid wasting time for on/off control of the beam. In this case, to periodically change the closure domain width in the width direction as described above, the beam irradiation may be performed by repeating a process to stop and resume the scanning of the beam, rather than scanning the beam at a constant rate along the width direction. The distance (traveling distance) p between adjacent beam retention points is set to satisfy the following relation: scanning-direction beam diameter d2*1.5≦p≦scanning-direction beam diameter d2*2.5. If p is smaller than d2*1.5, closure domains will be formed in a continuous shape. If p is larger than d2*2.5, closure domains will be formed discontinuously in the width direction or the width ratio (Wmax/Wmin) will excessively increase.
To form the aforementioned closure domains, it is necessary to stop the movement of the beam for as long a period as possible at each beam retention point. When the average scanning rate is 100 m/s or higher, the beam needs to be retained for at least 2 μs. When the average scanning rate is 30 m/s or higher, this effect can be further enhanced if the beam is retained for 8 μs or more. An upper limit for the beam retention time is preferably 20 μs from the perspective of suppressing damage to the coating.
[Irradiation Line Interval: 15 mm or Less]
Electron beam irradiation is preferably performed so that closure domain regions can be formed along the width direction at periodic interval s in the rolling direction of 15 mm or less. The reason is that excessively increasing the irradiation line interval is less effective for increasing the magnetic domain refining effect, and thus makes less contribution to the improvement of iron loss properties. No particular limitations are placed on the lower limit for the line interval, yet the lower limit is restricted to some extent by the volume of closure domains as described above. If the line interval is excessively small, however, productivity deteriorates. Therefore, a preferred lower limit is 5 mm. In addition, the line interval needs to be set so that (Wave*D)/s is in a range of 0.0007 mm to 0.0016 mm.
[Beam Current: 0.5 mA or More and 30 mA or Less]
A lower beam current is preferred from the perspective of beam diameter reduction. The reason is that when more charged particles repel one another, it is hard to converge the beam. Therefore, the upper limit for the beam current is set to 30 mA. The beam current is more preferably 20 mA or less. On the other hand, if the beam current is excessively low, the magnetic domain refining effect cannot be obtained. Therefore, the lower limit is 0.5 mA.
[Pressure in a Processing Chamber: 3 Pa or Less]
The electron beam increases in diameter when scattered by gas molecules, and thus requires a pressure of 3 Pa or less. The lower limit for the pressure is practically about 10−5 Pa considering the fact that excessively decreasing the lower limit would cause a rise in the cost of the vacuum system such as a vacuum pump.
[Working Distance (WD): 1000 mm or Less]
Working distance (WD) refers to the distance from the center of the focus coil to the steel sheet surface. This distance has a significant influence on the beam diameter. When the WD is reduced, the beam path is shortened and the beam converges more easily. Therefore, the WD is preferably 1000 mm or less.
[Coil Arrangement: Two-Stage Focus Coil]
To form the aforementioned Gaussian-shaped electron beam on the steel sheet, it is necessary to forcedly converge electrons emitted from a thermal electron source through a focus coil. However, when electrons are accelerated at high voltage, they pass through the focus coil in a very short time in which they will not be able to acquire sufficient convergence ability or a desired profile. Although a method of increasing magnetic field strength by increasing the coil current is known, an excessively large amount of heat is generated in the coil and the circuit board related to the convergence. Therefore, using at least two focus coils makes it possible to disperse heat and stably form a Gaussian-shaped beam.
[Scanning Distance of the Electron Beam Along the Width Direction on the Surface of the Steel Sheet: 200 mm or More]
As the scanning distance in the width direction of the electron beam on the surface of the steel sheet increases, the number of electron guns necessary to irradiate a wide coil with the electron beam decreases. For example, in the case of a coil having a width of 1000 mm, five electron guns are required for a scanning distance of 200 mm and twenty for 50 mm. Therefore, in view of production efficiency and maintainability, the scanning distance is preferably as large as possible. Therefore, the scanning distance is set to 200 mm or more. A preferred scanning distance is 300 mm or more. If the scanning distance is excessively increased, however, it is necessary to increase the WD or the deflection angle. In the former case, the problem of an increased beam diameter arises, while in the latter case, deflection aberration is more pronounced and the deflected beam assumes an elliptical shape on the steel sheet, which is not preferable from the perspective of beam diameter reduction. Therefore, the upper limit for the scanning distance is preferably 650 mm.
[Electron Beam Source: LaB6]
In general, LaB6 is known to be advantageous for outputting a high intensity beam and for facilitating beam diameter reduction, and thus is preferably used.
Grain-oriented electrical steel sheets of 0.23 mm in thickness, each having a forsterite film and a phosphate-based tension coating on a surface thereof, were subjected to magnetic domain refining treatment under various electron beam irradiation conditions as listed in Table 1. The magnetic flux density B8 upon magnetization at 800 A/m was approximately 1.935 T. The scanning direction of the electron beam was perpendicular to the rolling direction of the steel sheet and the processing chamber pressure was 0.02 Pa. The beam current was adjusted in an output range of 1 kW to 3 kW. WD was set to 300 mm for No. 12 and 900 mm for the rest. In the profile shape column of Table 1, “#1” denotes a Gaussian shape comparable to #1 in
270
1.2
#4
1.2
1.1
3.1
320
1.4
0.7
1.3
0.5
<1 (N/A)
0.4
<1 (N/A)
Table 2 indicates the presence/absence of damage to the coating due to magnetic domain refinement, dimensions of closure domain region, iron loss W17/50, and harmonic level MHL15/50.
29
31
0.64
1.1
2.5
1.65
1.72
100
1.1
1.76
1.0
1.0
According to the disclosure, when using a LaB6 cathode at an accelerating voltage of 150 kV and performing electron beam irradiation under the conditions specified herein, low iron loss and low magnetostriction properties were obtained, namely, iron loss W17/50 was as low as 0.66 W/kg to 0.68 W/kg and magnetostrictive harmonic level MHL15/50 as low as 29 dBA. When using a tungsten cathode, iron loss was as low as 0.67 W/kg and magnetostriction as low as 30 dBA. Additionally, in the case of using a single-stage focus coil at the LaB6 cathode, iron loss was as low as 0.67/kg and magnetostriction as low as 29 dBA. Furthermore, for No. 15 and No. 16, model transformers were made and subjected to noise measurement. The noise level was determined to be 33 dBA for No. 15 and 35 dBA for No. 16, and the measurement results demonstrated that reducing the magnetostrictive harmonic level contributes the reduction of transformer noise.
According to the present disclosure, it is possible to provide a grain-oriented electrical steel sheet that has low iron loss properties and exhibits low noise performance when incorporated in a transformer, and a production method therefor. Therefore, the present disclosure can improve the energy efficiency of the transformer and enables its application in broader environments.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2015-034204 | Feb 2015 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2016/000745 | 2/12/2016 | WO | 00 |
