Grain-Oriented Electrical Steel Coating with SiO2 Interlayer Adhesion
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Solution Overview
Problem
Conventional methods struggle to achieve sufficient coating adhesion and magnetic stability in grain oriented electrical steel sheets where the glass film is intentionally suppressed or removed, leading to insufficient insulation coating adherence and increased iron loss.
Innovation Solution
A grain oriented electrical steel sheet with a SiO2 intermediate oxide film layer and a tension-insulation coating, where metallic elements like Al, Cu, Cr, or Ca are concentrated at the interface, and controlled thermal history and oxidation conditions are applied to enhance coating adhesion without deteriorating magnetic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the glass film is removed or not formed to reduce pinning effect and improve magnetic domain motion, then iron loss is reduced, but coating adhesion becomes insufficient
Solution Approach 1:
An intermediate oxide film layer is introduced between the steel sheet and the tension-insulation coating. This intermediate layer serves as a mediator that provides excellent coating adhesion while allowing the steel sheet surface to remain free of glass film, thus maintaining good magnetic domain motion and low iron loss.
Solution Approach 2:
The coating structure is segmented into multiple layers: the steel sheet, an intermediate oxide film layer, and the tension-insulation coating. This segmentation allows each layer to perform its specific function independently - the intermediate oxide film provides adhesion while the outer coating provides insulation and tension.
2Reliability
If the tension-insulation coating is thickened to improve coating adhesion on glass film-free surfaces, then adhesion is improved, but iron loss reduction effect is compromised
Solution Approach 1:
The intermediate oxide film layer acts as an intermediary that provides the necessary adhesion interface, allowing the use of thinner tension-insulation coating while maintaining both good adhesion and low iron loss characteristics.
3Ease of manufacture
If conventional coating methods are used on glass film-free surfaces, then manufacturing is simple, but both coating adhesion and magnetic stability are insufficient
Solution Approach 1:
The intermediate oxide film layer is formed on the steel sheet surface before applying the tension-insulation coating. This preliminary action creates an optimal surface for coating adhesion, ensuring both excellent coating performance and magnetic stability while maintaining manufacturing simplicity.
Solution Approach 2:
The intermediate oxide film serves as a mediator layer that bridges the steel sheet and the tension-insulation coating, providing both adhesion and magnetic stability without complicating the manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides excellent coating adhesion and maintains magnetic stability, reducing iron loss and improving insulation properties on the steel sheet surface.
Implementation Method 1
an intermediate oxide film layer which is arranged on the base steel sheet, includes SiO2, and has an average thickness of 1.0 nm to 1.0 μm
Implementation Method 2
a time differential curve fM(t) of a glow discharge optical emission spectrum of a metallic element M (M: Al, Cr, Cu, or Ca) in the SiO2 intermediate oxide film layer
Data Source
AI summary
A grain oriented electrical steel sheet includes: by mass %, 0.010% or less of C; 2.50 to 4.00% of Si; 0.0010 to 0.0100% of acid soluble Al; 0.012% or less of N; 1.00% or less of Mn; 0.02% or less of S; and a balance comprising Fe and impurities, and has a tension-insulation coating at steel sheet surface and a SiO2 intermediate oxide film layer with an average thickness of 1.0 nm to 1.0 μm at an interface between the tension-insulation coating and the steel sheet surface. In the grain oriented electrical steel, a time differential curve fM(t) of a glow discharge optical emission spectrum of a metallic element M (Al) in the SiO2 intermediate oxide film layer satisfies a predetermined condition.