Patent Application
20250122591
The present disclosure relates to a non-oriented electrical steel sheet and a method of manufacturing the same, and more particularly, to a high-efficiency non-oriented electrical steel sheet and a method of manufacturing the same.
Electrical steel sheets may be classified into oriented electrical steel sheets and non-oriented electrical steel sheets depending on their magnetic properties. Oriented electrical steel sheets exhibit excellent magnetic properties particularly in the rolling direction of the steel sheets because they are produced to be easily magnetized in the rolling direction, and thus are mostly used as cores for large, medium, and small-sized transformers which require low core loss and high magnetic permeability. On the other hand, non-oriented electrical steel sheets have uniform magnetic properties regardless of the direction of the steel sheets, and thus are commonly used as core materials for small motors, small power transformers, stabilizers, etc.
In one aspect, the present disclosure provides a high-efficiency non-oriented electrical steel sheet and a method of manufacturing the same.
However, the above description is an example, and the scope of the present disclosure is not limited thereto.
According to an aspect of the present disclosure, there is provided a method of manufacturing a non-oriented electrical steel sheet, the method including providing a steel material containing silicon (Si), manganese (Mn), and aluminum (AI), hot rolling the steel material, first heat treating the hot-rolled steel material before coiling, coiling the first heat-treated steel material, uncoiling and cold rolling the coiled steel material, and cold annealing the cold-rolled steel material.
The steel material may include Si: 2.0 wt % to 4.0 wt %, Mn: 0.1 wt % to 0.5 wt %, Al: 0.3 wt % to 0.9 wt %, carbon (C): more than 0 wt % and not more than 0.003 wt %, phosphorus (P): more than 0 wt % and not more than 0.015 wt %, sulfur(S): more than 0 wt % and not more than 0.003 wt %, nitrogen (N): more than 0 wt % and not more than 0.003 wt %, titanium (Ti): more than 0 wt % and not more than 0.003 wt %, and a balance of iron (Fe) and unavoidable impurities.
The first heat treatment may be performed at a temperature higher than a temperature for the coiling, before the hot-rolled steel material is cooled to room temperature.
The hot rolling may be performed at a slab reheating temperature (SRT) of 1110° C. to 1150° C. and a finishing delivery temperature (FDT) of 860° C. to 900° C., the first heat treatment may include maintaining a temperature of 850° C. to 1000° C. for 5 min. to 10 min., and the coiling may be performed at a temperature of 550° C. to 650° C.
The cold annealing may include performing annealing under conditions of a heating rate: 20° C./s or more, an annealing start temperature: 900° C. to 1100° C., and a holding time: 30 sec. to 120 sec., and performing cooling under a condition of a cooling rate: 30° C./s or more.
The cold rolling may be performed without preliminary annealing after the steel material is coiled.
According to another aspect of the present disclosure, there is provided a non-oriented electrical steel sheet including silicon (Si): 2.0 wt % to 4.0 wt %, manganese (Mn): 0.1 wt % to 0.5 wt %, aluminum (Al): 0.3 wt % to 0.9 wt %, carbon (C): more than 0 wt % and not more than 0.003 wt %, phosphorus (P): more than 0 wt % and not more than 0.015 wt %, sulfur(S): more than 0 wt % and not more than 0.003 wt %, nitrogen (N): more than 0 wt % and not more than 0.003 wt %, titanium (Ti): more than 0 wt % and not more than 0.003 wt %, and a balance of iron (Fe) and unavoidable impurities, wherein a ratio of an area fraction of inclusions with an average diameter of 5 μm or more to an area fraction of inclusions with an average diameter of 2 μm or less among inclusions constituting a final microstructure is greater than 0.3, and wherein the non-oriented electrical steel sheet has a core loss (W10/400) of 12.5 W/kg or less and a magnetic flux density (B50) of 1.66 T or more.
According to an embodiment of the present disclosure, a high-efficiency non-oriented electrical steel sheet and a method of manufacturing the same may be provided.
However, the scope of the present disclosure is not limited to the above effect.
A method of manufacturing a non-oriented electrical steel sheet, according to an embodiment of the present disclosure, will now be described in detail. The terms used herein are appropriately selected in consideration of their functions in the present disclosure, and definitions of these terms should be made based on the whole content of the present specification.
Electrical steel sheets are generally classified into oriented electrical steel sheets and non-oriented electrical steel sheets. Oriented electrical steel sheets are mostly used in stationary machines such as transformers, and non-oriented electrical steel sheets are commonly used in rotating machines such as motors. The properties of electrical steel sheets may be evaluated based on magnetic flux density and core loss. The magnetic flux density is mostly evaluated as B50, and the core loss is generally evaluated as W15/50 but evaluated as W10/400 when high-frequency characteristics are required as in electric vehicles. B50 indicates the magnetic flux density at 5000 A/m, W15/50 indicates the core loss at 50 Hz and 1.5 T, and W10/400 indicates the core loss at 400 Hz and 1.0 T.
Due to regulations aimed at reducing CO2 emissions to combat global warming, existing internal combustion engine vehicles are being rapidly replaced by eco-friendly vehicles (e.g., hybrid electric vehicles (HEVs) and electric vehicles (EVs)), and more particularly, by EVs. As the demand for EVs increases, the energy conversion efficiency of EV drive motors is improving, and thus excellent magnetic properties of motor core materials are required. Non-oriented electrical steel sheets, which are used as motor core materials, serve to convert electrical energy into mechanical energy in rotating machines, and magnetic properties, i.e., low core loss and high magnetic flux density, are critical for energy saving. In particular, non-oriented electrical steel sheets with low core loss at high frequency (e.g., 400 Hz) are required to improve motor efficiency during high-speed operation where energy loss is high. To meet these requirements, non-oriented electrical steel sheet products are being developed by increasing resistivity or reducing material thickness through the addition of elements such as silicon (Si), manganese (Mn), and aluminum (Al). However, when alloying elements such as Si, Mn, and Al increase, the rolling process may not be performed properly, leading to a reduced a cold rolling recovery rate and difficulties in thickness reduction, and when the thickness of the electrical steel sheets is reduced, advanced production techniques are required, production costs increase, and productivity decreases.
Referring to
The steel material provided for the hot rolling process is a steel material for manufacturing a non-oriented electrical steel sheet, and includes or comprises, for example, Si: 2.0 wt % to 4.0 wt %, Mn: 0.1 wt % to 0.5 wt %, Al: 0.3 wt % to 0.9 wt %, carbon (C): more than 0 wt % and not more than 0.003 wt %, phosphorus (P): more than 0 wt % and not more than 0.015 wt %, sulfur(S): more than 0 wt % and not more than 0.003 wt %, nitrogen (N): more than 0 wt % and not more than 0.003 wt %, titanium (Ti): more than 0 wt % and not more than 0.003 wt %, and a balance of iron (Fe) and unavoidable impurities.
In aspects, the steel material provided for the hot rolling process is a steel material for manufacturing a non-oriented electrical steel sheet, and consists essentially of or consists of, for example, Si: 2.0 wt % to 4.0 wt %, Mn: 0.1 wt % to 0.5 wt %, Al: 0.3 wt % to 0.9 wt %, carbon (C): more than 0 wt % and not more than 0.003 wt %, phosphorus (P): more than 0 wt % and not more than 0.015 wt %, sulfur(S): more than 0 wt % and not more than 0.003 wt %, nitrogen (N): more than 0 wt % and not more than 0.003 wt %, titanium (Ti): more than 0 wt % and not more than 0.003 wt %, and a balance of iron (Fe) and unavoidable impurities.
The functions and contents of example components to which the non-oriented electrical steel sheet manufacturing method according to the technical feature of the present disclosure is applicable will now be described. However, the non-oriented electrical steel sheet manufacturing method according to the technical feature of the present disclosure is not limited to the following example composition, and may be expanded to an arbitrary composition capable of enabling the functions of a non-oriented electrical steel sheet.
Si is a major element added as a component for increasing resistivity and reducing core loss (or eddy current loss). When the content of Si is less than 2.0 wt %, a desired low core loss value at high frequency is not easily achieved, and when the content increases, magnetic permeability and magnetic flux density decrease. When the content of Si is greater than 4.0 wt %, brittleness increases to cause difficulties in cold rolling and reduce productivity.
Mn increases resistivity together with Si and improves texture. When Mn is added more than 0.5 wt %, coarse MnS precipitates are formed to deteriorate magnetic properties, e.g., a decrease in magnetic flux density. Furthermore, when the content of Mn is greater than 0.5 wt %, the decrease in core loss is small compared to the amount added, and cold rollability significantly deteriorates. Because fine MnS precipitates may be formed and grain growth may be suppressed when the content of Mn is less than 0.1 wt %, the composition of Mn may be controlled to 0.1 wt % to 0.5 wt %.
Al is a major element added as a component for increasing resistivity and reducing core loss (or eddy current loss) together with Si. Al serves to reduce magnetic deviation by reducing magnetic anisotropy. Al induces AlN precipitation when combined with N. When the content of Al is less than 0.3 wt %, the above-described effect may not be easily expected and fine nitrides may be formed to increase the deviation in magnetic properties, and when the content of Al is greater than 0.9 wt %, cold rollability deteriorates, and nitrides are excessively formed to reduce magnetic flux density and deteriorate magnetic properties.
C: More than 0 wt % and not More than 0.003 wt %
C is an element for forming carbides such as TiC and NbC to increase core loss, and the less the better. The content of C is limited to 0.003 wt % or less. When the content of C is greater than 0.003 wt %, magnetic aging occurs to deteriorate magnetic properties, and when the content of C is 0.003 wt % or less, magnetic aging is suppressed.
P: More than 0 wt % and not More than 0.015 wt %
P is a grain boundary segregation element and an element for developing texture. When the content of P is greater than 0.015 wt %, grain growth is suppressed, magnetic properties deteriorate, and cold rollability is reduced due to the segregation effect.
S: More than 0 wt % and not More than 0.003 wt %
S forms precipitates such as MnS and CuS to increase core loss, and suppresses grain growth, and thus the less the better. The content of S is limited to 0.003 wt % or less. When the content of S is greater than 0.003 wt %, core loss increases.
N: More than 0 wt % and not More than 0.003 wt %
N forms precipitates such as AlN, TIN, and NbN to increase core loss, and suppresses grain growth, and thus the less the better. The content of N is limited to 0.003 wt % or less. When the content of N is greater than 0.003 wt %, core loss increases.
Ti: More than 0 wt % and not More than 0.003 wt %
Ti forms fine precipitates such as TiC and TIN and suppresses grain growth. Ti deteriorates magnetic properties, and thus the less the better. The content of Ti is limited to 0.003 wt % or less. When the content of Ti is greater than 0.003 wt %, magnetic properties deteriorate.
The steel material having the above-described composition is hot-rolled. The hot rolling of the steel material (S20) may be performed under conditions of a slab reheating temperature (SRT): 1000° C. to 1200° C. (more strictly, 1110° C. to 1150° C.) and a finishing delivery temperature (FDT): 860° C. to 900° C.
When the SRT is higher than 1200° C. (more strictly, 1150° C.), precipitates such as C, S, and N in the slab may be redissolved and fine precipitates may occur in subsequent rolling and annealing processes to suppress grain growth and deteriorate magnetic properties. When the SRT is lower than 1000° C. (more strictly, 1110° C.), rolling load may increase and the final product may have high core loss. After the steel material is hot-rolled (S20), the hot-rolled plate may have a thickness of, for example, 1.8 mm to 2.6 mm. Because a cold rolling reduction ratio increases and texture deteriorates when the hot-rolled plate is thick, the thickness may be controlled to 2.6 mm or less.
The hot-rolled steel material may be first heat-treated before coiling (S30). The first heat treatment (S30) may be continuously performed before the hot-rolled steel material is cooled to room temperature. After the first heat treatment, the steel material may be cooled to room temperature. The first heat treatment may be annealing. The first heat treatment (S30) may be performed at a temperature higher than the temperature of the subsequent coiling (S40). For example, when the coiling temperature is 550° C. to 650° C., the first heat treatment (S30) may include maintaining a temperature of 850° C. to 1000° C. for 5 min. to 10 min. When the first heat treatment temperature is lower than 850° C., fine inclusions such as nitrides are formed from the surface layer, and the magnetic properties of the final product deteriorate due to insufficient growth of the inclusions. On the other hand, when the first heat treatment temperature is higher than 1000° C., inclusions are formed and grains grow excessively to cause a significant grain size deviation, and oxidation occurs seriously to negatively affect the final product. Therefore, to obtain a uniform microstructure of the hot-rolled plate, the first heat treatment temperature may be controlled to 850° C. to 1000° C.
The first heat-treated steel material may be coiled under a condition of a coiling temperature (CT): 550° C. to 650° C. When the CT is lower than 550° C., the annealing effect of the steel material does not occur and thus grains do not grow, and when the CT is higher than 650° C., oxidation may increase during cooling and thus picklability may deteriorate.
The coiled steel material is uncoiled and cold-rolled (S50). A cold rolling reduction ratio may be 80% to 85%, and the cold-rolled steel material may have a thickness of 0.35 mm or less (more strictly, 0.25 mm or less). To provide rollability, the plate temperature may be increased to 150° C. to 200° C. for warm rolling.
In general, after hot rolling and coiling and before cold rolling, preliminary annealing (e.g., annealing and pickling line (APL)) may be performed on the hot-rolled plate. For example, the preliminary annealing may include performing annealing under conditions of a heating rate: 20° C./s or more, an annealing temperature: 950° C. to 1100° C., and a holding time: 30 sec. to 120 sec., performing cooling under a condition of a cooling rate: 30° C./s or more, and performing picking.
However, in the present disclosure, it is found that, because the hot-rolled steel material is first heat-treated before coiling as described above, cold rolling may be performed without preliminary annealing immediately after the oxide layer formed on the surface is removed using a pickling solution.
The cold-rolled steel material may be cold-annealed. The cold annealing (S60) may include performing annealing under conditions of a heating rate: 20° C./s or more, an annealing temperature: 900° C. to 1100° C., and a holding time: 30 sec. to 120 sec., and performing cooling under a condition of a cooling rate: 30° C./s or more. In the cold annealing, when the annealing temperature is lower than 900° C., fine grains may be formed to increase hysteresis loss, and when the annealing temperature is higher than 1100° C., coarse grains may be formed to increase eddy current loss.
The cold annealing is performed with the cold-rolled plate obtained after the cold rolling. A temperature capable of achieving an optimal grain size is applied in consideration of core loss reduction and mechanical properties. In the cold annealing, heating is performed under a mixed atmosphere condition to prevent surface oxidation and nitrification. The surface is further smoothed in a mixed atmosphere of nitrogen and hydrogen. When the cold annealing temperature is lower than 900° C., fine grains may be formed to increase hysteresis loss, and when the cold annealing temperature is higher than 1100° C., coarse grains may be formed to increase eddy current loss.
Meanwhile, a coating process may be performed to form an insulating coating layer after the final cold annealing. By forming the insulating coating layer, punchability may be improved and insulation may be ensured. The insulating coating layer formed on and under the cold-rolled material may have a thickness of about 1 μm to 2 μm.
The non-oriented electrical steel sheet manufactured using the above-described method may be a non-oriented electrical steel sheet including Si: 2.0 wt % to 4.0 wt %, Mn: 0.1 wt % to 0.5 wt %, Al: 0.3 wt % to 0.9 wt %, C: more than 0 wt % and not more than 0.003 wt %, P: more than 0 wt % and not more than 0.015 wt %, S: more than 0 wt % and not more than 0.003 wt %, N: more than 0 wt % and not more than 0.003 wt %, Ti: more than 0 wt % and not more than 0.003 wt %, and a balance of Fe and unavoidable impurities, wherein an average grain size is 80 μm to 150 μm, and a ratio of an area fraction of inclusions with an average diameter of 5 μm or more to an area fraction of inclusions with an average diameter of 2 μm or less among inclusions constituting a final microstructure is greater than 0.3. The non-oriented electrical steel sheet may have a core loss (W10/400) of 12.5 W/kg or less, a magnetic flux density (B50) of 1.66 T or more, a yield strength of 400 MPa or more, and a tensile strength of 500 MPa or more.
The present disclosure provides a non-oriented electrical steel sheet capable of achieving high magnetic flux density and low core loss by controlling the microstructure of a hot-annealed material based on mass-producible process conditions, and a method of manufacturing the same.
Referring to
In a method of manufacturing a non-oriented electrical steel sheet, according to an embodiment of the present disclosure, after the non-oriented electrical steel sheet is hot-rolled, the first heat treatment (S30) is continuously performed before the hot-rolled material is cooled to a temperature below the coiling temperature. In this case, the first heat treatment may include maintaining a temperature of 850° C. to 1000° C. for 5 min. to 10 min. Due to the first heat treatment, APL may be omitted and an electrical steel sheet with better properties may be manufactured.
In the present disclosure, it is found that, by applying the above-described heat treatment, a microstructure in which a ratio of an area fraction of inclusions with an average diameter of 5 μm or more to an area fraction of inclusions with an average diameter of 2 μm or less among inclusions constituting the finally annealed material is greater than 0.3 may be ensured, and in this case, a core loss (W 10/400) of 12.5 W/kg or less and a magnetic flux density (B50) of 1.66 T or more may be simultaneously achieved. The distribution of inclusions of all sizes on a 10×10 mm2 cross-section of a laminated structure of the finally annealed material was analyzed based on brightness and contrast using the backscattered electron detector (BSD) mode of a scanning electron microscope (SEM).
The final product manufactured using the non-oriented electrical steel sheet manufacturing method of the present disclosure exhibits a uniform microstructure and improved magnetic properties. In this case, a core loss of 12.5 W/kg or less at W 10/400 and a magnetic flux density of 1.65 T or more, and more specifically, a core loss of 12.0 W/kg or less at W10/400 and a magnetic flux density of 1.66 T or more, may be achieved.
As described above, reducing plate thickness and increasing resistivity are necessary to reduce the core loss of non-oriented electrical steel sheets. However, reducing plate thickness requires advanced production techniques, reduces productivity during processes, and increases the costs of processing and lamination in motor core production. Furthermore, while high-alloy elements such as Si, Al, and Mn are added to increase resistivity, the addition of such alloying elements complicates cold rolling. Non-oriented electrical steel sheets for high-efficiency electric vehicles are required to achieve high magnetic flux density and low core loss, and an optimal alloy composition and an advanced processing technique are required to increase resistivity.
In terms of alloy composition, Si, Al, and Mn are major alloying elements used to increase resistivity. In addition to the combination of these elements, elements capable of improving cold rollability, e.g., Cr, Cu, and Ni, are also being considered. However, such elements change the magnetic properties and the mechanical properties, and thus optimal conditions may not be easily found.
In terms of non-oriented electrical steel sheet manufacturing processes, it is known that APL is essential to achieve high magnetic flux density and low core loss in the final product of a non-oriented electrical steel sheet containing more than 3% Si. Although the texture may be improved by controlling a heating rate, magnetic properties deteriorate due to microstructural non-uniformity and thus microstructural control of a hot-rolled structure is essential starting from APL which is an intermediate process.
Considering the above, in the present disclosure, a hot-rolled material is heat-treated after hot rolling and before cooling to room temperature. Due to the hot-rolled material heat treatment, recrystallization/grain growth may be induced in the hot-rolled material and thus cold rolling may be performed without APL. As such, the process may be simplified, productivity may be increased, and high-quality non-oriented electrical steel sheets may be manufactured.
Test examples will now be described for better understanding of the present disclosure. However, the following test examples are merely to promote understanding of the present disclosure, and the present disclosure is not limited to thereto.
The present test examples provide samples with the alloying element composition (unit: wt %) of Table 1.
Referring to Table 1, the composition of non-oriented electrical steel sheets according to the test examples satisfies Si: 2.0 wt % to 4.0 wt %, Mn: 0.1 wt % to 0.5 wt %, Al: 0.3 wt % to 0.9 wt %, C: more than 0 wt % and not more than 0.003 wt %, P: more than 0 wt % and not more than 0.015 wt %, S: more than 0 wt % and not more than 0.003 wt %, N: more than 0 wt % and not more than 0.003 wt %, Ti: more than 0 wt % and not more than 0.003 wt %, and a balance of Fe. A hot-rolled plate with a thickness of 2.0 mm was produced by reheating a slab with the above-described composition to 1150° C. and performing hot rolling under a condition of a FDT of 890° C. After the hot rolling, heat treatment was continuously performed under various temperature conditions. Then, a cold-rolled plate with a thickness of 0.25 t was produced by performing cold rolling, and final annealing was performed at 980° C. for 40 sec. Thereafter, a final product was manufactured through a coating process. The final annealing was performed in a mixed atmosphere of 30% hydrogen −70% nitrogen. In this case, a heating rate of 20° C./s and a cooling rate of 30° C./s were used.
Table 2 shows process conditions, core losses (W10/400), and magnetic flux densities (B50) of the present test examples.
Among heat treatment methods in Table 2, first heat treatment corresponds to the heat treatment (S30) according to an embodiment of the present disclosure, which is described above in relation to
Referring to Table 2, in Test Examples 1, 2, 3, and 4, the hot-rolled material heat treatment (S30) described above in relation to
In Test Examples 11, 12, and 13, the preliminary annealing (S45) described above in relation to
On the other hand, in Test Examples 5, 6, 7, 8, 9, and 10, the hot-rolled material heat treatment (S30) described above in relation to
The above test examples of the present disclosure show that, by heat treating a hot-rolled material after hot rolling and before cooling to room temperature, recrystallization/grain growth may be induced in the hot-rolled material and thus cold rolling may be performed without APL.
While the present disclosure has been particularly shown and described with reference to embodiments thereof, it will be understood by one of ordinary skill in the art that various changes in form and details may be made therein without departing from the scope of the present disclosure as defined by the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2022-0076986 | Jun 2022 | KR | national |
This application is a continuation of International Application No. PCT/KR2023/007914 filed on Jun. 9, 2023, which claims priority to and the benefit of Korean Patent Application No. 10-2022-0076986 filed in the Korean Intellectual Property Office on Jun. 23, 2022, the entire contents of both of which applications are incorporated herein by reference herein in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/KR2023/007914 | Jun 2023 | WO |
| Child | 18987670 | US |
