JPWO2021085421A1 - 方向性電磁鋼板とその製造方法 - Google Patents
方向性電磁鋼板とその製造方法 Download PDFInfo
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- JPWO2021085421A1 JPWO2021085421A1 JP2021511685A JP2021511685A JPWO2021085421A1 JP WO2021085421 A1 JPWO2021085421 A1 JP WO2021085421A1 JP 2021511685 A JP2021511685 A JP 2021511685A JP 2021511685 A JP2021511685 A JP 2021511685A JP WO2021085421 A1 JPWO2021085421 A1 JP WO2021085421A1
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Abstract
Description
2MgO+SiO2→Mg2SiO4
の反応を起こして鋼板表面にフォルステライト質の被膜を形成する。このフォルステライト被膜は、製品板に対して絶縁性や耐食性を付与することの他に、鋼板表面に引張応力を付与して磁気特性を改善する効果があるため、均一で密着性に優れていることが要求される。なお、上記フォルステライト質の被膜は、以降、「下地被膜」あるいは単に「被膜」とも称する。
[1]フォルステライト質の下地被膜を有する磁区細分化処理用の方向性電磁鋼板であって、該下地被膜を60℃の5mass%HCl水溶液で60秒間酸洗したときの酸洗減量が1.8g/m2以下であり、下地被膜−地鉄界面のSn,Sb,MoおよびWの合計濃度が0.01〜0.15mass%であることを特徴とする方向性電磁鋼板である。
記
・A群;Al:0.010〜0.040mass%およびN:0.003〜0.012mass%
・B群;Se:0.0030〜0.030mass%および/またはS:0.0040〜0.030mass%
・C群;Al:0.010〜0.040mass%、N:0.003〜0.012mass%、Se:0.0030〜0.030mass%および/またはS:0.0040〜0.030mass%
<実験1>
C:0.068mass%、Si:3.38mass%、Mn:0.07mass%、Al:0.03mass%およびN:0.008mass%を含有する鋼を溶製し、連続鋳造法でスラブとした後、1410℃の温度に加熱し、熱間圧延して板厚2.2mmの熱延板とし、1050℃×60秒の熱延板焼鈍を施した後、一次冷間圧延して中間板厚1.7mmとし、1100℃×80秒の中間焼鈍を施した後、200℃の温度で圧延する温間圧延して最終板厚0.23mmの冷延板とした。次いで、50vol%H2−50vol%N2、露点57℃の湿潤雰囲気下で830℃×100秒の一次再結晶焼鈍を兼ねた脱炭焼鈍を施した。次いで、MgOを主剤とし、添加剤としてSnO2をSn換算で全体に対して3mass%添加した焼鈍分離剤をスラリー状にして鋼板表面に塗布し、乾燥した後、二次再結晶を発現させる保定処理した後、H2雰囲気下で、1150℃の温度に20時間保持する純化処理を行う仕上焼鈍を施し、フォルステライト質の下地被膜を有する方向性電磁鋼板を製造した。この際、上記保定処理においては、雰囲気ガス中のH2濃度を0〜10vol%の範囲で種々に変化させ、かつ、保定処理温度を750℃〜1050℃の範囲、保定処理時間を5時間〜120時間の範囲で種々に変化させた。また、保定処理を施した後の1050℃以上から純化処理温度まで(以降、この間を「高温域昇温時」とも称する)は、雰囲気ガスとして98vol%N2+2vol%H2、露点−5℃のドライガスを炉内に通入するとともに、炉内圧力を1.5〜6mmH2Oの範囲で種々に変化させた。なお、本発明において、上記のフォルステライト質とは、少なくとも50mass%がフォルステライトであることをいう。
そこで、発明者らは、上記の実験結果に基づき、酸洗減量と被膜−地鉄界面のSn濃度を適正範囲に制御する方法について検討した。
仕上焼鈍の条件を、100vol%N2雰囲気下で、900℃×40時間の保定処理した後、1150℃の純化処理温度まで昇温するに際して、1050℃以上純化処理温度までの高温域昇温時に、雰囲気ガスとして98vol%N2+2vol%H2で露点−5℃のドライガスを、炉内圧力が4mmH2Oとなるよう通入する条件を標準条件とし、これに対して、保定処理温度、保定処理時間、保定処理中に通入する雰囲気ガスのH2濃度、および、1050℃以上純化処理温度までの高温域昇温時の雰囲気ガスの炉内圧力(炉圧)を種々に変更し、その他は上記<実験1>と同じ条件として仕上焼鈍板を製造し、仕上焼鈍後の鋼板の酸洗減量と被膜−地鉄界面のSn濃度の変化を調査した。
まず、保定処理温度は、被膜−地鉄界面のSn濃度に大きな影響を及ぼさないが、酸洗減量に大きく影響し、高過ぎても低過ぎても酸洗減量は増大し、酸洗減量を最小化する適正範囲がある(図2(a))。
また、保定処理時間は、保定処理温度と同様の傾向があり、被膜−地鉄界面のSn濃度には大きな影響を及ぼさないが、酸洗減量に大きく影響し、高過ぎても低過ぎても酸洗減量は増大し、酸洗減量を最小化する適正範囲がある(図2(b))。
また、保定処理時の雰囲気ガス中のH2濃度は、酸洗減量および被膜−地鉄界面のSn濃度の両方に影響し、H2濃度が高くなるほど酸洗減量は増加し、被膜−地鉄界面のSn濃度は低下する傾向がある(図2(c))。
また、1050℃から純化処理温度までの高温域昇温時におけるH2含有雰囲気ガスの炉内圧力(炉圧)も、酸洗減量および被膜−地鉄界面のSn濃度の両方に影響し、炉内圧力が高くなるほど酸洗減量は減少し、被膜−地鉄界面のSn濃度は上昇する(図2(d))。
まず、酸洗減量については、仕上焼鈍において適正温度で適正時間の保定処理を施した場合には、保定処理中にフォルステライト被膜がゆっくりと形成されて、フォルステライト粒径が微細化、緻密化し、粒界強度が改善される結果、酸洗による腐食の進行が遅れ、酸洗減量が低下する。しかし、保定処理温度が低すぎると、フォルステライト被膜が保定温度域でほとんど形成されず、その後の昇温過程で急激に反応するため、隙間の大きな粗雑な構造となり、一方、保定処理温度が高すぎると、被膜形成の反応速度が高まるため、フォルステライト粒径が粗大化して粒界強度が弱まり、酸洗減量が増大する。また、保定処理時間が短すぎると保定処理の効果が十分に得られず、一方、長すぎるとフォルステライトの粒径が粗大化する。また、保定処理中のH2濃度を高めると、被膜形成反応が促進されて、フォルステライトの粒径が粗大化するため、酸洗減量は増大する。また、高温域昇温時の炉圧を高めると、コイルに巻いた鋼板間(コイル層間)のガスと雰囲気ガスとの置換が遅れるため、フォルステライト被膜の形成がゆっくりとなり、酸洗減量が低下する。
C:0.02〜0.08mass%
Cは、0.02mass%に満たないと、Cによる粒界強化効果が失われ、スラブに割れが生じるなど、製造に支障を来たす欠陥を生ずるようになる。一方、0.08mass%を超えると、脱炭焼鈍で、磁気時効の起こらない0.005mass%以下に低減することが困難となる。よって、Cは0.02〜0.08mass%の範囲とする。好ましくは0.025〜0.075mass%の範囲である。
Siは、鋼の比抵抗を高め、鉄損を低減すのに必要な元素である。この効果は、2.5mass%未満では十分ではなく、一方、4.5mass%を超えると、加工性が低下し、圧延して製造すること困難となる。よって、Siは2.5〜4.5mass%の範囲とする。好ましくは2.8〜4.0mass%の範囲である。
Mnは、鋼の熱間加工性を改善するために必要な元素である。この効果は、0.03mass%未満では十分ではなく、一方、0.30mass%を超えると、製品板の磁束密度が低下するようになる。よって、Mnは0.03〜0.30mass%の範囲とする。好ましくは0.04〜0.20mass%の範囲である。
まず、二次再結晶を発現させるためにインヒビターを利用する場合で、例えば、AlN系インヒビターを利用するときには、AlおよびNを、それぞれAl:0.010〜0.040mass%、N:0.003〜0.012mass%の範囲で含有させるのが好ましい。また、MnS・MnSe系インヒビターを利用する場合には、前述した量のMnと、S:0.0040〜0.030mass%およびSe:0.0030〜0.030mass%のうちの1種または2種を含有させることが好ましい。それぞれの含有量が、上記下限値より少ないと、インヒビター効果が十分に得られず、一方、上限値を超えると、スラブ加熱時にインヒビター成分が未固溶で残存し、磁気特性の低下をもたらす。なお、AlN系とMnS・MnSe系のインヒビターは併用して用いてもよい。
上述した成分組成を有する鋼を常法の精錬プロセスで溶製した後、従来公知の造塊−分塊圧延法または連続鋳造法で鋼素材(スラブ)を製造してもよいし、あるいは、直接鋳造法で100mm以下の厚さの薄鋳片を製造してもよい。上記スラブは常法に従い、例えば、インヒビター成分を含有する場合には、1350℃程度以上の温度まで加熱し、一方インヒビター成分を含まない場合は、1300℃以下の温度に加熱した後、従来公知の条件で熱間圧延する。なお、インヒビター成分を含有しない場合には、鋳造後加熱することなく直ちに熱間圧延の供してもよい。また、薄鋳片の場合には、熱間圧延してもよいし熱間圧延を省略してそのまま以後の工程に進めてもよい。
ここで、上記焼鈍分離剤は、主剤として少なくとも50mass%のMgOを含み、添加剤としてSn,Sb,MoおよびWの化合物のうちの少なくとも1種を、金属換算で、焼鈍分離剤全体に対して0.3〜5mass%の範囲で含有するものを用いる必要がある。これらの元素は、Feとのサイズミスフィットパラメータが大きいため、転位の移動抵抗が高めて鋼板の高温強度を高めるので、磁区細分化処理時の熱変形が抑制されて、被膜が地鉄から受ける応力が緩和されるので、磁区細分化処理による被膜剥離が起こり難くなる。なお、好ましい添加剤の含有量は0.8〜4mass%の範囲である。
1)二次再結晶を発現させる保定処理は、不活性雰囲気下で800℃以上950℃以下の温度で10時間以上100時間以下保持すること、
2)上記保定処理終了後、純化処理する1150℃以上1250℃以下の温度まで昇温する際、1050℃以上から上記純化処理温度までの高温域昇温時は、雰囲気ガスとしてH2を1vol%以上含有する露点10℃以下のドライガスを炉内圧力が3.5mmH2O以上となるよう通入すること、
の2つの条件を満たすことが必要である。
次いで、上記脱炭焼鈍後の鋼板表面に、MgOを主剤とし、表2に示したように、種々のSn,Sb,MoおよびW化合物を添加材として種々の量含有する焼鈍分離剤をスラリー状にして塗布、乾燥した後、Ar雰囲気下で、920℃の温度に80時間保持する保定処理した後、H2雰囲気下で、1200℃×10時間の純化処理する仕上焼鈍を施した。この際、1050℃から純化処理温度までの昇温時(高温域昇温時)は、雰囲気ガスとして、H2を20vol%含有する露点−20℃のドライガスを、炉内圧力(炉圧)が6mmH2Oとなるように通入した。
上記仕上焼鈍後のフォルステライト被膜を有する鋼板について、前述した<実験1>と同様、60℃の5%HCl水溶液に60秒間浸漬して酸洗したときの下地被膜の酸洗減量(g/m2)を測定するとともに、被膜−地鉄界面のSn,Sb,MoおよびWの合計濃度を、塩酸酸洗して酸素目付量が酸洗前の5〜10%になるまで低減した後、蛍光X線測定装置を用い、大気中で20kV、2mAの条件で測定し、事前に作成しておいた検量線により定量した。
次いで、上記仕上焼鈍後の鋼板は、未反応の焼鈍分離剤を除去し、絶縁被膜を塗布し、焼き付けと平坦化処理を兼ねた平坦化焼鈍した後、電子ビームを電流密度80mA/mm2で鋼板表面に照射して磁区細分化処理を施して製品板とした後、該製品板について、被膜剥離の有無を光学顕微鏡(10倍)で調査した。
次いで、上記脱炭焼鈍後の鋼板表面に、MgOを主剤し、WO3をW換算で1mass%含有する焼鈍分離剤をスラリー状にして塗布、乾燥した後、Ar雰囲気下で、920℃の温度に50時間保持する保定処理した後、H2雰囲気下で、1200℃×10時間の純化処理する仕上焼鈍を施した。この際、1050℃から純化処理温度までの高温域昇温時は、炉内圧力(炉圧)が6mmH2Oとなるよう制御するとともに、炉内に通入する雰囲気ガスのH2濃度を0〜80vol%、露点を−50〜20℃の範囲で、表3に示したように種々に変化させた。
上記仕上焼鈍後のフォルステライト被膜を有する鋼板について、前述した実施例1と同様にして、酸洗減量を測定するとともに、被膜−地鉄界面のWの濃度を測定した。
次いで、上記仕上焼鈍後の鋼板は、未反応の焼鈍分離剤を除去し、絶縁被膜を塗布し、焼き付けと平坦化処理を兼ねた平坦化焼鈍した後、電子ビームを電流密度80mA/mm2で鋼板表面に照射して磁区細分化処理を施して製品板とした後、該製品板について、前述した実施例1と同様にして、被膜剥離の有無を調査した。
次いで、上記脱炭焼鈍後の鋼板表面に、MgOを主剤し、MoO3をMo換算で2mass%含有する焼鈍分離剤をスラリー状にして塗布、乾燥した後、Ar雰囲気下で、920℃の温度に50時間保持する保定処理した後、H2雰囲気下で、1200℃×10時間の純化処理する仕上焼鈍を施した。この際、1050℃から純化処理温度までの高温域昇温時は、炉内に通入する雰囲気ガスとして、H2濃度が75vol%、露点が−20℃のドライガスを、炉内圧力(炉圧)が6mmH2Oとなるよう通入した。
上記仕上焼鈍後のフォルステライト被膜を有する鋼板について、前述した実施例1と同様にして、酸洗減量を測定するとともに、被膜−地鉄界面のSn,SbおよびMoの合計濃度を測定した。
次いで、上記仕上焼鈍後の鋼板は、未反応の焼鈍分離剤を除去し、絶縁被膜を塗布し、焼き付けと平坦化処理を兼ねた平坦化焼鈍した後、電子ビームを電流密度80mA/mm2で鋼板表面に照射して磁区細分化処理を施し、製品板とした後、該製品板について、前述した実施例1と同様にして、被膜剥離の有無を調査した。
次いで、上記脱炭焼鈍後の鋼板表面に、MgOを主剤し、MoO3をMo換算で4mass%含有する焼鈍分離剤をスラリー状にして塗布、乾燥した後、乾燥N2雰囲気下で、920℃の温度に40時間保持する保定処理した後、H2雰囲気下で、1200℃×10時間の純化処理する仕上焼鈍を施した。この際、1050℃から純化処理温度までの昇温時(高温域昇温時)は、炉内に通入する雰囲気ガスとして、H2濃度を1vol%以上含有する露点が−5℃のドライガスを、炉内圧力(炉圧)が1.5mmH2Oと6mmH2Oの2条件となるよう通入した。
上記仕上焼鈍後のフォルステライト被膜を有する鋼板について、前述した実施例1と同様にして、酸洗減量と、被膜−地鉄界面のSbおよびMoの合計濃度を測定したところ、酸洗減量は、炉圧が1.5mmH2Oのときは1.92g/m2、炉圧が6mmH2Oのときは1.12g/m2で、被膜−地鉄界面のSbおよびMoの合計濃度は、炉圧が1.5mmH2Oのときは0.008mass%、炉圧が6mmH2Oのときは0.071mass%であった。
次いで、上記仕上焼鈍後の鋼板は、未反応の焼鈍分離剤を除去し、絶縁被膜を塗布し、焼き付けと平坦化処理を兼ねた平坦化焼鈍した後、電子ビームの電流密度を10〜120mA/mm2の範囲で変化させて鋼板表面に照射して磁区細分化処理を施し、製品板とした後、該製品板について、前述した実施例1と同様にして、被膜剥離の有無を調査するとともに、鉄損W17/50をJIS C 2550の交流磁化特性の測定法に準拠して測定した。
Claims (7)
- フォルステライト質の下地被膜を有する磁区細分化処理用の方向性電磁鋼板であって、
該下地被膜を60℃の5mass%HCl水溶液で60秒間酸洗したときの酸洗減量が1.8g/m2以下であり、
下地被膜−地鉄界面のSn,Sb,MoおよびWの合計濃度が0.01〜0.15mass%であることを特徴とする方向性電磁鋼板。 - 上記鋼板は、C:0.0050mass%以下、Si:2.5〜4.5mass%、Mn:0.03〜0.30mass%を含有し、残部がFeおよび不可避的不純物からなる成分組成を有することを特徴とする請求項1に記載の方向性電磁鋼板。
- 上記鋼板は、上記成分組成に加えてさらに、Ni:0.01〜1.50mass%、Cr:0.01〜0.50mass%、Cu:0.01〜0.50mass%、P:0.005〜0.20mass%、Sn:0.005〜0.50mass%、Sb:0.005〜0.20mass%、Bi:0.005〜0.10mass%、Mo:0.005〜0.10mass%、B:0.0002〜0.0025mass%、Te:0.0005〜0.010mass%、Nb:0.001〜0.010mass%、V:0.001〜0.010mass%、W:0.002〜0.050mass%、Ti:0.001〜0.010mass%およびTa:0.001〜0.010mass%のうちから選ばれる1種または2種以上を含有することを特徴とする請求項2に記載の方向性電磁鋼板。
- C:0.02〜0.08mass%、Si:2.5〜4.5mass%、Mn:0.03〜0.30mass%を含有し、残部がFeおよび不可避的不純物からなる鋼素材を熱間圧延して熱延板とした後、1回の冷間圧延または中間焼鈍を挟む2回以上の冷間圧延により最終板厚の冷延板とし、一次再結晶を兼ねた脱炭焼鈍を施した後、MgOを50mass%以上含有する焼鈍分離剤を鋼板表面に塗布し、仕上焼鈍し絶縁被膜を塗布し、焼き付けした後、磁区細分化処理を施す方向性電磁鋼板の製造方法において、
上記焼鈍分離剤として、Sn,Sb,MoおよびWのうちのいずれか1以上の化合物を、該金属換算で焼鈍分離剤全体に対して0.3〜5mass%の範囲で含有するものを用いるとともに、
上記仕上焼鈍時において、不活性雰囲気下で800℃以上950℃以下の温度で10時間以上100時間以下保持する保定処理を施した後、1150℃以上1250℃以下の温度で純化処理を施す際、1050℃以上から上記純化処理温度までの間、雰囲気ガスとしてH2を1vol%以上含有する露点10℃以下のドライガスを炉内圧力が3.5mmH2O以上となるよう通入することを特徴とする方向性電磁鋼板の製造方法。 - 上記鋼素材は、上記成分組成に加えてさらに、下記A〜C群のうちのいずれか1群のインヒビター形成成分を含有することを特徴とする請求項4に記載の方向性電磁鋼板の製造方法。
記
・A群;Al:0.010〜0.040mass%およびN:0.003〜0.012mass%
・B群;Se:0.0030〜0.030mass%および/またはS:0.0040〜0.030mass%
・C群;Al:0.010〜0.040mass%、N:0.003〜0.012mass%、Se:0.0030〜0.030mass%および/またはS:0.0040〜0.030mass% - 上記鋼素材は、不可避的不純物中のAl,N,SおよびSeの含有量が、Al:0.01mass%未満、N:0.0050mass%未満、S:0.0040mass%未満およびSe:0.0030mass%未満であることを特徴とする請求項4に記載の方向性電磁鋼板の製造方法。
- 上記鋼素材は、上記成分組成に加えてさらに、Ni:0.01〜1.50mass%、Cr:0.01〜0.50mass%、Cu:0.01〜0.50mass%、P:0.005〜0.20mass%、Sn:0.005〜0.50mass%、Sb:0.005〜0.20mass%、Bi:0.005〜0.10mass%、Mo:0.005〜0.10mass%、B:0.0002〜0.0025mass%、Te:0.0005〜0.010mass%、Nb:0.001〜0.010mass%、V:0.001〜0.010mass%、W:0.002〜0.050mass%、Ti:0.001〜0.010mass%およびTa:0.001〜0.010mass%のうちから選ばれる1種または2種以上を含有することを特徴とする請求項4〜6のいずれか1項に記載の方向性電磁鋼板の製造方法。
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