WO2019188585A1 - 方向性電磁鋼板用絶縁皮膜を形成するための塗布液、方向性電磁鋼板の製造方法、および方向性電磁鋼板 - Google Patents
方向性電磁鋼板用絶縁皮膜を形成するための塗布液、方向性電磁鋼板の製造方法、および方向性電磁鋼板 Download PDFInfo
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
- C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
- C23C22/24—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing hexavalent chromium compounds
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- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
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- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
- C21D8/12—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of articles with special electromagnetic properties
- C21D8/1244—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of articles with special electromagnetic properties the heat treatment(s) being of interest
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- C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
- C21D8/12—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of articles with special electromagnetic properties
- C21D8/1277—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of articles with special electromagnetic properties involving a particular surface treatment
- C21D8/1283—Application of a separating or insulating coating
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- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/46—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for sheet metals
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
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- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
- C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
- C23C22/24—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing hexavalent chromium compounds
- C23C22/33—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing hexavalent chromium compounds containing also phosphates
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
- C23C22/68—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous solutions with pH between 6 and 8
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- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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Definitions
- a grain-oriented electrical steel sheet is a steel sheet having a crystal structure with the (110) [001] orientation as the main orientation and usually containing 2% by mass or more of Si. Its main application is iron core materials such as transformers, and in particular, materials with low energy loss during transformation, that is, materials with low iron loss are required.
- the coating liquid for insulating film formation described in Patent Document 6 and Patent Document 7 is formed of a mixture of alumina sol and boric acid.
- the film tension of the insulating film formed by baking this coating liquid is larger than that of the insulating film obtained by baking the coating liquid composed of colloidal silica, primary phosphate and chromic acid. can get.
- this insulating film still has room for further improvement in terms of corrosion resistance, and the alumina sol as a raw material is often expensive.
- a coating liquid according to an aspect of the present invention is a coating liquid for forming an insulating film for grain-oriented electrical steel sheet, A solvent, One or more of layered clay mineral powders having a specific surface area of 20 m 2 / g or more; It is characterized by containing.
- the coating solution described in (1) above is The layered clay mineral powder may have a specific surface area of 150 m 2 / g or less.
- the coating liquid described in (1) or (2) above is The layered clay mineral powder may be one or more powders selected from the group consisting of kaolin, talc, and pyrophyllite.
- the coating liquid according to any one of (1) to (3) above You may contain an inorganic dispersing agent more than 0 mass% and 20 mass% or less with respect to the said layered clay mineral powder.
- the coating solution described in (4) above is The inorganic dispersant may be one or more selected from the group consisting of sodium diphosphate, sodium hexametaphosphate, sodium silicate, and potassium silicate.
- the coating solution according to any one of (1) to (5) above, The content of the chromium compound may be 4% by mass or less based on the layered clay mineral powder.
- the grain-oriented electrical steel sheet according to one aspect of the present invention is With the base material, An insulating film provided on the surface of the base material; A grain-oriented electrical steel sheet having The insulating film is Containing SiO 2 and containing one or two of Al 2 O 3 and MgO, The porosity is 10% or less.
- the grain-oriented electrical steel sheet according to (8) above is The insulating film may further contain one or more selected from the group consisting of Fe 2 O 3 , Na 2 O, K 2 O, and P 2 O 5 .
- the content of the chromium compound in the insulating film may be 4% by mass or less based on the dehydrated product of the layered clay mineral.
- a grain-oriented electrical steel sheet that can form an insulating film with excellent corrosion resistance while not using a chromium compound or reducing the amount used, and that can further produce a grain-oriented electrical steel sheet having excellent iron loss.
- a coating solution for forming an insulating coating for an electrical steel sheet is provided.
- the manufacturing method of the grain-oriented electrical steel sheet which can manufacture the grain-oriented electrical steel sheet which is excellent in corrosion resistance, and has the further excellent iron loss, without using a chromium compound or reducing the usage-amount is provided.
- a grain-oriented electrical steel sheet that is excellent in corrosion resistance and has an excellent iron loss while not using a chromium compound or reducing the amount of use.
- the present inventors have found that a coating solution in which a powder of a layered clay mineral having a specific surface area of 20 m 2 / g or more is dispersed in a solvent does not add a binder as described above or reduces the amount used, but an insulating film It has been found that it is easy to form and a film tension equal to or higher than that of an insulating film obtained by baking a coating solution containing colloidal silica, primary phosphate and chromic acid can be obtained. And the present inventors can form an insulating film excellent in corrosion resistance even when not using a chromium compound or reducing the amount used, and can manufacture a grain-oriented electrical steel sheet having an excellent iron loss. I found.
- a binder for example, primary phosphate, lithium silicate, water-soluble lithium salt, etc.
- the coating liquid according to the present embodiment does not contain a binder and may be composed of a layered clay mineral powder and a solvent. Thereby, the effect that the water resistance of the film after baking becomes favorable is acquired. Further, when phosphoric acid or phosphate is used as the binder, the coating solution tends to gel. However, when the binder is not included, this gelation can be suppressed.
- the layered clay mineral powder includes a 1: 1 silicate layer represented by a composition formula X 2-3 Si 2 O 5 (OH) 4 , and a composition formula X 2-3 (Si, Al) 4 O 10 (OH) 2.
- a 2: 1 silicate layer represented by (X is Al, Mg, Fe, etc.) has a laminated structure, either alone or in combination. There may be a case where at least one of water molecules and ions is included between layers of the layered structure.
- Ball mills, vibration mills, bead mills, jet mills and the like are effective as the pulverizing means.
- any of dry pulverization in which powder is pulverized and wet treatment in a slurry state in which layered clay mineral powder is dispersed in water or alcohol is effective. Since the specific surface area of each of the various pulverizing means increases with the pulverization time, a clay mineral powder having a required specific surface area and a dispersion thereof can be obtained by managing the pulverization time.
- the coating liquid for forming an insulating film according to this embodiment is prepared by adding a layered clay mineral powder having a specific surface area of 20 m 2 / g or more to a solvent such as water and, if necessary, adding other additives and mixing and stirring. It is obtained by doing.
- the layered clay mineral powder to be used may be used alone or in combination.
- a layered clay mineral powder having a specific surface area of 20 m 2 / g or more is prepared by a dry pulverization treatment, it may thicken and gel after mixing with a solvent such as water. It is effective to add the inorganic dispersant in the range of 20% by mass or less with respect to the layered clay mineral powder at the time of preparation.
- solvent used for the coating solution in addition to water, for example, alcohols such as ethyl alcohol, methyl alcohol, and propyl alcohol can be used supplementarily.
- solvent used in the coating solution it is desirable to use water that does not have flammability.
- the method for manufacturing a grain-oriented electrical steel sheet according to the present embodiment is to form an insulating film for grain-oriented electrical steel sheets on the base material of the grain-oriented electrical steel sheet, that is, the grain-oriented electrical steel sheet that has been subjected to the final finish annealing process. And a step of applying a baking process to the base material after application.
- the coating solution is a coating solution containing a layered clay mineral powder having a specific surface area of 20 m 2 / g or more. An inorganic dispersant is added to this coating solution as necessary.
- the grain-oriented electrical steel sheet after final finish annealing may not have a finish annealing film.
- the coating amount of the coating solution is not particularly limited, but is excellent in film strength, space factor, corrosion resistance and water resistance, and further, in terms of obtaining an iron loss reduction effect, It is preferable to apply so as to be in the range of 1 g / m 2 to 10 g / m 2 . More preferably, the coating amount of the coating solution, as the amount of film after the insulating film forming a 2g / m 2 ⁇ 8g / m 2. In addition, the coating amount after baking processing can be calculated
- the baking temperature is preferably 600 ° C. or higher.
- the baking temperature is preferably set to 1000 ° C. or less.
- a preferable lower limit of the baking temperature is 700 ° C. or higher.
- the upper limit with preferable baking temperature is 950 degrees C or less.
- the baking time is preferably 5 seconds to 300 seconds, more preferably 10 seconds to 120 seconds.
- the heating method which performs a baking process is not specifically limited, For example, a radiation furnace, a hot air furnace, induction heating, etc. are mentioned.
- the grain-oriented electrical steel sheet according to this embodiment includes a base material of the grain-oriented electrical steel sheet and one or two selected from Al 2 O 3 and MgO, containing SiO 2 provided on the surface of the base material. And an insulating film containing seeds.
- the insulating film may further contain one or more selected from Fe 2 O 3 , Na 2 O, K 2 O, and P 2 O 5 .
- This insulating film is a dense film, and specifically has a porosity of 10% or less.
- the insulating film has the above-described configuration, so that it does not include the binder as described above or can be used as a dense insulating film while reducing the amount used.
- a film tension equal to or higher than that of an insulating film obtained by baking a coating solution containing colloidal silica, primary phosphate and chromic acid can be obtained.
- even if it does not use a chromium compound or reduces the usage-amount it can be set as the insulation film excellent in corrosion resistance, and the grain-oriented electrical steel sheet which has the further outstanding iron loss is obtained.
- the porosity in the insulating film (the area ratio of pores contained in the insulating film) is measured by the following method.
- SEM 5000 times magnification
- the insulating film of the grain-oriented electrical steel sheet according to the present embodiment contains SiO 2 and contains one or two selected from Al 2 O 3 and MgO, and further Fe 2 O 3 , Na 2 O, K 2 O, and one or may contain two or more selected from P 2 O 5.
- the coating liquid for forming the above-described insulating film for grain-oriented electrical steel sheet according to the present embodiment is applied and subjected to baking treatment at a temperature of 600 ° C. or higher and 1000 ° C. or lower. Can be formed.
- SiO 2 contained in the insulating film formed by the above method one or two selected from Al 2 O 3 and MgO; and Fe 2 O 3 , Na 2 O, K 2 O, and P 2
- One or more components selected from O 5 are dehydrated products of layered clay minerals and inorganic dispersants.
- the dehydrated product of the layered clay mineral contained in the insulating film is preferably a dehydrated product of one or more layered clay minerals selected from kaolin, talc, and pyrophyllite.
- the kaolin dehydration product is composed of Al 2 O 3 and SiO 2 in a molar ratio of approximately 1: 2
- the talc dehydration product is approximately composed of MgO and SiO 2 in a molar ratio of 3: 4 to dehydrate the pyrophyllite.
- the product is composed of Al 2 O 3 and SiO 2 in an approximate molar ratio of 1: 4.
- the molar ratio fluctuates by about 10% and may contain Fe 2 O 3 as an impurity.
- an inorganic dispersant may be added to the coating solution for forming the insulating film for grain-oriented electrical steel sheets, but these are also dehydrated to become anhydrous after baking, often dehydrating layered clay minerals. Reacts with product.
- the insulating film contains a dehydrated product derived from an inorganic dispersant or a reaction product with a dehydrated product derived from the layered clay mineral in an amount of more than 0% by mass and less than 20% by mass with respect to the dehydrated product of the layered clay mineral. Also good.
- the inorganic dispersant the above-described ones described in the section of the coating solution can be cited as suitable as well.
- sodium diphosphate and sodium hexametaphosphate which are a kind of inorganic dispersant, are composed of Na 2 O and P 2 O 5 after baking.
- sodium silicate it consists of Na 2 O and SiO 2 .
- potassium silicate it is composed of K 2 O and SiO 2 .
- a coating solution having the composition shown in Table 1 was prepared.
- a part of the prepared solution was collected, and the state of the coating solution (presence or absence of gelation) was observed after standing for 2 days at room temperature.
- the coating liquid shown in Example 13 is an example in which two types of layered clay mineral powder are included.
- the obtained grain-oriented electrical steel sheet with an insulating film was evaluated for film characteristics, magnetic characteristics, water resistance and corrosion resistance. Moreover, the porosity of the insulating film was measured by the method described above. Table 1 shows the results. The evaluation method of each evaluation shown in Table 1 is as follows.
- Iron loss Measured according to the method described in JIS C 2550-1 (2011). Specifically, the iron loss per unit mass (W 17/50 ) is measured under the conditions of a measurement magnetic flux density amplitude of 1.7 T and a frequency of 50 Hz.
- the coating liquid having a large specific surface area is easily gelled and tends to deteriorate the workability of the coating liquid.
- Example 12 by increasing the concentration of the dispersant corresponding to the increase in the specific surface area, It can be seen that the viscosity stability can be maintained.
- the dispersant for preventing gelation of the dispersion is added in excess of 20% by mass as in Example 12, the coating composition is affected, and the coating tension is increased even if a layered clay mineral powder having a large specific surface area is used. Tends to cause deterioration. Therefore, it can be seen that the upper limit of addition of the dispersant is preferably 20% by mass.
- FIG. 1 and FIG. 2 the result of having observed the cross section of the grain-oriented electrical steel sheet in which the insulating film of the comparative example 2 and Example 2 was provided by SEM (JEOL JSM7000) in FIG. 1 and FIG. 2 is shown.
- reference numerals 11 and 21 denote insulating films
- reference numerals 12 and 22 denote finish annealed films (hereinafter, description is omitted).
- the insulating film of Example 2 was found to be a dense film with very few voids.
- the insulating film of Example 2 is dense, it is considered that the film tension is excellent and the iron loss is improved.
- Example B Next, the results of evaluating the film properties and magnetic properties by changing the baking temperature will be shown.
- a coating solution having the same composition as in Example 2 was applied by a roll coater and dried in the same procedure as in Example 2 so that the amount of the insulating film after baking treatment was 5 g / m 2 .
- the baking temperature was changed to the conditions shown in Table 2 to perform the baking process.
- the baking time is the same as in Example A. Table 2 shows the results.
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Abstract
Description
本願は、2018年3月28日に、日本に出願された特願2018-061745号に基づき優先権を主張し、その内容をここに援用する。
しかしながら、上記絶縁皮膜を形成するための塗布液には、6価クロムが含まれており、こうした6価クロムを含まずに、張力等の各種皮膜特性に優れた絶縁皮膜が得られる、方向性電磁鋼板の絶縁皮膜形成用の塗布液の開発が待望されている。
しかしながら、クロム酸を含まず、クロム酸以外の添加物を用いる絶縁皮膜形成用塗布液によって得られる絶縁皮膜には皮膜張力の観点で、さらなる改良が望まれている。また、これら技術で用いられている添加物は、クロム酸よりも高価なものが多い。
しかしながら、この絶縁皮膜は耐食性の観点でさらなる改良の余地が残されており、また原料となるアルミナゾルは価格が高価なものが多い。
例えば、特許文献8では、含水珪酸塩粉末と第一燐酸塩からなる塗布液が開示されている。また、特許文献9では、含水珪酸塩粉末と第一燐酸塩とコロイダルシリカからなる塗布液が開示されている。さらに、特許文献10では、含水珪酸塩の一種であるカオリンと珪酸リチウムからなる塗布液が開示されている。これら文献に記載の塗布液を焼き付けて得られる絶縁皮膜は、いずれもコロイダルシリカと第一燐酸塩およびクロム酸から構成される塗布液を焼き付けて得られる絶縁皮膜と、同等以上の皮膜張力が得られる。また、得られた方向性電磁鋼板は、優れた鉄損を有する。
しかしながら、これらの塗布液による絶縁皮膜は、絶縁皮膜の耐水性や耐食性の観点でさらなる改良の余地が残されている。
(1)本発明の一態様に係る塗布液は、方向性電磁鋼板用絶縁皮膜を形成するための塗布液であって、
溶媒と、
比表面積20m2/g以上の層状粘土鉱物粉の1種または2種以上と、
を含有することを特徴とする。
(2)上記(1)に記載の塗布液は、
前記層状粘土鉱物粉の比表面積が150m2/g以下であってもよい。
(3)上記(1)または(2)に記載の塗布液は、
前記層状粘土鉱物粉が、カオリン、タルク、およびパイロフィライトからなる群から選択される1種または2種以上の粉末であってもよい。
(4)上記(1)から(3)のいずれか1項に記載の塗布液は、
前記層状粘土鉱物粉に対して0質量%超20質量%以下の無機分散剤を含有してもよい。
(5)上記(4)に記載の塗布液は、
前記無機分散剤が、二燐酸ナトリウム、ヘキサメタ燐酸ナトリウム、珪酸ナトリウム、および珪酸カリウムからなる群から選択される1種または2種以上であってもよい。
(6)上記(1)から(5)のいずれか1項に記載の塗布液は、
クロム化合物の含有量が、前記層状粘土鉱物粉に対して4質量%以下であってもよい。
方向性電磁鋼板の母材に対し、上記(1)から(6)のいずれか1項に記載の方向性電磁鋼板用絶縁皮膜を形成するための塗布液を塗布する工程と、
塗布後の前記母材に対し600℃以上1000℃以下の温度で焼き付け処理を施して絶縁皮膜を形成する工程と、
を含むことを特徴とする。
母材と、
前記母材の表面に設けられた絶縁皮膜と、
を有する方向性電磁鋼板であって、
前記絶縁皮膜が、
SiO2を含有し、且つAl2O3およびMgOの1種または2種を含有し、
空隙率が10%以下であることを特徴とする。
(9)上記(8)に記載の方向性電磁鋼板は、
前記絶縁皮膜が、さらにFe2O3、Na2O、K2O、およびP2O5からなる群から選択される1種または2種以上を含有してもよい。
(10)上記(8)または(9)に記載の方向性電磁鋼板は、
前記絶縁皮膜のクロム化合物の含有量が、層状粘土鉱物の脱水生成物に対して4質量%以下であってもよい。
本明細書中において、「工程」との用語は、独立した工程だけではなく、他の工程と明確に区別できない場合であってもその工程の所期の目的が達成されれば、本用語に含まれる。
また、以下の実施形態の各要素は、それぞれの組み合わせが可能であることは自明である。
本実施形態に係る方向性電磁鋼板用絶縁皮膜を形成するための塗布液(以下、単に「絶縁皮膜形成用塗布液」とも称す)は、比表面積20m2/g以上の層状粘土鉱物粉と、水等の溶媒と、を含有する。
そして、本発明者らは、クロム化合物を使用しないかまたは使用量を低減しても、耐食性に優れた絶縁皮膜を形成でき、さらに優れた鉄損を有する方向性電磁鋼板を製造することができることを見出した。
本実施形態に係る塗布液は、バインダーを含まず、層状粘土鉱物粉と溶媒とから構成されてもよい。これにより、焼付後の被膜の耐水性が良好になるという効果が得られる。また、バインダーとして燐酸や燐酸塩を用いた場合、塗布液がゲル化する傾向にあるが、バインダーを含まない場合には、このゲル化を抑制することもできる。
層状粘土鉱物粉は、組成式X2-3Si2O5(OH)4で表現される1:1珪酸塩層と、組成式X2-3(Si,Al)4O10(OH)2(XはAl、Mg、Fe等)で表現される2:1珪酸塩層とが、単独または混合して積層構造となっている。層状構造の層間には、水分子およびイオンの少なくとも一方を含む場合もある。
また、特に限定されるものではないが、層状粘土鉱物粉の比表面積が150m2/g以下であることが好ましい。層状粘土鉱物粉の比表面積がこの範囲以下であることで、分散剤の添加により分散液の安定性(粘度安定性)が保ち易くなる。
層状粘土鉱物粉の比表面積は、JIS Z 8830:2013の方法により測定される。
工業用途で市販されている層状粘土鉱物粉では比表面積20m2/g以上のものを入手することは難しい。そのため、例えば市販品に対し粉砕処理を施すことにより、比表面積20m2/g以上の層状粘土鉱物粉を得ることができる。
各種粉砕手段とも、粉砕時間とともに比表面積が増大するため、粉砕時間を管理することにより所要の比表面積を有する粘土鉱物粉およびその分散液を得ることができる。
ただし、有機系の分散剤を添加すると絶縁皮膜焼き付け時に分解して炭化し方向性電磁鋼板中に浸炭する場合があるため、無機系の分散剤が好ましい。無機系の分散剤の例として、ポリ燐酸塩や水ガラスを挙げることができる。前者の具体的なものとして、二燐酸ナトリウム、ヘキサメタ燐酸ナトリウムがある。後者の具体的なものとして、珪酸ナトリウム、珪酸カリウムがある。
無機分散剤の添加量は、1質量%以上であることがより好ましい。
乾式粉砕処理の場合には、粉砕時の分散剤添加を行わなくてもよい。
本実施形態に係る絶縁皮膜形成用塗布液の調製は、比表面積20m2/g以上の層状粘土鉱物粉を水等の溶媒に加え、さらに必要に応じて、その他の添加剤を加え、混合撹拌することで得られる。用いる層状粘土鉱物粉は単独でも、複数を混合してもよい。乾式粉砕処理によって比表面積20m2/g以上の層状粘土鉱物粉を準備した場合には、水等の溶媒との混合後に増粘、ゲル化する場合があり、これを抑制するために、塗布液調製時に前記の無機分散剤を層状粘土鉱物粉に対し20質量%以下の範囲で添加することが効果的である。
次に、本実施形態に係る方向性電磁鋼板の製造方法について説明する。
本実施形態に係る方向性電磁鋼板の製造方法は、方向性電磁鋼板の母材、つまり最終仕上げ焼鈍の工程までが完了した方向性電磁鋼板に対し、方向性電磁鋼板用絶縁皮膜を形成するための塗布液を塗布する工程と、塗布後の母材に対し焼き付け処理を施す工程と、を有する。そして、塗布液は比表面積20m2/g以上の層状粘土鉱物粉を含む塗布液である。この塗布液には必要に応じて無機分散剤が添加されている。
最終仕上げ焼鈍後の方向性電磁鋼板は、上記塗布液(つまり、本実施形態に係る絶縁皮膜形成用塗布液)を塗布する前の母材となる方向性電磁鋼板である。最終仕上げ焼鈍後の方向性電磁鋼板は特に限定されるものではない。
母材となる方向性電磁鋼板は、具体的には、例えば、Siを2質量%~4質量%含有する鋼片を熱延、熱延板焼鈍、および冷間圧延を施した後、脱炭焼鈍を行う。この後、MgOの含有量が50質量%以上である焼鈍分離剤を塗布し、最終仕上げ焼鈍を行うことにより得られる。最終仕上げ焼鈍後の方向性電磁鋼板は、仕上げ焼鈍皮膜を有していなくてもよい。
最終仕上げ焼鈍後の方向性電磁鋼板(母材)に、本実施形態に係る絶縁皮膜形成用塗布液を塗布した後、焼付け処理を行う。
塗布液の塗布量は特に限定されるものではないが、皮膜強度、占積率、耐食性および耐水性に優れ、さらに、鉄損低減効果を得る点で、絶縁皮膜形成後の皮膜の量として、1g/m2~10g/m2の範囲となるように塗布することが好適である。より好適には、塗布液の塗布量は、絶縁皮膜形成後の皮膜の量として、2g/m2~8g/m2である。なお、焼き付け処理後の塗布量は絶縁皮膜剥離前後の質量差から求めることができる。
焼き付け温度が低い場合は焼き付け時間を長くとることが好ましい。焼き付け温度の好ましい下限は700℃以上である。焼き付け温度の好ましい上限は950℃以下である。また、焼き付け時間は、5秒~300秒が好ましく、より好ましくは10秒~120秒である。
なお、焼き付け処理後の絶縁皮膜の厚さは、方向性電磁鋼板の母材の板厚方向を含む断面をSEM(走査型電子顕微鏡)で観察することによって求めることができる。
本実施形態に係る方向性電磁鋼板は、方向性電磁鋼板の母材と、母材の表面に設けられた、SiO2を含有し、且つAl2O3およびMgOから選択される1種または2種を含有する絶縁皮膜と、を有する。
また、この絶縁皮膜は、さらにFe2O3、Na2O、K2O、およびP2O5から選択される1種以上を含有してもよい。
本実施形態に係る方向性電磁鋼板では、絶縁皮膜が上記の構成を備えることで、前述のようなバインダーを含まないかまたは使用量を低減しつつも、緻密な絶縁皮膜とすることができ、かつ、コロイダルシリカ、第一燐酸塩およびクロム酸を含む塗布液を焼き付けて得られる絶縁皮膜と同等以上の皮膜張力が得られる。
また、クロム化合物を使用しないかまたは使用量を低減しても、耐食性に優れた絶縁皮膜とすることができ、さらに優れた鉄損を有する方向性電磁鋼板が得られる。
また、二値化画像の空隙を充填した画像から空隙(気孔)の面積を含めた断面の面積Aを得る(図3の例では、A=260μm2)。
そして、空隙率Fを、F=1-AC/Aから算出する(図3の例では、F=1-197/260=24.1%)。
なお、一つの方向性電磁鋼板の絶縁皮膜に対し、SEM(倍率5000倍)で観察を行って5つの画像を得て、各画像について上記の手法で空隙率を算出する。これらの平均値を算出して、絶縁皮膜の空隙率とする。
空隙率が10%以下である絶縁皮膜は、前述の本実施形態に係る方向性電磁鋼板用絶縁皮膜を形成するための塗布液を塗布し、600℃以上1000℃以下の温度で焼き付け処理を施すことで形成することができる。
無機分散剤としては、塗布液の項において説明した前述のものが、同様に好適なものとして挙げられる。例えば、無機分散剤の一種である二燐酸ナトリウムやヘキサメタ燐酸ナトリウムは、焼き付け後にNa2OとP2O5から構成されるものになる。珪酸ナトリウムの場合は、Na2OとSiO2から構成されるものになる。珪酸カリウムの場合は、K2OとSiO2から構成されるものになる。
まず、市販のカオリナイト、タルク、パイロフィライトの微粉(比表面積はすべて10m2/g)を用意し、下記表1に示す各種手段により粉砕処理を行った。分散剤を添加する場合には、湿式粉砕では処理前の水スラリー作成時に、乾式粉砕では粉砕処理後の塗布液調整時に分散剤を添加した。粉砕処理後にJIS Z 8830:2013の方法により、層状粘土鉱物粉の比表面積の測定を行った。
・コロイダルシリカ20質量%水分散液:100質量部
・燐酸アルミニウム50質量%水溶液:60質量部
・無水クロム酸:6質量部
表1にその結果を示す。表1に示す各評価の評価方法は、以下のとおりである。
皮膜張力は、絶縁皮膜の片面を剥離したときに生じる鋼板の反りから計算する。具体的な条件は、以下のとおりである。
電磁鋼板の片面のみの絶縁皮膜をアルカリ水溶液により除去する。その後、電磁鋼板の反りから、下記式により、皮膜張力を求める。
式:皮膜張力=190×板厚(mm)×板の反り(mm)/{板長さ(mm)}2[MPa]
JIS C 2550-1(2011)に記載の方法に準じて測定する。具体的には、測定磁束密度の振幅1.7T、周波数50Hzにおける条件下で単位質量当たりの鉄損(W17/50)として測定する。
耐水性は、溶出皮膜量で評価した。沸騰水中に試験片を1時間浸漬して、浸漬前後の試験片の重量変化を求め、これを溶出皮膜量とした。絶縁被膜形成量に対する溶出皮膜量の比率である皮膜溶出率(%)を表1に示す。皮膜溶出率(%)が小さいほど耐水性が良好である。
耐食性は、JIS Z 2371(塩水噴霧試験)により評価した。その結果を試験後の錆面積率(%)として表1に示す。錆面積率(%)が小さいほど耐食性が良好である。
K:カオリナイト
T:タルク
P:パイロフィライト
BD:ボールミル(乾式)
BW:ボールミル(湿式)
BM:ビーズミル(湿式)
SHMP:ヘキサメタ燐酸ナトリウム
SS:珪酸ナトリウム
PS:珪酸カリウム
しかしながら、実施例12のように分散液のゲル化防止のための分散剤を20質量%を超えて添加すると、皮膜組成に影響を与え、比表面積の大きい層状粘土鉱物粉を用いても皮膜張力の劣化をもたらす傾向がある。したがって、分散剤添加の上限を20質量%とすることが好ましいことがわかる。
図2に示すとおり、実施例2の絶縁皮膜は、空隙の極めて少ない緻密な皮膜となることが明らかとなった。図2に示すように、実施例2の絶縁皮膜は、緻密であるために、皮膜張力に優れ、鉄損が改善されていると考えられる。
次に、焼き付け温度を変更して、皮膜特性および磁気特性を評価した結果を示す。
実施例2と同様の組成の塗布液を、実施例2と同様の手順で、焼き付け処理後の絶縁皮膜量が5g/m2となるようにロールコーターで塗布して乾燥した。そして、焼付け温度を表2に示す条件に変更して焼き付け処理を行った。焼き付け時間は実施例Aと同じである。表2にその結果を示す。
Claims (10)
- 溶媒と、
比表面積20m2/g以上の層状粘土鉱物粉の1種または2種以上と、
を含有する
ことを特徴とする方向性電磁鋼板用絶縁皮膜を形成するための塗布液。 - 前記層状粘土鉱物粉の比表面積が150m2/g以下である
ことを特徴とする請求項1に記載の方向性電磁鋼板用絶縁皮膜を形成するための塗布液。 - 前記層状粘土鉱物粉が、カオリン、タルク、およびパイロフィライトからなる群から選択される1種または2種以上の粉末である
ことを特徴とする請求項1または2に記載の方向性電磁鋼板用絶縁皮膜を形成するための塗布液。 - 前記層状粘土鉱物粉に対して0質量%超20質量%以下の無機分散剤を含有する
ことを特徴とする請求項1から3のいずれか1項に記載の方向性電磁鋼板用絶縁皮膜を形成するための塗布液。 - 前記無機分散剤が、二燐酸ナトリウム、ヘキサメタ燐酸ナトリウム、珪酸ナトリウム、および珪酸カリウムからなる群から選択される1種または2種以上である
ことを特徴とする請求項4に記載の方向性電磁鋼板用絶縁皮膜を形成するための塗布液。 - クロム化合物の含有量が、前記層状粘土鉱物粉に対して4質量%以下である
ことを特徴とする請求項1から5のいずれか1項に記載の方向性電磁鋼板用絶縁皮膜を形成するための塗布液。 - 方向性電磁鋼板の母材に対し、請求項1から6のいずれか1項に記載の方向性電磁鋼板用絶縁皮膜を形成するための塗布液を塗布する工程と、
塗布後の前記母材に対し600℃以上1000℃以下の温度で焼き付け処理を施して絶縁皮膜を形成する工程と、
を含む
ことを特徴とする方向性電磁鋼板の製造方法。 - 母材と、
前記母材の表面に設けられた絶縁皮膜と、
を有する方向性電磁鋼板であって、
前記絶縁皮膜が、
SiO2を含有し、且つAl2O3およびMgOの1種または2種を含有し、
空隙率が10%以下である
ことを特徴とする方向性電磁鋼板。 - 前記絶縁皮膜が、さらにFe2O3、Na2O、K2O、およびP2O5からなる群から選択される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8に記載の方向性電磁鋼板。 - 前記絶縁皮膜のクロム化合物の含有量が、層状粘土鉱物の脱水生成物に対して4質量%以下である
ことを特徴とする請求項8または9に記載の方向性電磁鋼板。
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