JP2021509145A - 超低鉄損方向性電磁鋼板の製造方法 - Google Patents
超低鉄損方向性電磁鋼板の製造方法 Download PDFInfo
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Abstract
Description
シリコン(Si)は、鋼の比抵抗を増加させて鉄損を減少させる役割を果たす。但し、Siの含有量が少なすぎる場合には、鋼の比抵抗が小さくなって鉄損特性が劣化し、高温焼鈍時に相変態区間が存在し、2次再結晶が不安定になるという問題が発生する可能性がある。これに対し、Siの含有量が多すぎる場合には、脆性が大きくなって冷間圧延が困難になるという問題が発生するおそれがある。したがって、上述した範囲でSiの含有量を調節することができる。より具体的に、Siは2.6〜4.5重量%含まれることができる。
アルミニウム(Al)は、最終的にAlN、(Al,Si)N、(Al,Si,Mn)Nの形の窒化物になって抑制剤として作用する成分である。Alの含有量が少なすぎる場合には、抑制剤として十分な効果を期待することが難しい。また、Alの含有量が多すぎる場合には、Al系の窒化物が過度に粗大に析出されて成長するため、抑制剤としての効果が不足する可能性がある。したがって、上述した範囲でAlの含有量を調節することができる。
Mnは、Siと同様に、比抵抗を増加させて鉄損を減少させるという効果があり、Siとともに窒化処理によって導入される窒素と反応して(Al,Si,Mn)Nの析出物を形成することにより、1次再結晶粒の成長を抑制して2次再結晶を起こすのに重要な元素である。しかし、Mnの含有量が多すぎる場合には、熱延中にオーステナイト相変態を促進するため、1次再結晶粒のサイズを減少させて2次再結晶を不安定にする。また、Mnの含有量が少なすぎる場合には、オーステナイト形成元素として熱延再加熱時にオーステナイト分率を高めて析出物の固溶量を多くし、再析出時に析出物の微細化及びMnSの形成を介した1次再結晶粒が過度に多くならないようにするという効果が不十分になる可能性がある。したがって、上述した範囲でMnの含有量を調節することができる。
Sb、Sn、又はCuは、結晶粒界偏析元素として結晶粒界の移動を妨害する元素であるため、結晶粒成長抑制剤として{110}<001>方位のゴス結晶粒の生成を促進し、2次再結晶が円滑に発達するようにするため、結晶粒サイズの制御に重要な元素である。Sb又はSnを単独又は複合添加した含有量が少なすぎる場合には、その効果が減少するという問題が生じる可能性がある。これに対し、Sb、Sn、又はCuを単独又は複合添加した含有量が多すぎると、結晶粒界偏析が激しく起こり、鋼板の脆性が大きくなって圧延時における板破断が発生するおそれがある。
フォルステライト被膜は、方向性電磁鋼板の製造工程中に脱炭及び窒化焼鈍を行った後、2次再結晶を形成するための高温焼鈍時における素材間の相互融着(sticking)を防止するために焼鈍分離剤を塗布する過程で、塗布剤の主成分である酸化マグネシウム(MgO)が方向性電磁鋼板に含有されたシリコン(Si)と反応して形成されるようになる。
Ti(OR)4→Ti*(OH)x−1(OR)4−x→(HO)x(RO)3−xTi−O−Ti(OH)x−1(OR)4−1→Ti−O−Ti network
シリコン(Si)を3.4重量%、アルミニウム(Al)を0.03重量%、マンガン(Mn):0.10重量%、アンチモン(Sb)を0.05重量%、スズ(Sn)を0.05重量%、銅(Cu)を0.05重量%含み、残部Fe及びその他の不可避不純物からなる鋼スラブを設けた。
Claims (18)
- 方向性電磁鋼板を設ける段階と、
前記方向性電磁鋼板の一面又は両面の一部又は全部に、常圧プラズマCVD工程(APP−CVD)を用いてプラズマ状態で気相のセラミック前駆体を接触反応させることにより、セラミックコーティング層を形成する段階と、を含むことを特徴とする方向性電磁鋼板の製造方法。 - 前記セラミックコーティング層は、大気圧条件下で高密度無線周波数を用いることで、電磁鋼板の表面に磁場を形成してプラズマを発生させた状態で、Ar、He、及びN2のうち1種以上からなる第1ガスと気相のセラミック前駆体を混合した後、これを電磁鋼板の表面に接触反応させることによって形成されることを特徴とする請求項1に記載の方向性電磁鋼板の製造方法。
- 前記セラミックコーティング層は、H2、O2、及びH2Oのうち1種からなる第2ガスを前記第1ガス及び気相のセラミック前駆体に追加混合した後、これを電磁鋼板の表面に接触反応させることによって形成されることを特徴とする請求項2に記載の方向性電磁鋼板の製造方法。
- 前記第1ガス及び第2ガスは、前記セラミック前駆体の気化点以上の温度に加熱されることを特徴とする請求項3に記載の方向性電磁鋼板の製造方法。
- 前記セラミックコーティング層がTiO2であるとき、前記セラミック前駆体として、TTIP(Titanium Isopropoxide、Ti{OCH(CH3)2}4、又はTiCl4を用いることを特徴とする請求項1に記載の方向性電磁鋼板の製造方法。
- 前記セラミックコーティング層は、厚さが0.1〜0.6μmであることができ、コーティング層の厚さごとの鉄損改善率が7〜14%であることを特徴とする請求項1に記載の方向性電磁鋼板の製造方法。
- 前記方向性電磁鋼板を設ける段階は、
重量%で、シリコン(Si):2.6〜4.5%、アルミニウム(Al):0.020〜0.040%、マンガン(Mn):0.01〜0.20%、残部Fe及びその他の不可避不純物からなる鋼スラブを設ける段階と、
前記鋼スラブを加熱し、熱間圧延して熱延板を製造する段階と、
前記熱延板を冷間圧延して冷延板を製造する段階と、
前記冷延板を脱炭焼鈍して、脱炭焼鈍された鋼板を得る段階と、
前記脱炭焼鈍された鋼板に焼鈍分離剤を塗布し、最終焼鈍する段階と、を含むことを特徴とする請求項1に記載の方向性電磁鋼板の製造方法。 - 前記冷延板を脱炭焼鈍して、脱炭焼鈍された鋼板を得る段階は、冷延板を脱炭と同時に浸窒するか、又は脱炭後に浸窒し、焼鈍して脱炭焼鈍された鋼板を得る段階であることを特徴とする請求項7に記載の方向性電磁鋼板の製造方法。
- 前記APP−CVD工程前後に、200〜1250℃の温度範囲で電磁鋼板に予熱(Pre Heating)及び/又は後熱(Post Heating)を行うことを特徴とする請求項1に記載の方向性電磁鋼板の製造方法。
- 表面にフォルステライト被膜が形成された方向性電磁鋼板を設ける段階と、
前記被膜が形成された方向性電磁鋼板の一面又は両面の一部又は全部に、常圧プラズマCVD工程(APP−CVD)を用いてプラズマ状態で気相のセラミック前駆体を接触反応させることにより、セラミックコーティング層を形成する段階と、を含む方向性電磁鋼板の製造方法。 - 前記セラミックコーティング層は、大気圧条件下で高密度無線周波数を用いることで、電磁鋼板の表面に磁場を形成してプラズマを発生させた状態で、Ar、He、及びN2のうち1種以上からなる第1ガスと気相のセラミック前駆体を混合した後、これを電磁鋼板の表面に接触反応させることによって形成されることを特徴とする請求項10に記載の方向性電磁鋼板の製造方法。
- 前記セラミックコーティング層は、H2、O2、及びH2Oのうち1種からなる第2ガスを前記第1ガス及び気相のセラミック前駆体に追加混合した後、これを電磁鋼板の表面に接触反応させることによって形成されることを特徴とする請求項11に記載の方向性電磁鋼板の製造方法。
- 前記第1ガス及び第2ガスは、前記セラミック前駆体の気化点以上の温度に加熱されることを特徴とする請求項12に記載の方向性電磁鋼板の製造方法。
- 前記セラミックコーティング層がTiO2であるとき、前記セラミック前駆体として、TTIP(Titanium Isopropoxide、Ti{OCH(CH3)2}4、又はTiCl4を用いることを特徴とする請求項10に記載の方向性電磁鋼板の製造方法。
- 前記セラミックコーティング層は、厚さが0.1〜0.6μmであることができ、コーティング層の厚さごとの鉄損改善率が7〜14%であることを特徴とする請求項10に記載の方向性電磁鋼板の製造方法。
- 前記方向性電磁鋼板を設ける段階は、
重量%で、シリコン(Si):2.6〜4.5%、アルミニウム(Al):0.020〜0.040%、マンガン(Mn):0.01〜0.20%、残部Fe及びその他の不可避不純物からなる鋼スラブを設ける段階と、
前記鋼スラブを加熱し、熱間圧延して熱延板を製造する段階と、
前記熱延板を冷間圧延して冷延板を製造する段階と、
前記冷延板を脱炭焼鈍して、脱炭焼鈍された鋼板を得る段階と、
前記脱炭焼鈍された鋼板に焼鈍分離剤を塗布し、最終焼鈍する段階と、を含むことを特徴とする請求項10に記載の方向性電磁鋼板の製造方法。 - 前記冷延板を脱炭焼鈍して、脱炭焼鈍された鋼板を得る段階は、冷延板を脱炭と同時に浸窒するか、又は脱炭後に浸窒し、焼鈍して脱炭焼鈍された鋼板を得る段階であることを特徴とする請求項16に記載の方向性電磁鋼板の製造方法。
- 前記APP−CVD工程前後に、200〜1250℃の温度範囲で電磁鋼板に予熱(Pre Heating)及び/又は後熱(Post Heating)を行うことを特徴とする請求項10に記載の方向性電磁鋼板の製造方法。
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