Grain Oriented Steel Sheet Coating Adhesion

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Solution Overview

Problem

Existing oriented magnetic steel plates face issues with coating adhesion deterioration, particularly during slit and angular shearing, leading to 'frame peeling', and exhibit increased watt loss characteristics when used in transformers, which hampers the production of high-efficiency transformers.

Innovation Solution

Incorporating specific compounds such as Ce, La, Pr, Nd, Sc, and Y into the annealing separator with MgO, along with Ti, Sr, Ca, and Ba, to enhance coating adhesion and reduce 3X frequency watt loss, while optimizing the composition and processing of the steel plate to achieve improved edge peeling resistance and magnetic characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If Al-based inhibitors (AlN, MnS) are added to raise magnetic flux density, then magnetic permeability is improved, but coating adhesion deteriorates

Engineering Contradiction:
Improvemagnetic flux densityVSAvoidcoating adhesion
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The patent introduces rare earth elements (La, Ce, Pr, Nd, Sc, Y) as intermediary substances that mediate between the Al-based inhibitors and the forsterite coating. These rare earth elements form a buffer layer or modify the interface structure, preventing direct harmful interactions while maintaining the magnetic flux density enhancement effect of Al-based inhibitors and improving coating adhesion

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a composite inhibitor system combining Al-based inhibitors (AlN, MnS) with rare earth elements. This composite approach allows the material to simultaneously achieve high magnetic flux density (from Al-based inhibitors) and good coating adhesion (from rare earth elements that form stable compounds with forsterite)

Inventive Principle:
Principle #40Composite materials

2Loss of energy

If primary coating with forsterite is applied to improve insulation, then electrical resistance is improved, but edge peeling resistance deteriorates during shearing

Engineering Contradiction:
Improveelectrical resistanceVSAvoidedge peeling resistance
Core Design Contradiction:
Loss of energyVSStrength

Solution Approach 1:

The patent modifies the chemical composition parameters of the coating system by adding rare earth elements to the forsterite-based primary coating. This changes the physical and chemical properties of the coating, particularly its bonding characteristics, enabling it to maintain good adhesion during shearing operations while preserving the electrical insulation properties

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent applies different compositional characteristics to different aspects of the coating: forsterite provides the base insulation and adhesion, while rare earth elements specifically enhance edge peeling resistance during shearing operations, creating localized improvement in the coating's mechanical properties

Inventive Principle:
Principle #3Local quality

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 results in oriented magnetic steel plates with excellent coating adhesion, reduced edge peeling resistance, and lower 3X frequency watt loss, enabling the production of transformers with improved efficiency and reduced building factors, thus addressing the challenges of coating durability and watt loss.

Implementation Method 1

making AlN and MnS function as inhibitors inhibiting crystal grain growth

Methodology Applied
Scientific EffectGrain growth inhibition:

Implementation Method 2

making the rolling ratio in the final cold rolling process a strong rolling ratio over 80%. Due to this method, the orientation density of the crystal grains in the {110}orientation rises

Methodology Applied
Scientific EffectSecondary recrystallization:

Implementation Method 3

at the time of the final annealing of the oriented magnetic steel plate, usually an annealing separator having MgO as its main ingredient is used

Methodology Applied
Scientific EffectAnnealing: Annealing

Implementation Method 4

giving a ceramic coating or insulating coating giving surface tension to the steel plate

Methodology Applied
Scientific EffectElectrical insulation:

Implementation Method 5

giving a ceramic coating or insulating coating giving surface tension to the steel plate

Methodology Applied
Scientific EffectSurface tension: Surface Tension

Implementation Method 6

making AlN and MnS function as inhibitors inhibiting crystal grain growth

Methodology Applied
Scientific EffectPrecipitation: Precipitation

Implementation Method 7

making the rolling ratio in the final cold rolling process a strong rolling ratio over 80%

Methodology Applied
Scientific EffectPlastic deformation: Plasticity

Data Source

PatentEP1889927B1Grain oriented electromagnetic steel sheet having excellent film adhesion and process for producing the same
Publication Date: 2015.07.01 NIPPON STEEL & SUMITOMO METAL CORP

AI summary

The present invention provides oriented magnetic steel plate with excellent coating adhesion, in particular coating edge peeling resistance, that is, oriented magnetic steel plate with excellent coating adhesion containing, by mass%, Si: 1.8 to 7% and having a primary coating having forsterite as its main ingredient on its surface, said oriented magnetic steel plate characterized in that said primary coating contains one or more of Ce, La, Pr, Nd, Sc, and Y in an areal weight per side of 0.001 to 1000 mg/m2; characterized in that said primary coating contains Ti in an areal weight per side of 1 to 800 mg/m2; and characterized in that said primary coating contains one or more of Sr, Ca, and Ba in an areal weight per side of 0.01 to 100 mg/m2.