CN114561512B - 用激光刻痕脱碳板以改善取向硅钢片磁致伸缩的方法 - Google Patents
用激光刻痕脱碳板以改善取向硅钢片磁致伸缩的方法 Download PDFInfo
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Abstract
用激光刻痕脱碳板以改善取向硅钢片磁致伸缩的方法:冶炼后浇注成坯;铸坯加热;两段常化处理;酸洗后冷轧;脱碳退火;对脱碳板激光刻痕;涂敷退火隔离剂;经对退火隔离剂烘干后高温退火;涂敷退火隔离剂后涂敷绝缘涂料;对绝缘涂层经烘干后烧结;对成品板激光刻痕。本发明通过采用高温加热,使基板磁致伸缩在λp‑p17/50≤600nm/m,A加权磁致伸缩速度在AWV17/50≤53dB(A),磁感应强度B8≥1.92T,并经在脱碳板上激光刻痕,获得高张力隔离底层、绝缘涂层及成品板横向激光刻痕,在基板上形成复合张力,从而获得磁致伸缩λp‑p17/50≤200nm/m,A加权磁致伸缩速度AWV17/50≤49dB(A),磁感应强度B8≥1.915T。
Description
技术领域
本发明属于硅钢及生产技术领域,具体涉及改善取向硅钢片磁致伸缩的方法。
背景技术
取向硅钢是输变电行业关键原材料,主要用于制造各种变压器铁芯。随着城市化进程加快,建筑密度提高,居民小区所设置的变电站,由于其造成的噪声成为噪音污染,从而影响到了居民生活,对于居民的生活质量不利。
变压器噪声的产生本源是由于取向硅钢片的磁致伸缩所致。取向硅钢片在磁化过程中会伸长或缩短,称之为磁致伸缩。这种磁致伸缩在交变磁场中进行磁化时,则就会使制备变压器的取向硅钢片产生振动,故而形成了噪音。变压器产生的噪音的程度,一方面同变压器用料即取向硅钢片有关,另一方面也同变压器的设计、制造等因素有关。
降低变压器噪声可以通过降低取向硅钢片磁致伸缩来实现。那么降低磁致伸缩现象,可以从以下两方面予以实现:一是从材料内部因素而言,就是提高取向硅钢基板晶粒取向度,即提高磁感应强度和优化磁畴结果;二是从外部因素而言,是增加张应力,主要措施是提高涂层张力和激光刻痕。如经检索的:
中国专利申请号为CN2015102426851.9的文献,其公开了一种《低噪音变压器用取向硅钢片的制造方法》,该文献采用刻痕加工方式在硅钢片的单面或双面形成特定形状的沟槽,沟槽的底面与硅钢片表面平行或近似平行,沟槽内壁单侧或多侧与法向平面法向平面存在夹角θ,夹角θ的范围控制在-60°至0之间;将刻痕工艺分别设置在脱碳退火工艺前后、高温退火工艺后以及绝缘涂层平整退火工艺后;刻痕单脉冲激光束能量控制在0.002J/mm~1.3J/mm之间。其制造的取向硅钢片虽然铁损低,经过消除应力退火后性能不发生劣化,且同等制造和测试条件下的变压器噪音水平降低。该文献提出了在不同工序对硅钢片进行刻痕加工,从而获得低噪音变压器用取向硅钢,同本发明中优化工艺获得高磁感应强度和优化磁畴的取向硅钢,表面涂敷高张力隔离底层和绝缘涂层,两次激光刻痕从而明显改善取向硅钢磁致伸缩的方法明显不同。
中国专利申请号为CN201510673773.0的文献,公开了《一种低噪音特性取向硅钢及其制造方法》,该文献通过优化以下几方面工艺:1)控制硅钢基板中Cu元素和S元素比例;2)提高T2涂层厚度,增加绝缘涂层的张力;3)控制成品磁性能和晶粒尺寸;4)优化常化退火工艺;5)优化一次再结晶退火工艺;6)优化高温退火工艺,使低噪音特性取向硅钢的LVA(17)≤55dB(A),由低噪音特性取向硅钢制得的变压器噪音均≤57dB(A)。该文献通过控制Cu元素和S元素,提高绝缘涂层厚度,增加涂层张力,控制晶粒尺寸和提高成品磁性能,从而获得低噪音特性的取向硅钢,与本发明中通过两次激光刻痕从而明显改善取向硅钢磁致伸缩的方法明显不同。
中国专利申请号为CN202010881892.6的文献,其公开了《一种具有高张力隔离底层和绝缘涂层的低噪音取向硅钢》,该文献需要通过优化以下几方面工艺:1)通过在退火隔离剂中加入关键添加剂;2)控制氧化镁颗粒尺寸;3)控制取向硅钢成分;4)绝缘涂层中加入胶体和氧化物添加剂;5)优化绝缘涂层烘干温度;6)优化高温退火工艺。使其制造的取向硅钢片铁损和噪音水平降低。该文献通过控制氧化镁颗粒尺寸、加入关键添加剂,优化高温退火工艺从而在取向硅钢表面形成优良隔离底层;在绝缘涂层中加入胶体和氧化物添加剂,优化绝缘涂层烘干工艺,形成高张力绝缘涂层,从而获得低噪音取向硅钢,与本发明中通过两次激光刻痕从而明显改善取向硅钢磁致伸缩的方法明显不同。
中国专利申请号为CN201910527697.0的文献,公开了《一种取向硅钢用高张力涂层的制备方法》,该文献在现有绝缘涂层的成分基础上,依次加入磷酸二氢钾、氧氯化锆,形成高张力涂层溶液并涂敷到取向硅钢表面,获得高张力涂层。该文献制备的取向硅钢张力虽然效果好,性能优异,该文献通过在绝缘涂层中加入磷酸二氢钾、氧氯化锆,从而在取向硅钢表面形成高张力绝缘涂层,其与本发明中通过优化工艺获得高磁感应强度和优化磁畴的取向硅钢,两次激光刻痕从而明显改善取向硅钢磁致伸缩的方法明显不同。
发明内容
本发明的目的在于克服现有技术存在的不足,提供一种通过采用高温板坯加热取向硅钢的工艺路线,使成品晶粒尺寸合适且均匀,基板磁致伸缩在λp-p17/50≤600nm/m,A加权磁致伸缩速度(1.7T,50HZ)在AWV17/50≤53dB(A),磁感应强度B8≥1.92T,并经在脱碳板上沿轧向激光刻痕,获得高张力隔离底层、高张力绝缘涂层以及成品板横向激光刻痕,在基板上形成复合张力,从而获得磁致伸缩λp-p17/50≤200nm/m,A加权磁致伸缩速度(1.7T,50HZ)AWV17/50≤49dB(A),磁感应强度B8≥1.915T的用激光刻痕脱碳板以改善取向硅钢片磁致伸缩的方法。
实现上述目的的技术措施
用激光刻痕脱碳板以改善取向硅钢片磁致伸缩的方法,其步骤:
1)经冶炼后浇注成坯;
2)对铸坯加热,控制加热温度不低于1350℃;
3)采用两段式常化处理,首先加热至1020~1200℃,然后以5~15℃/s的冷却速度降温至850~950℃,最后以10~50℃/s的冷却速度冷却至室温;
4)经酸洗后冷轧至产品厚度;
5)进行脱碳退火,并控制脱碳退火温度在830~860℃,脱碳后碳含量控制在不超过30ppm;
6)对脱碳板进行激光刻痕:在脱碳板表面沿轧向进行激光刻痕;激光刻痕采用CO2激光器或固体激光器或光纤激光器;并将激光器能量密度控制在5~1.5J/mm;控制所刻沟槽的:宽度在34~205μm,深度在0.5~12μm,沟槽之间间距在3~8mm,沟槽方向与基板轧向夹角不超过5°;
7)涂敷退火隔离剂,控制非刻痕处隔离底层厚度在1~2μm,刻痕处隔离底层厚度在1.5~5μm;
8)经对退火隔离剂烘干后进行高温退火,高温退火温度在1050~1250℃,并在此温度下保温,保温时间不低于20个小时;
9)经清洗钢板表面涂敷退火隔离剂后涂敷绝缘涂料,控制非刻痕处绝缘涂层厚度在1~
3μm,刻痕处绝缘涂层厚度在1~5μm;
10)对绝缘涂层经烘干后进行烧结,其中:控制烘干温度在380~700℃,烧结温度在720~900℃;
11)对成品板进行激光刻痕:在成品钢板表面垂直于轧向进行激光刻痕;激光刻痕采用CO2激光器或固体激光器或光纤激光器。
其在于:所述退火隔离剂的组成及所占份数:氧化镁:100份,二氧化钛:2~10份,硼酸镁:0.01~1份,添加剂Al或Ca或Sn或Cr或Zn中的一种或几种:0.1~10份,水:700~1000份。
其在于:所述绝缘涂料的原料组成及重量百分比含量为:磷酸二氢钾:20~45%,硅溶胶:25~45%,铬酐:2~5%,添加剂Co或Ni或Al或Ca或Na的氢氧化物中的一种或几种:0.5~5%,余量为水。
其在于:其适用于取向硅钢板的化学成分及重量百分比含量在:C:0.05~0.09%,Si:3.0~3.5%,Mn:0.05~0.10%,S:0.01~0.04%,Als:0.02~0.04%,N:70~110ppm,Cu:0.05~0.20%,余量为铁及不可避免杂质。
本发明之所以控制加热温度不低于1350℃,是由于在平衡状态下,AlN的固溶温度约为1280℃,MnS固溶温度约为1320℃,为保证二次再结晶发展完全并获得高磁性,板坯加热温度不低于1350℃,AlN和MnS热轧过程中可完全固溶。
本发明之所以控制常化温度在1020~1200℃,然后以5~15℃/s的冷却速度降温至850~950℃,是由于在此温度下,钢中的Si3N4和部分AlN固溶,此时本发明钢中γ相最多,氮在γ相中的固溶度是在α相中的9倍。以5~15℃/s的冷却速度降温至850~950℃,确保钢种固溶AlN和MnS均匀弥散析出,保证后续高温退火发展完善二次再结晶晶粒。
本发明之所以控制脱碳退火温度在830~860℃,脱碳后碳含量控制在不超过30ppm,是由于在此温度和加热速度下,有利于完成初次再结晶,使基体中有足够数量的(110)[001]初次晶粒(二次晶核)以及有利于它们长大的初次再结晶织构和组织;碳含量不超过30ppm,保证后续高温退火时处于单一的α相,发展完善的二次再结晶组织,并消除产品的磁时效。
本发明之所以激光刻痕采用CO2激光器或固体激光器或光纤激光器;并将激光器能量密度控制在5~1.5J/mm;控制所刻沟槽的:宽度在34~205μm,深度在0.5~12μm,沟槽之间间距在3~8mm,沟槽方向与基板轧向夹角不超过5°,是为了取向硅钢表面形成底层中主要是Mg2SiO4,此外还有MgAl2O4(尖晶石)和Mns,底层深入到钢基中,在钢板中产生拉力,可使180°磁畴细化和减少尖钉装闭合磁畴数量,提高磁性能;在脱碳板轧向方向上进行刻痕,通过控制沟槽的深度、宽度、间距等参数,沟槽经高温退火后隔离底层厚度增加,提高底层对钢板轧向上的拉力,从而改善磁性能。
本发明之所以控制非刻痕处隔离底层厚度在1~2μm,刻痕处隔离底层厚度在1.5~5μm,是由于取向硅钢表面形成底层在钢板轧向方向上产生拉力,可提高磁性能;但内氧化层中SiO2质点附近形成V形排列的尖钉装闭合畴,对180°畴壁起钉扎作用,会恶化磁性能,因此非刻痕处隔离底层厚度需要控制在合理范围。刻痕处隔离底层厚度增加可明显提高钢板轧向上产生的拉力,同时刻痕宽度有限,底层厚度增加带来的恶化磁性能的影响可以忽略。
本发明之所以对退火隔离剂烘干后进行高温退火,控制高温退火温度在1050~1250,℃并在此温度下保温,保温保持不低于20小时,是由于较高的温度和时长保证钢基净化退火效果,将钢基中的不利元素(S元素和氮元素)完全净化,从而获得优良的磁性能。
本发明之所以控制非刻痕处绝缘涂层厚度在1~3μm,刻痕处绝缘涂层厚度在1~5μm,是由于应力涂层的热膨胀系数同钢基的热膨胀系数相比低的多,在平整拉伸退火后冷却时由于热膨胀系数的差别,在钢板中可以产生2~3MPa的拉力,应力涂层所产生的拉力可使磁畴细化,可以明显改善磁性能;绝缘涂层厚度超过3μm,提高拉力的效果明显减弱,同时会明显降低叠片系数,影响下游用户使用。刻痕处宽度有限,较厚的绝缘涂层对磁性能影响可以忽略。
本发明之所以控制烘干温度在380~700℃,烧结温度在720~900℃,是由于绝缘涂层烧结黏化前需要充分脱水,保证烧结成型后绝缘涂层表面光滑,烘干温度需要控制在合理的范围内,提高绝缘涂层烧结后光滑程度;烧结温度较低会导致绝缘涂层不够致密,烧结温度过高会导致绝缘涂层烧裂起粉,降低应力涂层的效果。
本发明之所以采用由氧化镁:氧化镁:100份,二氧化钛:2~10份,硼酸镁:0.01~1份,添加剂Al或Ca或Sn或Cr或Zn中的一种或几种:0.1~10份,水:700~1000份组成的退火隔离剂,是由于氧化镁在高温退火过程中一方面作为隔离涂层使用,另一方面同氧化膜中SiO2起反应,生成Mg2SiO4和MgAl2O4(尖晶石),是取向硅钢表面形成底层的重要组成部分。TiO2可以在高温退火过程中释放O2,从而控制钢卷各圈之间的气氛;硼酸镁在高温下分解将硼渗入钢种形成BN,可抑制二次晶粒过大,可以有效改进底层质量和提高磁性能。添加剂可以同氧化膜中SiO2起反应,可以阻止钢中氮跑出,保证析出的细小AlN不发生变化,而且在高温下可以侵蚀晶界,控制晶界移动,提高磁性能。
本发明之所以采用由磷酸二氢钾:20~45%,硅溶胶:25~45%,铬酐:2~5%,添加剂Co或Ni或Al或Ca或Na的氢氧化物中的一种或几种:0.5~5%,余量为水组成的绝缘涂料,是由于加入磷酸二氢钾起黏结剂作用,改善绝缘涂层和底层的附着性;加入铬酐改进涂液的润湿性和使磷酸盐中自有磷酸更稳定;以硅溶胶为主要成分的应力涂层热膨胀系数明显低于钢基的热膨胀系数,在平整拉伸退火后冷却时由于热膨胀系数的差别,在钢板中产生3~5MPa的拉力,提高产品磁性能;添加剂Co或Ni或Al或Ca或Na的氢氧化物中的一种或几种可以防止磷酸盐中的磷往底层扩散而降低应力涂层的拉力。
本发明与现有技术相比,其特点:
1,本发明由于采用高温板坯加热取向硅钢的工艺路线,使成品晶粒尺寸合适且均匀,磁性能优良的产品,基板磁致伸缩λp-p17/50≤600nm/m,A加权磁致伸缩速度(1.7T,50HZ)AWV17/50≤53dB(A),磁感应强度B8≥1.92T。
2,本发明由于采用在脱碳板上沿轧向进行激光刻痕,从而获得高张力隔离底层、高张力绝缘涂层以及成品板横向激光刻痕,在基板上形成复合张力,从而获得更低磁致伸缩或噪音性能的取向硅钢产品,磁致伸缩λp-p17/50≤200nm/m,A加权磁致伸缩速度(1.7T,50HZ)AWV17/50≤49dB(A),磁感应强度B8≥1.915T。
需要说明的是:产品的噪声特性用产品在磁感应强度1.7T,频率为50Hz下的加权磁致伸缩速度AWV17/50来表示,测试方法依据标准是IEC61672-1,该方法采用多普勒激光测震仪,测量材料交流磁化过程中磁致伸缩的各个谐波组分的频率及振幅,然后换算成声压级,从而表征材料的噪声特性。
附图说明
图1是本发明采用高温板坯加热取向硅钢典型的晶粒组织(未刻痕);
图2是本发明在脱碳板表面激光刻痕后沟槽的2D形貌图;
图3是成品板表面激光刻痕后的2D形貌图。
具体实施方式
下面结合对本发明做详细具体的描述:
表1为本发明各实施例及对比例的工艺参数列表;
表2为本发明各实施例及对比例的脱碳板采用不同刻痕工艺对应的磁性能及
噪音性能列表;
表3为本发明各实施例及对比例的成品板采用不同刻痕工艺对应的磁性能及噪音性能。
表4为本发明各实施例的钢板成分取值列表;
表5为本发明各实施例的退火隔离剂及绝缘涂料各组分取值列表。
本发明各实施例均按照以下步骤生产:
1)经冶炼后浇注成坯;
2)对铸坯加热,控制加热温度不低于1350℃;
3)采用两段式常化处理,首先加热至1020~1200℃,然后以5~15℃/s的冷却速度降温至850~950℃,最后以10~50℃/s的冷却速度冷却至室温;
4)经酸洗后冷轧至产品厚度;
5)进行脱碳退火,并控制脱碳退火温度在830~860℃,脱碳后碳含量控制在不超过30ppm;
6)对脱碳板进行激光刻痕:在脱碳板表面沿轧向进行激光刻痕;激光刻痕采用CO2激光器或固体激光器或光纤激光器;并将激光器能量密度控制在5~1.5J/mm;控制所刻沟槽的:宽度在34~205μm,深度在0.5~12μm,沟槽之间间距在3~8mm,沟槽方向与基板轧向夹角不超过5°;
7)涂敷退火隔离剂,控制非刻痕处隔离底层厚度在1~2μm,刻痕处隔离底层厚度在1.5~5μm;
8)经对退火隔离剂烘干后进行高温退火,高温退火温度在1050~1250℃,并在此温度下保温,保温时间不低于20个小时;
9)经清洗钢板表面涂敷退火隔离剂后涂敷绝缘涂料,控制非刻痕处绝缘涂层厚度在1~3μm,刻痕处绝缘涂层厚度在1~5μm;
10)对绝缘涂层经烘干后进行烧结,其中:控制烘干温度在380~700℃,烧结温度在720~900℃;
11)对成品板进行激光刻痕:在成品钢板表面垂直于轧向进行激光刻痕;激光刻痕采用CO2激光器或固体激光器或光纤激光器。
表1本发明各实施例及对比例的工艺参数列表
续表1
表2本发明各实施例及对比例脱碳板磁性能和噪音性能列表
表3本发明各实施例及对比例成品板在不同刻痕工艺时的磁性能和噪音性能列表
需要说明的是:产品的噪声特性用产品在磁感应强度1.7T,频率为50Hz下的加权磁致伸缩速度AWV17/50来表示。其测试方法依据标准是IEC61672-1,该方法采用多普勒激光测震仪,测量材料交流磁化过程中磁致伸缩的各个谐波组分的频率及振幅,然后换算成声压级,从而表征材料的噪声特性。
表4本发明各实施例的钢板成分取值列表(wt%)
表5本发明退火隔离剂及绝缘涂料各组分取值列表(wt%)
从表2及3中可以看出,通过优化生产工艺,可以获得高磁感应强度和优化磁畴的取向硅钢,再辅以高张力隔离底层和绝缘涂层、激光刻痕等措施,可以获得低磁致伸缩或噪音性能的取向硅钢产品。
以上实施例仅为最佳例举,并非对本发明的保护范围限定。
Claims (2)
1.用激光刻痕脱碳板以改善取向硅钢片磁致伸缩的方法,其步骤:
1)经冶炼后浇注成坯;
2)对铸坯加热,控制加热温度在1392℃;
3)采用两段式常化处理,首先加热至1175℃,然后以5~15℃/s的冷却速度降温至850~950℃,最后以10~50℃/s的冷却速度冷却至室温;
4)经酸洗后冷轧至产品厚度;
5)进行脱碳退火,并控制脱碳退火温度在855℃,脱碳后碳含量在21PPm;
6)对脱碳板进行激光刻痕:在脱碳板表面沿轧向进行激光刻痕;激光刻痕采用光纤激光器;激光能量密度在0.025J/mm;所刻沟槽的:宽度在87μm,深度在1.1μm,沟槽之间间距在4mm,沟槽方向与基板轧向夹角不超过5°;
7)涂敷退火隔离剂,非刻痕处隔离底层厚度在1.4μm,刻痕处隔离底层厚度在2.3μm;
8)经对退火隔离剂烘干后进行高温退火,高温退火温度在1200℃,并在此温度下保温,
保温时间不低于20个小时;
9)经清洗钢板表面涂敷退火隔离剂后涂敷绝缘涂料,控制非刻痕处绝缘涂层厚度在2.2μm,刻痕处绝缘涂层厚度在2.4μm;
10)对绝缘涂层经烘干后进行烧结,其中:控制烘干温度在683℃,烧结温度在852℃;
11)对成品板进行激光刻痕:在成品钢板表面垂直于轧向进行激光刻痕;激光刻痕采用CO2激光器或固体激光器或光纤激光器。
2.用激光刻痕脱碳板以改善取向硅钢片磁致伸缩的方法,其步骤:
1)经冶炼后浇注成坯;
2)对铸坯加热,控制加热温度在1374℃;
3)采用两段式常化处理,首先加热至1175℃,然后以5~15℃/s的冷却速度降温至850~950℃,最后以10~50℃/s的冷却速度冷却至室温;
4)经酸洗后冷轧至产品厚度;
5)进行脱碳退火,并控制脱碳退火温度在850℃,脱碳后碳含量在15PPm;
6)对脱碳板进行激光刻痕:在脱碳板表面沿轧向进行激光刻痕;激光刻痕采用CO2激光器;激光能量密度在0.05J/mm;所刻沟槽的:宽度在103μm,深度在1.5μm,沟槽之间间距在4mm,沟槽方向与基板轧向夹角不超过5°;
7)涂敷退火隔离剂,非刻痕处隔离底层厚度在1.6μm,刻痕处隔离底层厚度在2.6μm;
8)经对退火隔离剂烘干后进行高温退火,高温退火温度在1200℃,并在此温度下保温,保温时间不低于20个小时;
9)经清洗钢板表面涂敷退火隔离剂后涂敷绝缘涂料,控制非刻痕处绝缘涂层厚度在2.6μm,刻痕处绝缘涂层厚度在2.9μm;
10)对绝缘涂层经烘干后进行烧结,其中:控制烘干温度在677℃,烧结温度在863℃;
11)对成品板进行激光刻痕:在成品钢板表面垂直于轧向进行激光刻痕;激光刻痕采用CO2激光器或固体激光器或光纤激光器。
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