Low-Coercivity Wire Rod Composition for Fast Magnetic Response
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Solution Overview
Problem
Existing electromagnetic pure iron materials exhibit high coercivity, making them difficult to magnetize and demagnetize, which hinders the rapid conversion of electrical energy in circuits and slows down response speed in electronic components.
Innovation Solution
A wire rod with optimized alloy composition and controlled microstructure, comprising specific percentages of Fe, C, Si, Mn, Al, O, N, Ca, and unavoidable impurities, along with controlled manufacturing processes to achieve low coercivity, including smelting, continuous casting, primary rolling, heating, wire rod rolling, Stelmor fan cooling, and annealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electromagnetic pure iron materials are used, then the material structure is simple and easy to manufacture, but the coercivity is high making it difficult to magnetize and demagnetize
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters of the alloy, including limiting C≤0.003%, Si≤0.01%, Mn≤0.20%, P≤0.015%, S≤0.008%, Ti≤0.003%, Al=0.30-0.45%, and adding specific amounts of O (0.0015-0.0035%), N (0.001-0.003%), and Ca (0.0005-0.0015%). This systematic parameter optimization resolves the contradiction by achieving low coercivity through controlled composition rather than complex processing
Solution Approach 2:
The patent creates a composite material system by combining electromagnetic pure iron with small amounts of specific alloying elements (Mn, Al, O, N, Ca) to form a new material with superior magnetic properties. The composite structure includes ferrite grains (200-800μm) with controlled inclusions, achieving coercivity≤25A/m through the synergistic effect of multiple elements rather than using pure iron alone
2Speed
If the coercivity is reduced to improve response speed, then the magnetic properties improve, but the manufacturing precision requirements increase
Solution Approach 1:
The patent establishes specific parameter ranges for each alloying element to achieve the optimal balance between response speed and manufacturing precision. By defining Al=0.30-0.45% as the critical range and setting precise upper limits for impurities (C≤0.003%, Si≤0.01%, P≤0.015%, S≤0.008%, Ti≤0.003%), the patent makes the manufacturing process controllable while achieving coercivity≤25A/m and ferrite grain size of 200-800μm
Solution Approach 2:
The patent copies the successful composition formula from similar low-coercivity materials and adapts it for wire rod production. By replicating the effective element combinations (particularly Al=0.30-0.45% with controlled O and N) and processing parameters, the patent achieves consistent low coercivity results that improve response speed while maintaining manufacturability
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 resulting wire rod exhibits a coercivity of ≤ 25 A/m, with uniform ferrite grain size ranging from 200µm to 800µm, enhancing its soft magnetic properties and suitability for high-performance electronic components.
Implementation Method 1
annealing: an annealing heating temperature is 870-910°C, a holding time is 1-2 hours, and then cooling to below 500°C at a cooling rate of ≤ 50°C/h
Implementation Method 2
The microstructure of the low-coercivity wire rod comprises ferrite grains
Data Source
AI summary
Disclosed in the present invention is a low-coercivity wire rod, which contains Fe and inevitable impurities, and further contains the following chemical elements in percentages by mass: 0 < C ≤ 0.003%, Si ≤ 0.01%, Mn: 0.1-0.2%, Al: 0.30-0.45%, O: 0.0015-0.0035%, N: 0.001-0.003%, and Ca: 0.0005-0.0015%. Correspondingly, further disclosed in the present invention is a manufacturing method for the wire rod. In the present invention, by means of a rational chemical component design and structural regulation, a wire rod having low coercivity can be obtained.