WO2022186357A1 - 方向性電磁鋼板の仕上げ焼鈍条件の決定方法およびその決定方法を用いた方向性電磁鋼板の製造方法 - Google Patents
方向性電磁鋼板の仕上げ焼鈍条件の決定方法およびその決定方法を用いた方向性電磁鋼板の製造方法 Download PDFInfo
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- annealing
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- 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
- 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
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- 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
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/74—Methods of treatment in inert gas, controlled atmosphere, vacuum or pulverulent material
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- 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
- C21D11/00—Process control or regulation for heat treatments
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- 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
- C21D3/00—Diffusion processes for extraction of non-metals; Furnaces therefor
- C21D3/02—Extraction of non-metals
- C21D3/04—Decarburising
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- 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
- C21D8/1255—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 with diffusion of elements, e.g. decarburising, nitriding
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- 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
- C21D8/1272—Final recrystallisation annealing
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- 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
- C21D8/1277—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
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
- G01N23/22—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by measuring secondary emission from the material
- G01N23/223—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by measuring secondary emission from the material by irradiating the sample with X-rays or gamma-rays and by measuring X-ray fluorescence
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/16—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of sheets
- H01F1/18—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of sheets with insulating coating
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2223/00—Investigating materials by wave or particle radiation
- G01N2223/60—Specific applications or type of materials
- G01N2223/624—Specific applications or type of materials steel, castings
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Definitions
- the present invention relates to a method for determining finish annealing conditions for a grain-oriented electrical steel sheet.
- the present invention relates to a method for determining finish annealing conditions for grain-oriented electrical steel sheets for obtaining grain-oriented electrical steel sheets at a high yield.
- the present invention also relates to a method for manufacturing a grain-oriented electrical steel sheet using the method for determining finish annealing conditions.
- Electrical steel sheets are soft magnetic materials that are widely used as materials for iron cores of transformers and motors. Among them, grain-oriented electrical steel sheets are highly concentrated in the ⁇ 110 ⁇ ⁇ 001> orientation, which is called the Goss orientation. However, due to its excellent magnetic properties, it is mainly used for the iron cores of large transformers.
- the grain-oriented electrical steel sheet is obtained by hot-rolling a steel material containing a large amount of Si and then further cold-rolling the cold-rolled sheet. It is generally manufactured by coating and performing final annealing.
- the high degree of integration in the Goss orientation is achieved by holding the steel at a high temperature of 800° C. or higher for a long time to cause secondary recrystallization in the finish annealing.
- finish annealing secondary recrystallization is caused, and then the steel is heated to a high temperature of about 1200°C to discharge impurities in the steel, and the internal oxide film generated in the decarburization annealing process and MgO are mainly formed.
- a forsterite-based undercoating is formed by reacting with the annealing separator.
- This undercoating has the effect of reducing iron loss by applying tension to the steel sheet, and also functions as a binder for the insulating coating that is subsequently deposited, contributing to the improvement of the insulating properties and corrosion resistance of the steel sheet.
- the internal oxide film formed during decarburization annealing is affected by the residual oxides in the previous process and the texture of the steel sheet surface, oxidation is performed by a non-equilibrium reaction, and decarburization occurs at the same time as oxidation. It is affected by complex oxidation behavior due to factors such as In addition, since such decarburization annealing is also annealing at a high dew point, it is extremely difficult to maintain a uniform atmosphere in the furnace, and uneven oxidation occurs on the front and back surfaces of the steel sheet, the coil ends and the center, and the like. The problem was that it was easy.
- the steel sheet wound into a coil is placed in an up-end state in which the coil axis is vertical in the finish annealing furnace, and is held at high temperature for a long time, so temperature unevenness in the coil is reduced. occurs. Due to this temperature unevenness, there is a problem that coating properties vary in the longitudinal direction and the sheet width direction of the coil.
- Patent Literature 1 proposes a method of promoting refinement of a steel sheet by repeating increases and decreases in furnace pressure in a specific temperature range of finish annealing.
- Patent Document 2 discloses a method for improving the coil shape by using MgO with a limited angle of repose and bulkiness as an annealing separator and optimizing the winding tension of the coil after applying the annealing separator. Proposed.
- Patent Document 3 deterioration of magnetic properties and film properties is suppressed by using a sealing material with a specific grain size at the lower end of the inner cover when performing finish annealing in a hearth rotating box furnace. A method to do so is proposed.
- Patent Documents 4 and 5 propose a method of increasing the flow rate of the atmospheric gas in the final annealing of the Bi-added steel sheet to increase the tension applied to the undercoating.
- JP-A-2000-239736 Japanese Patent Application Laid-Open No. 2001-303137 JP-A-08-209248 JP-A-09-003541 JP-A-09-111346
- the present invention has been made in view of the above-described problems of the conventional technology, and its purpose is to improve the properties of the undercoat such as forsterite at the upper and lower parts of the coil and the inner and outer winding parts during finish annealing.
- a method for determining finish annealing conditions for grain-oriented electrical steel sheets for producing high-quality grain-oriented electrical steel sheets with a high yield that meets the above-mentioned strict quality requirements in recent years by imparting good coating properties to parts and It is to propose a manufacturing method using the determination method.
- the cause of the yield decrease is that the finish annealing conditions vary depending on the position in the coil.
- the present invention is as follows. 1. After hot-rolling a steel material for a grain-oriented electrical steel sheet, it is cold-rolled once or cold-rolled twice or more with intermediate annealing, and then subjected to decarburization annealing that also serves as primary recrystallization annealing. , After applying an annealing separator and winding into a coil shape, finish annealing is performed to form a base film, and then flattening annealing is performed to make a product sheet.
- the concentration component of the control item of the finish annealing is determined based on the evaluation result of the influence of the control item of the finish annealing on the properties of the undercoat with respect to the concentration component.
- the concentration component index (M) is any one of O concentration, Si concentration, Al concentration, Mn concentration, P concentration, Fe 2 SiO 4 intensity ratio, SiO 2 intensity ratio and FeO intensity ratio on the steel plate surface Alternatively, the method for determining finish annealing conditions for a grain-oriented electrical steel sheet according to 1 above, wherein there are two or more types.
- control item of the finish annealing is any one or more of the temperature increase rate between 950 and 1100 ° C. of the final finish annealing, the atmosphere switching temperature, the homogenization heat treatment time, and the homogenization heat treatment temperature.
- the present invention it is possible to stably produce a grain-oriented electrical steel sheet with excellent properties of the underlying coating regardless of the position in the longitudinal and width directions of the coil. Therefore, the present invention greatly contributes to improvement of product quality, improvement of yield, and reduction of manufacturing cost.
- FIG. 3 is a diagram showing the relationship between the atmosphere switching temperature with respect to the P strength of the steel sheet and the coating properties.
- FIG. 10 is a diagram simulating temperature distribution at a representative point of 830° C. during finish annealing in a coil. The optimum atmosphere switching temperature calculated from the P intensity of the entire coil length and width, and the estimated temperature obtained from the calculation at each coil position at the atmosphere switching temperature of 700 ° C., 800 ° C., and 900 ° C. It is the figure which mapped the difference.
- the cold-rolled sheet was heated at a rate of 100°C/s between 500 and 700°C during the heating process using a horizontal (horizontal) continuous annealing furnace, and further heated to 860°C.
- decarburization annealing which also serves as primary recrystallization annealing, was performed by holding at this temperature for 140 seconds.
- the intensity of P which is one of the enriched components in the internal oxide film
- this intensity is the intensity of X-rays. Therefore, in the present invention, the intensity and the concentration (the amount of enrichment) may be understood as synonymous) were analyzed.
- an energy dispersion type fluorescent X-ray device was used, and the conditions were voltage: 50 kv and current: 10 mA.
- This P intensity analysis was performed every 50 mm in the plate width direction and every 50 m in the longitudinal direction to create a distribution map of the X-ray P intensity. This map is shown in FIG.
- the total length of the coil is 5000m and the total width is 1000mm.
- the X-ray P intensity varies gently within the range of 1.4 to 2.6 kcps in both the longitudinal direction and the width direction of the steel plate. This is considered to be due to the influence of the atmosphere gas flow in the annealing furnace and the surface properties of the steel sheet in the previous process.
- An annealing separator obtained by slurrying a powder mainly composed of MgO containing 5 mass% titanium oxide and 0.1 mass% sodium borate with water is applied to the cold-rolled steel sheet after decarburization annealing on the surface of the steel sheet. After coating and drying, it was coiled for final annealing.
- finish annealing was performed by changing the atmosphere switching temperature, which is one of the control items in the finish annealing, to form an undercoating on the surface of the steel sheet.
- the uniformity of the undercoating on the product sheet after final annealing was evaluated.
- the results are summarized in FIG. 2 in terms of the relationship between the intensity of P in the internal oxide film of the steel sheet after decarburization annealing and the atmosphere switching temperature.
- the uniformity of the undercoating was evaluated as "uniform" when the thickness of the coating had a constant uniform appearance, and as "partially defective" when there was a portion thinner than the surroundings.
- the optimum value of the atmosphere switching temperature for finish annealing (also simply referred to as the optimum value in the present invention) can be calculated from 1080 - 100 x (P strength) (also referred to as the optimum function f (M) in the present invention), and The difference (in the present invention, also referred to as the allowable value ⁇ ) between this and the actual atmosphere switching temperature (also referred to as the set value (H) in the present invention) given from the H 2 switching temperature of the finish annealing of the representative point described later is It was found that if the temperature is within 180° C., a good undercoat is formed. Therefore, the uniformity of the undercoating can be ensured by adjusting the atmosphere (for example, H 2 ) switching temperature of the finish annealing according to the P intensity of the internal oxide film.
- the representative point is a measurement point with a thermocouple attached to the hearth at a position in contact with the winding lower part of the coil.
- the set value (H) referred to in the present invention may be the temperature that the steel plate actually reaches, such as the actual atmosphere switching temperature mentioned above as an example, that is, the output value.
- the value of the so-called input such as the set temperature) and the value of what is actually controlled such as the amount of fuel gas and the amount of electric power input are acceptable, and if they are unified in one simulation, any of the above values It can be suitably used in the present invention.
- thermocouples were attached to the coil to perform finish annealing. and the temperature inside the coil was simulated using the finite element method.
- the final annealing at this time is performed by heating between room temperature and 950°C at a temperature increase rate of 25°C/h in an N2 atmosphere, and heating between 950 to 1100°C at a temperature increase rate of 20 °C/h in an H2 atmosphere.
- the next recrystallization was completed.
- purification treatment was performed by heating between 1100 and 1200° C. in an atmosphere of H 2 at a rate of temperature increase of 10° C./h and maintaining the temperature at 1200° C. for 10 hours.
- each temperature mentioned above and the temperature applied to the following annealing are described as the representative temperature for control (the temperature at the representative point), which is the temperature of the thermocouple attached to the lower hearth in contact with the coil.
- FIG. 3 shows the result of simulating the temperature distribution of the entire steel sheet in the coil by the finite element method when the temperature at the representative point during the annealing is 830° C. in this heat pattern.
- This figure is also shown with a 50 mm pitch in the width direction and a 50 m pitch in the longitudinal direction.
- the total length of the coil is 5000m and the total width is 1000mm. From the results of FIG. 3, it can be seen that the temperature is the lowest near the representative point slightly below the center of the plate width of the coil middle winding portion, and the difference between the maximum temperature and the minimum temperature is about 200°C.
- this experiment was further advanced according to the following procedures. That is, the appropriate temperature for switching the atmosphere from N 2 to H 2 was calculated from the P intensity at each coil position using the above formula of 1080-100 ⁇ (P intensity). In addition, the simulated temperature at each coil position at each time point of the atmosphere switching temperature at 700, 800, and 900° C., which were set candidate values (h 0 , h 1 , h 2 ), was calculated. Then, the difference ⁇ between the calculated appropriate temperature for switching from N2 to H2 and the simulated temperature at each coil position was displayed by mapping. The results are shown in FIG.
- the set value (H) of the atmosphere switching temperature can be set to 800.degree.
- the finish annealing conditions were the same as those described above except for the atmosphere switching temperature.
- the annealing separating agent was removed, a coating agent mainly composed of phosphate was applied, and flattening annealing was performed while baking.
- the coating appearance of this coil was determined by a surface inspection device, and uniform appearance without unevenness in color tone or dot-like defects in the coating was regarded as acceptable for the coating. As a result, a high coating pass rate of 99.7% was obtained.
- the insulating coating here, the glass coating mainly composed of phosphate
- the acceptance rate of the coating reflects the properties of the underlying coating.
- the coating acceptance rate is the percentage of the surface area of the coil that has a uniform appearance. For example, if the surface area of the evaluated coil is 100,000 m 2 and the surface area of the passed portion is 90,000 m 2 , the pass rate is 90.0%.
- the atmosphere switching temperature of the finish annealing was controlled using one representative point, so although the film characteristics at the representative point were good, there were defective parts over the entire coil length and width, resulting in a high yield. It was difficult to get good quality.
- the control that does not aim for a local optimum value and makes the range in which the coating properties are good the range that maximizes the area of the steel sheet wound into a coil (hereinafter simply referred to as the coil area).
- the undercoat was evaluated by variously changing the concentration component and the control item to be targeted, and the relationship between the amount of the concentration component and the control item that optimizes the properties of the undercoat was formulated.
- finish annealing including homogenization heat treatment or homogenization heat treatment and finish annealing may be performed separately, but both are simply referred to as finish annealing.
- finish annealing including homogenization heat treatment or homogenization heat treatment and finish annealing may be performed separately, but both are simply referred to as finish annealing.
- the same processing may be performed by obtaining a relational expression that provides a good coating from the value of the concentration component and the value of the control item in actual manufacturing.
- control item in addition to the atmosphere switching temperature described above, any one or more of the temperature increase rate between 950 and 1100 ° C. of the final finish annealing, the homogenization heat treatment time, and the homogenization heat treatment temperature can be used.
- the control item means one or two or more items appropriately selected from the above four items.
- a generalized description of the procedure of the present invention is as follows. First, the concentration of the enriched component in the internal oxide film of the decarburization annealing is derived, for example, by monitoring or calculation for each section divided by a certain area in the width direction and the longitudinal direction of the steel sheet (this concentration Let the concentration of the component be M). Next, the effect of the final annealing control items on the properties of the undercoating with respect to the above M is evaluated. Based on these evaluation results, the relational expression f(M) between the above M and the control items that makes the properties of the undercoat good is obtained, and the allowable value ⁇ ⁇ that makes the properties of the undercoat good is obtained. .
- a plurality of setting candidate values (h 0, h 1, h 2 . . . ) are selected and placed.
- the distribution of the actual (or calculated) control items on the steel sheet given by setting each of a plurality of setting candidate values (h 0, h 1, h 2 . . . ) is determined in advance by monitoring or calculation, for example, for each section divided by a certain area in the width direction and the longitudinal direction.
- the finer the fixed area in the present invention the finer the correspondence becomes possible. be. Therefore, it is practical and desirable to set the pitch in the width direction in the range of 1 to 400 mm and the pitch in the longitudinal direction in the range of 5 to 200 mm.
- the set value (H) of the control item that maximizes the total area of the sections within the range of the allowable value ⁇ ⁇ is set to the set candidate value (h 0, h 1, h 2... ). That is, the concentrated component in the internal oxide film, which is the monitoring index [concentrated component index (M)], is as described above.
- the optimum value of the control item for the finish annealing depending on the coil position is derived as described above. Then, using the function f(M), the setting candidate values h 0, h 1, h 2 .
- a setting value (H) is set from the setting candidate values (h 0 , h 1 , h 2 .
- control items are any one or more of the heating rate between 950 and 1100 ° C. of the final finish annealing, the atmosphere switching temperature, the homogenization heat treatment time, and the homogenization treatment temperature. can be done. This is because the optimum ranges of these items tend to change depending on the quality of the decarburized annealed plate.
- f(M) between the control item and the monitoring index (concentration M) and ⁇ can be obtained in advance in a laboratory or obtained by data analysis of the results of an actual machine.
- the method of obtaining f (M) is not particularly limited, but specifically, when laboratory experimental results are used, a fluorescent X-ray spectrometer, FTIR, or the like is used to calculate the concentrated component of the decarburized annealing plate, and A regression equation can be obtained based on the results of observation of coating appearances of product sheets obtained by variously changing the finish annealing conditions to be adjusted.
- the above-mentioned product sheet may be subjected to an adhesion test conforming to JIS C2550, and a regression equation may be obtained based on the results of evaluating the film adhesion for each finish annealing condition.
- a regression equation may be obtained based on the results of evaluating the film adhesion for each finish annealing condition.
- data analysis the comparison between the concentrated component strength of the decarburized annealed sheet and the conditions of the finish annealing is used, and the above acceptance criteria for the coating acceptance rate are used to obtain the regression equation with the coating adhesion acceptance rate. you should ask for
- the same equipment as in the method of obtaining f (M) is used, and if the test result is the appearance of the coating, for example, the pass/fail judgment is based on visual inspection.
- the parameter is changed by about 20 to find the range in which the base film is good, and if the value in that range is halved, ⁇ can be asked for.
- ⁇ can be obtained by finding the range where It is also possible to set the optimum value and range using various machine learning algorithms such as SVM, random forest, principal component analysis, etc., without being limited to formulating using linear regression.
- the steel material (slab) used for the production of the grain-oriented electrical steel sheet subjected to the finish annealing whose conditions are determined using the present invention may be a conventionally known steel material used for the production of the grain-oriented electrical steel sheet.
- the specific composition of the steel material is as follows. C: 0.01 to 0.10 mass% If the C content is less than 0.01 mass%, the grain boundary strengthening effect of C is lost, and defects such as cracks in the slab occur that hinder production. On the other hand, if the C content exceeds 0.10 mass%, it becomes difficult to reduce the C content to 0.004 mass% or less at which magnetic aging does not occur in decarburization annealing. Therefore, C is preferably in the range of 0.01 to 0.10 mass%. More preferably, the lower limit is 0.02 mass% and the upper limit is 0.08 mass%.
- Si 2.5 to 4.5 mass% Si is an element necessary to increase the resistivity of steel and reduce iron loss. Such an effect is not sufficient at less than 2.5 mass%, while at more than 4.5 mass%, workability is lowered, making it difficult to roll and manufacture. Therefore, Si is preferably in the range of 2.5 to 4.5 mass%. More preferably, the lower limit is 2.8 mass% and the upper limit is 3.7 mass%.
- Mn 0.01 to 0.50 mass%
- Mn is an element necessary for improving the hot workability of steel. The above effect is not sufficient if the content is less than 0.01 mass%. On the other hand, if it exceeds 0.50 mass %, the magnetic flux density of the product sheet will decrease. Therefore, Mn is preferably in the range of 0.01 to 0.50 mass%. More preferably, the lower limit is 0.02 mass% and the upper limit is 0.20 mass%.
- Components other than C, Si and Mn differ depending on whether or not an inhibitor is used to cause secondary recrystallization.
- Al and N are respectively Al: 0.01 to 0.04 mass%, N: 0.003 It is preferably contained in the range of to 0.015 mass%.
- MnS/MnSe inhibitor in addition to the amount of Mn described above, one or two of S: 0.002 to 0.03 mass% and Se: 0.003 to 0.03 mass% preferably contains If the amount of each added is less than the above lower limit, a sufficient inhibitor effect cannot be obtained. On the other hand, if the above upper limit is exceeded, the inhibitor remains undissolved during heating of the slab, resulting in deterioration of magnetic properties.
- the AlN-based and MnS/MnSe-based inhibitors may be used in combination.
- the content of Al, N, S and Se, which are the inhibitor-forming components described above, is reduced as much as possible, and Al: less than 0.01 mass%, It is preferable to use a steel material with N: less than 0.005 mass%, S: less than 0.005 mass%, and Se: less than 0.005 mass%.
- the balance other than the above components is substantially Fe and unavoidable impurities.
- the slab which is the steel material to be used in the above manufacturing method, is obtained by melting the steel having the chemical composition suitable for the present invention described above by a conventional refining process, and then by a known ingot casting-slabbing rolling method or continuous casting method. It may be manufactured, or it may be directly cast into a thin slab with a thickness of 100 mm or less.
- the slab is heated to a predetermined temperature in accordance with a conventional method.
- a predetermined temperature For example, when an inhibitor-forming component is contained, it is heated to a temperature of about 1400° C., specifically a temperature of 1300 to 1450° C. to remove the inhibitor-forming component. After being dissolved in steel, it is hot rolled into a hot rolled sheet.
- hot rolling may be performed immediately after casting without heating.
- hot rolling may be performed, hot rolling may be skipped and the next step of hot-rolled sheet annealing may be performed, or when hot-rolled sheet annealing is not performed, cold rolling may be performed. You may proceed to the step of rolling.
- the conditions for hot rolling are not particularly limited as long as they are carried out in accordance with a conventional method.
- the hot-rolled sheet after hot rolling is subjected to hot-rolled sheet annealing as necessary.
- the soaking temperature for this hot-rolled sheet annealing is preferably in the range of 800 to 1150° C. in order to obtain good magnetic properties. If the soaking temperature is less than 800°C, the effect of hot-rolled sheet annealing is not sufficient, the band structure formed by hot rolling remains, and the primary recrystallization structure with regular grains cannot be obtained, and secondary recrystallization is not performed. Development may be inhibited. On the other hand, if the soaking temperature exceeds 1150° C., the grain size after annealing of the hot-rolled sheet becomes too coarse, and it becomes difficult to obtain a primary recrystallized structure with regular grain size.
- the hot-rolled sheet after hot-rolling or after hot-rolled sheet annealing, and the thin cast slab are cold-rolled once or cold-rolled twice or more with intermediate annealing to form a cold-rolled sheet having a final thickness. do.
- the annealing temperature of the intermediate annealing is preferably in the range of 900-1200°C. If the annealing temperature is less than 900° C., the recrystallized grains after intermediate annealing become finer, and the number of Goss nuclei in the primary recrystallized structure may decrease, resulting in deterioration of the magnetic properties of the product sheet. On the other hand, if the annealing temperature exceeds 1200° C., the crystal grains become too coarse and it becomes difficult to obtain a primary recrystallized structure with regular grains, as in hot-rolled sheet annealing.
- cold rolling to obtain the final plate thickness adopts warm rolling in which the steel plate temperature is raised to 100 to 300 ° C., or a temperature of 100 to 300 ° C. It is preferable to perform an inter-pass aging treatment in which the aging treatment is performed once or more than once. This improves the primary recrystallization texture and further improves the magnetic properties.
- the cold-rolled sheet with the final thickness is subjected to decarburization annealing that also serves as primary recrystallization annealing.
- decarburization annealing that also serves as primary recrystallization annealing.
- the heating process of the decarburization annealing it is preferable to perform rapid heating at a temperature rising rate of 50° C./s or more between 500 and 700° C. up to the soaking temperature.
- the soaking temperature for decarburization annealing is preferably 780 to 950° C.
- the soaking time is preferably 80 to 200 seconds. If the soaking temperature is lower than 780° C. or the soaking time is shorter than 80 seconds, insufficient decarburization or insufficient primary grain growth will occur.
- the soaking temperature exceeds 950° C. or the soaking time exceeds 200 seconds, the grain growth of the primary recrystallized grains proceeds excessively. More preferably, the soaking temperature is 800-930° C. and the soaking time is 90-150 seconds.
- the atmosphere during soaking in the decarburization annealing is preferably a wet hydrogen atmosphere in which the dew point is adjusted and the oxygen potential PH 2 O/PH 2 is in the range of 0.3 to 0.6.
- the PH 2 O/PH 2 ratio is less than 0.3, decarburization is insufficient, while when it exceeds 0.6, FeO tends to form on the surface of the steel sheet, degrading the coating properties. More preferably, it is in the range of 0.4 to 0.55.
- the oxygen potential PH 2 O/PH 2 of the atmosphere during heating for decarburization annealing does not need to be the same as during soaking, and may be controlled separately.
- the atmosphere during soaking does not need to be constant.
- the soaking process may be divided into two stages, and the oxygen potential PH 2 O/PH 2 in the latter stage may be a reducing atmosphere of 0.2 or less.
- the morphology of the internal oxide film formed on the surface layer of the steel sheet is improved, which is advantageous in improving the magnetic properties and film properties.
- a more preferable PH 2 O/PH 2 in the latter stage is 0.15 or less.
- the time ratio between the former stage and the latter stage is not particularly limited, but the latter stage is preferably about 25% or less of the former stage.
- a specific index [concentrated component index (M)] for the internal oxide film of the decarburized annealed sheet in the width direction and the longitudinal direction is to monitor a specific index [concentrated component index (M)] for the internal oxide film of the decarburized annealed sheet in the width direction and the longitudinal direction.
- a specific index [concentrated component index (M)] for the internal oxide film for example, the detection intensity of the elements such as O, Si, Al, Mn, and P on the surface of the steel plate by X-rays, gamma rays, infrared spectroscopy, etc. That is, the degree of enrichment (M) of the element, or the detection intensity ratio of the surface layer of the product of FeO, Fe 2 SiO 4 , and SiO 2 , that is, the degree of enrichment (M) of the product can be used.
- the analysis conditions are not particularly limited, although voltage of 10 to 60 kV and current of 1 to 30 mA are generally used, for example, when fluorescent X-ray analysis is used. In general, if the voltage is increased, information on the inside of the steel sheet can be obtained. It is also possible to use a combination of these measured values for the detection of the above elements. Alternatively, if there is already sufficient data, or if a change in strength at a specific position can be predicted from the characteristics of the apparatus, the concentration distribution may be derived by numerical simulation from the decarburization annealing temperature and atmospheric conditions.
- the above online analysis is desirably performed after decarburization annealing until the annealing separator is applied, but if the annealing separator does not contain the element to be measured, it may be performed after the application. .
- an annealing separator containing MgO as a main component is slurried, applied to the surface of the steel sheet, and then dried.
- the annealing separator contains 50 mass % or more of MgO as a main component. If the MgO content is less than 50% by mass, the main component for film formation is insufficient, and a good film cannot be obtained. Furthermore, the content of MgO is preferably 70 mass% or more.
- the total content of the above compounds is less than 50 mass%. If the content of such a compound is 50 mass % or more, the content of MgO becomes less than 50 mass %, causing poor formation of the forsterite film. More preferably, the total content of such compounds is 30 mass% or less. Also, the amount of the annealing separator to be applied to the surface of the steel sheet, hydration temperature and time may be within known ranges and are not particularly limited.
- the steel plate coated with the annealing separator is then heated and held in an annealing furnace with the steel plate coil placed on the up end (standing in the coil axial direction) to cause secondary recrystallization and then purification. Apply final annealing to process.
- finish annealing is preferably carried out by heating to a temperature of 1100° C. or higher to cause secondary recrystallization.
- the temperature range from 700 to 1100° C. should be raised at a rate of temperature increase of 2 to 50° C./h. is preferred.
- the atmosphere at 500° C. or lower is an inert atmosphere such as N 2 or Ar. Also, at any temperature between 500° C. and 1100° C., the inert atmosphere is switched to an atmosphere containing 5% or more of H 2 . If the switching temperature is less than 500°C, there is a danger of explosion, while if it exceeds 1100°C, the period during which the inert gas is introduced becomes too long and the film deteriorates.
- a forsterite coating (undercoating) is formed, and impurities contained in the steel sheet are discharged.
- Purification is performed at a temperature of 1120 to 1250 ° C. for 2 to 50 hours. Treatment is preferred. If the purification treatment temperature is less than 1120° C. or the holding time is less than 2 hours, the purification will be insufficient. On the other hand, if the temperature of the purification treatment exceeds 1250° C. or the holding time exceeds 50 hours, the coil will be buckled and deformed, resulting in a defective shape and a reduced yield. More preferably, the lower limit of the temperature of the purification treatment is 1150°C. On the other hand, the upper limit of the temperature of the purification treatment is 1230°C. More preferably, the lower limit of the holding time of the purification treatment is 3 hours. On the other hand, the upper limit of the holding time of the purification treatment is 40 hours.
- a preliminary heat treatment may be performed by holding the steel sheet at a predetermined temperature for a predetermined time, and a homogenization heat treatment may be performed to homogenize the element concentrations on the front and back surfaces of the steel sheet.
- This homogenization heat treatment is preferably carried out under the conditions of holding at a temperature of 800 to 950° C. for 5 to 200 hours. If the temperature is less than 800° C. or the time is less than 5 hours, the above effect cannot be sufficiently obtained. On the other hand, if the temperature exceeds 950° C. or the time exceeds 200 hours, the activity of MgO is lost and the film properties deteriorate.
- the homogenization heat treatment may be performed separately from the finish annealing, or may be incorporated in the first half of the finish annealing, and the homogenization heat treatment may be followed by the finish annealing.
- the conditions for the homogenization heat treatment overlap with the temperature range in which secondary recrystallization occurs.
- the step of causing recrystallization can be omitted.
- the finish annealing conditions (control items) in such finish annealing may be at least one condition selected from the above-described finish annealing conditions, such as the conditions for homogenization heat treatment, and a plurality of conditions. You can choose any condition. Further, in the present invention, even if the homogenization heat treatment is performed separately from the finish annealing, the conditions of the homogenization heat treatment are regarded as one of the conditions of the finish annealing.
- the heating rate from room temperature to the purification treatment temperature is in the range of 5 to 50° C./h on average.
- the rate of temperature rise is an average of 8° C./h or more.
- the rate of temperature increase be 30° C./h or less on average.
- the average temperature increase rate from the homogenization heat treatment temperature to the purification treatment temperature is in the range of 5 to 50 ° C./h. preferably.
- the average rate of temperature rise is more preferably 8° C./h or more.
- the average heating rate is more preferably 30° C./h or less.
- the finish annealing Since the finish annealing is carried out in a coiled state, it takes a long time for heat diffusion, and a temperature difference occurs in the coil. Such a temperature difference may be 500° C. or more in some cases. Therefore, even if the conditions for finish annealing are set based on the temperature history as described above, the temperature difference at each position (section) in the coil varies greatly depending on the position in the coil. must be understood by actual measurement or simulation. As for the simulation method, any of various proposed temperature simulation methods such as the finite difference method and the finite element method may be used. Also, in calculating such a simulation, it is desirable to attach thermocouples and other temperature measuring devices to each part of the coil to measure the temperature and take it into account in the calculation, as this will further increase the calculation accuracy.
- the monitoring result of the decarburized annealed sheet [concentrated component index (M)] and the control items of the finish annealing are matched as described above.
- control items for the matching finish annealing any one or more of the heating rate, the temperature for switching to the atmosphere containing H 2 , the homogenization heat treatment time, and the homogenization heat treatment temperature can be appropriately selected.
- the optimum conditions for finish annealing change according to the quality of the internal oxide film formed by decarburization annealing.
- the Fe oxide decomposes during the final annealing to generate oxygen, which adversely affects the film. Therefore, it is effective to lower the introduction temperature of H 2 in the annealing atmosphere to reduce the Fe oxide before the Fe oxide decomposes.
- the amount of the internal oxide film is small and the amount of the forsterite raw material is small. Therefore, it is necessary to replenish the oxygen component to the coating raw material by oxidation during the final annealing by increasing the introduction temperature of H 2 during the final annealing.
- the concentration (strength ) or the concentration (strength ratio) of either FeO or Fe 2 SiO 4 of the produced oxide increases, film formation is likely to occur, so the temperature increase rate during finish annealing, which is a control item for finish annealing, is reduced. It is effective to change conditions such as lowering the H 2 -containing atmosphere switching temperature or shortening the homogenization heat treatment time.
- the steel sheet is preferably washed with water, brushed, pickled, or the like in order to remove the unreacted annealing separating agent adhering to the surface of the steel sheet, and then flattened and annealed for shape correction.
- the finish annealing is performed in a state in which the steel sheet is wound around a coil, so that deterioration of the magnetic properties due to curling of the coil can be prevented.
- the insulating coating may be applied during the planarization annealing, or may be performed before or after the planarization annealing.
- magnetic domain refining treatment can be applied to further reduce iron loss.
- a method for refining the magnetic domains there are conventionally known methods, for example, forming grooves by etching the surface of a steel sheet that has been cold-rolled to the final thickness, or irradiating the surface of a product sheet with laser or plasma.
- a method of introducing linear or point-like thermal strain or impact strain can be used.
- a steel material (slab) is produced by melting a steel containing toxic impurities and using a continuous casting method to form a steel material (slab). After performing hot-rolled sheet annealing for 60 seconds, primary cold rolling was performed to obtain an intermediate sheet thickness of 1.8 mm. A cold-rolled sheet having a final thickness of 0.23 mm was obtained.
- the cold-rolled sheet is passed through a horizontal (horizontal) continuous annealing furnace, heated between 500 and 700° C. at a heating rate of 500° C./s, and held at 800° C. for 150 seconds.
- Decarburization annealing was performed, which also served as primary recrystallization annealing.
- the intensity ratio of Fe 2 SiO 4 , SiO 2 and FeO was measured online using an infrared spectrometer before being coiled.
- the measured value is digitized as (Fe 2 SiO 4 intensity ratio) / (sum of each intensity ratio of SiO 2 , Fe 2 SiO 4 , FeO), and this is divided into sections every 50 mm in the width direction and every 50 m in the longitudinal direction. I measured and made a map.
- an annealing separator obtained by slurrying a powder mainly composed of MgO containing 6 mass% titanium oxide and 3 mass% strontium sulfate with water is applied to the surface of the steel sheet, dried, and formed into a coil for final annealing. After winding up, finish annealing was performed. Finish annealing was carried out by heating between room temperature and 900° C. in an N 2 atmosphere at a heating rate of 10° C./h, and performing homogenization heat treatment at 900° C. for 12 to 60 hours. Subsequently, after heating between 900 to 950° C. and 950 to 1100° C.
- the temperature is heated between 1100 to 1200° C. in an H 2 atmosphere. was heated at a rate of temperature increase of 10° C./h and held at a temperature of 1200° C. for 10 hours for purification.
- the homogenization heat treatment temperature is set to 900 ° C.
- the homogenization heat treatment time is set to the above set value H for each coil based on the thermocouple installed on the hearth that is in contact with the inner winding portion of the coil. did.
- the homogenization heat treatment is uniformly performed at 900 ° C. for 10 coils, and the average value of the Fe 2 SiO 4 strength ratio of the entire steel plate is substituted into the above formula (1). : When the test was performed for 50 hours, the coating pass rate was 96.3% on the average of 10 coils.
- the slab After being made into a steel material (slab) by a continuous casting method, the slab is heated to 1260 ° C., hot-rolled to a hot-rolled plate having a thickness of 2.8 mm, and hot-rolled at 1100 ° C. for 60 seconds. After performing sheet annealing, cold rolling was performed to obtain a cold-rolled sheet having a final sheet thickness of 0.23 mm.
- the sheet is passed through a horizontal (horizontal) continuous annealing furnace, heated at a rate of 300°C/s between 500°C and 700°C during the heating process, held at 820°C for 120 seconds, and continued at 850°C.
- Decarburization annealing which also serves as primary recrystallization annealing, was performed for 30 seconds.
- the intensity (concentration) distribution of each of O, Si, Al, Mn and P was measured on-line using a fluorescent X-ray device before being wound into a coil. The measured values were measured at intervals of 50 mm in the width direction and 50 m in the longitudinal direction to create a map.
- an annealing separator obtained by slurrying a powder mainly composed of MgO containing 4 mass% titanium oxide and 2 mass% ammonium sulfate with water is applied to the surface of the steel sheet, dried, and formed into a coil for final annealing. After winding, finish annealing was performed.
- the final annealing is performed by heating between room temperature and 950°C at a heating rate of 10°C/h in an N2 atmosphere, heating between 950°C and 1100° C at various heating rates in an H2 atmosphere, and heating at 1100 to 1100°C.
- Purification treatment was performed by heating between 1200° C. in an H 2 atmosphere at a temperature increase rate of 10° C./h and maintaining the temperature at 1200° C. for 10 hours.
- the procedure for setting the heating rate between 950 and 1100 ° C. is based on the data analysis of the strength of each element [concentrated component index (M)] and the heating rate in the coil that has been performed so far.
- the optimum heating rate (optimal value) is obtained for each coil, and further, the heating rate (setting candidate values h 0, h 1, h 2 ... ).
- the difference between the optimum heating rate (optimal value) obtained from the intensity of each element and the heating rate at each position (each section of the coil) subjected to the temperature simulation is within a predetermined heating rate ( ⁇ ).
- the setting candidate value that maximizes the area is set to the setting value H.
- f(O , Si, Al, Mn, P) 8.8 x P (O) - 1.1 x P (Si) - 11 x P (Al) - 13 x P (Mn) + 6.0 x P (P) + 88 (°C/h ) (2)
- the conditions were set so that the total area of the compartments where the difference ⁇ from the (optimum value) obtained by (the optimum value) was ⁇ 4° C./h was maximized.
- the temperature rise rate was set based on the measurement with a thermocouple installed on the hearth that was in contact with the inner winding portion of the coil.
- the above equation (2) is the function f(M).
- ⁇ is set for each coil , an extremely high coating pass rate of 99.94% was obtained on the average of 10 coils.
- 10 coils were uniformly heated at a rate of 10° C./h (a value obtained by substituting the average value of each strength into the above equation (2)). In this case, the coating pass rate was 96.5% on average for 10 coils.
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Abstract
Description
また、本発明は、上記仕上げ焼鈍条件の決定方法を用いた方向性電磁鋼板の製造方法に関するものである。
しかしながら、近年における厳しい品質要求に応えるには、未だ十分とは言えない。特に、仕上げ焼鈍時のコイルの上部や下部(コイル幅方向両端部)ならびにコイルの内巻部や外巻部(コイル長手方向両端部)で発生する下地被膜特性の不良については、製品出荷の前に切り落とさざるを得ず、このために生じる歩留まり低下が、方向性電磁鋼板の製造コストの上昇を招いていた。
脱炭焼鈍板におけるO,Si,Al,Mn,Pのそれぞれの濃度あるいは酸化物生成成分のFe2SiO4、SiO2、FeOを含む内部酸化膜の濃化成分の状態(強度比)および、仕上げ焼鈍条件が、コイル内の位置によってそれぞればらついていることが歩留まり低下の原因である、
しかしながら、かかる内部酸化膜の濃化成分の状態と仕上げ焼鈍の条件について、コイル内でのばらつきを低減することは、現行の製造機器では困難である、
一方、内部酸化膜の濃化成分の状態に応じ、仕上げ焼鈍の条件を調整することで良好な下地被膜を得ることができれば、コイル内での下地被膜特性の劣化を低減することが可能である、
との知見を得た。
本発明者らは、かかる知見に基づきさらに検討を重ね、内部酸化膜の濃化成分の状態と仕上げ焼鈍の条件のコイル内ばらつきから歩留まりが最適となる制御モデルを構築し、本発明を完成させた。
1.方向性電磁鋼板用の鋼素材を熱間圧延した後、1回の冷間圧延または中間焼鈍を挟む2回以上の冷間圧延を施し、さらに、一次再結晶焼鈍を兼ねた脱炭焼鈍を施し、焼鈍分離剤を塗布してコイル状に巻き取ったのち、仕上げ焼鈍を施して下地被膜を形成し、ついで、平坦化焼鈍を施して製品板とする、方向性電磁鋼板の製造工程において、
上記仕上げ焼鈍の条件を決定するに際し、
1)前記脱炭焼鈍後の鋼板を、長手方向および幅方向に複数の区画に区分したときの該区画毎に、前記脱炭焼鈍後の鋼板における内部酸化膜中の濃化成分指標(M)の情報を得ること、
2)前記仕上げ焼鈍条件の決定に先立ち、前記濃化成分に対する、該仕上げ焼鈍の制御項目が前記下地被膜の特性へ与える影響の評価結果に基づいて、前記仕上げ焼鈍の制御項目の前記濃化成分指標(M)に対する最適関数f(M)を導出しておくこと、
3)前記仕上げ焼鈍の制御項目の設定値(H)となる複数の候補値に対する、前記区画毎の制御項目の分布についての、前記鋼板全体における情報を得ること、
4)前記区画毎の制御項目の分布が、前記f(M)に対して所定の許容値(±δ)の範囲内であるかを判別するとともに、前記許容値の範囲内となる区画の合計面積が最大となる制御項目の設定値(H)を前記複数の候補値から選択すること、
を行う方向性電磁鋼板の仕上げ焼鈍条件の決定方法。
<実験1>
C:0.06mass%、Si:3.3mass%、Mn:0.07mass%、Al:0.016mass%、S:0.003mass%を含有し、残部がFeおよび不可避的不純物からなる鋼を溶製し、連続鋳造法で鋼素材(スラブ)とした後、該スラブを1380℃に加熱し、熱間圧延して板厚2.2mmの熱延板とし、1000℃×60秒の条件の熱延板焼鈍を施した後、一次冷間圧延して中間板厚の1.8mmとし、1100℃×80秒の条件の中間焼鈍を施した後、二次冷間圧延して最終板厚0.23mmの冷延板とした。
また、本発明で言う設定値(H)とは、一例として挙げた、上記実際の雰囲気切り替え温度のような、実際に鋼板が到達した温度すなわちアウトプットの値を用いればよいが、命令温度(設定温度)のようないわゆるインプットの値および、燃料ガス量や投入電力量のような実際にコントロールされるものの値などでも良く、一つのシミュレートで統一していれば、上記のいずれの値も本発明に好適に用いることができる。
図3の結果から、コイル中巻き部の板幅中央よりやや下方の代表点寄りで温度が最も低くなっていること、最高温度と最低温度との差が200℃程度であることがわかる。
すなわち、N2からH2に雰囲気を切り替える適正な温度を、各コイル位置でのP強度から前述の1080-100×(P強度)の式を用いて算出した。また、設定候補値(h0、h1、h2)とした700、800、900℃での雰囲気切り替え温度の各時点の各コイル位置でのシミュレートされた温度を算出した。そして、上記算出されたN2からH2に切り替える適正な温度と、上記各コイル位置でのシミュレートされた温度との差Δをマッピング表示した。その結果を図4に示す。
その後、焼鈍分離剤を除去し、リン酸塩を主体とするコーティング剤を塗布して焼き付けを兼ねて平坦化焼鈍を行った。このコイルについて、表面検査装置により被膜外観を判定し、色調のムラや点状の被膜欠陥のない、均一な外観を被膜の合格とした。結果は、被膜合格率が99.7%と高い値が得られた。なお、かかる評価では絶縁被膜(ここではリン酸塩を主体とするガラス被膜)が透明であるため、かかる被膜合格率は、下地被膜の特性を評価している、と見做すことができる。
ここで、被膜合格率とは、コイルの表面積における、均一な外観を有する合格部分の割合である。例えば、評価したコイルの表面積を100,000m2として、合格となった部分の表面積が90,000m2であったとき、合格率は90.0%となる。
これに対し、本発明に従い、局所的な最適値を指向せず、被膜特性が良好な範囲をコイルに巻いた鋼板の面積(以下単にコイル面積ともいう)で最大となる範囲にする、前記制御項目(例えば上記仕上げ焼鈍の雰囲気切り替え温度)の設定値(H)の下で、仕上げ焼鈍を行うことにより、製造歩留まりを大幅に改善する効果が得られた。
また、ラボで、対象とする濃化成分と制御項目とを種々に変化させて下地被膜を評価し、該下地被膜の特性が最適となる濃化成分の量と制御項目との関係を数式化し、濃化成分の量から区画毎の適正な制御項目を決定し、かかる制御項目の設定候補値のうち区画数に対するヒストグラムから最大の区画数となる制御項目の設定候補値を選択し、この選択値を仕上げ焼鈍の制御項目の設定値(H)として採用する手順が挙げられる。なお、仕上げ焼鈍としては、均一化熱処理を含む仕上げ焼鈍または均一化熱処理と仕上げ焼鈍を別個に行う場合があるが、いずれも、単に仕上げ焼鈍とも称する。
或いは、実際の製造における濃化成分の値と制御項目の値から良好な被膜となる関係式を求めて同様の処理を行っても良い。
まず、脱炭焼鈍の内部酸化膜中の濃化成分の濃度を、鋼板の、板幅方向および長手方向で一定面積ごとに区切られた区画毎に、例えばモニタリングもしくは計算により導出する(この濃化成分の濃度をMとする)。
次いで、上記Mに対する、仕上げ焼鈍の制御項目が下地被膜の特性へ与える影響を評価する。
かかる評価結果に基づき、下地被膜の特性が良好となる、上記Mと上記制御項目との関係式f(M)を求めると共に、かかる下地被膜の特性が良好となる許容値±δを求めておく。
さらに、前述の手順と同様に、複数、設定候補値(h0、h1、h2…)を選んで置く。
また、仕上げ焼鈍にかかる制御項目について、複数の設定候補値(h0、h1、h2…)のそれぞれに設定することにより与えられる、鋼板上の実際(または計算上)の制御項目の分布を、板幅方向および長手方向で一定面積ごとに区切られた区画ごとに、例えばモニタリングもしくは計算により求めておく。
すなわち、上記したモニタリング指標[濃化成分指標(M)]である、内部酸化膜中の濃化成分は前述したとおりである。また、脱炭焼鈍後コイルのかかる濃化成分の濃度のモニタリングと合わせて、仕上げ焼鈍にかかる制御項目のコイル位置による最適値を前述の通り導出する。
次いで、前記関数f(M)と、前記設定候補値h0、h1、h2…と、前記許容範囲±δとを用い、前述した手法で、|f(M)-h0|≦δとなる区画の合計面積がコイル全面で最大となるよう、制御項目の設定候補値(h0、h1、h2…)の中より設定値(H)を設定する。
かかる制御項目は、前述の通り、最終仕上げ焼鈍の950~1100℃間の昇温速度、雰囲気切り替え温度、均一化熱処理時間および均一化処理温度のうちいずれか1種または2種以上を使用することができる。なぜなら、これらの項目は、特に脱炭焼鈍版の品質により最適範囲が変わりやすいためである。
f(M)の求め方は特に限定されないが、具体的には、ラボの実験結果を用いる場合は、蛍光X線分析装置やFTIR等を用い、脱炭焼鈍板の濃化成分を算出するとともに、調整したい仕上げ焼鈍の条件を種々に変更して得た製品板の被膜外観を観察した結果に基づいて、回帰式を求めれば良い。もしくは、上記製品板にJIS C2550に準拠した密着性試験を行って仕上げ焼鈍の条件毎に被膜密着性を評価した結果に基づいて、回帰式を求めれば良い。他方、データ解析を用いる場合は、脱炭焼鈍板の濃化成分強度と仕上げ焼鈍の条件との比較を用い、上記した被膜合格率の合格基準を用いて、被膜密着性合格率との回帰式を求めれば良い。
本発明を用いて条件が決定される仕上げ焼鈍を行う方向性電磁鋼板の製造に供する、鋼素材(スラブ)は、従来公知の方向性電磁鋼板の製造に用いる鋼素材でよい。この鋼素材の成分組成を具体的に説明すると、以下のとおりである。
C:0.01~0.10mass%
Cは、0.01mass%に満たないと、Cによる粒界強化効果が失われ、スラブに割れが生じるなど、製造に支障を来たす欠陥を生ずるようになる。一方、Cが0.10mass%を超えると、脱炭焼鈍で磁気時効を起こさない0.004mass%以下に低減することが困難となる。よって、Cは0.01~0.10mass%の範囲とするのが好ましい。より好ましくは、下限が0.02mass%であり、上限は0.08mass%である。
Siは、鋼の比抵抗を高め、鉄損を低減するのに必要な元素である。かかる効果は、2.5mass%未満では十分ではない一方で、4.5mass%を超えると、加工性が低下し、圧延して製造すること困難となる。よって、Siは2.5~4.5mass%の範囲とするのが好ましい。より好ましくは、下限が2.8mass%であり、上限が3.7mass%である。
Mnは、鋼の熱間加工性を改善するために必要な元素である。上記効果は、0.01mass%未満では十分ではない。一方、0.50mass%を超えると、製品板の磁束密度が低下するようになる。よって、Mnは0.01~0.50mass%の範囲とするのが好ましい。より好ましくは、下限が0.02mass%であり、上限が0.20mass%である。
まず、二次再結晶を生じさせるためにインヒビターを利用する場合で、例えば、AlN系インヒビターを利用するときは、AlおよびNをそれぞれAl:0.01~0.04mass%、N:0.003~0.015mass%の範囲で含有するのが好ましい。また、MnS・MnSe系インヒビターを利用するときは、前述した量のMnに加え、S:0.002~0.03mass%およびSe:0.003~0.03mass%のうちの1種または2種を含有するのが好ましい。それぞれ添加量が、上記下限値より少ないと、インヒビター効果が十分に得られない。一方、上記上限値を超えると、インヒビターがスラブ加熱時に未固溶で残存し、磁気特性の低下をもたらす。なお、AlN系とMnS・MnSe系のインヒビターは、併用してもよい。
上記製造方法に供する鋼素材となるスラブは、上述した本発明に適合する成分組成を有する鋼を常法の精錬プロセスで溶製した後、公知の造塊-分塊圧延法または連続鋳造法で製造してもよく、また、直接鋳造法で直接、100mm以下の厚さの薄スラブとしてもよい。
なお、上記のオンライン分析は、鋼板の表裏両面をコイル全長、全幅にわたって行うことが望ましいが、過去のデータや設備上の特徴からあらかじめ特定の部位の差(例えば鋼板表裏差など)がどの程度生じることがわかっている場合は、それを除いた部位の分析(例えば表(オモテ)面のみ)でもよい。
なお、本発明において、かかる仕上げ焼鈍における仕上げ焼鈍の条件(制御項目)とは、均一化熱処理の条件など、上述した仕上げ焼鈍の条件のうちから選んだ少なくとも1つの条件であればよく、複数の条件を選んでも良い。また、本発明において、均一化熱処理を仕上げ焼鈍と別個に行う場合であっても、均一化熱処理の条件は仕上げ焼鈍の条件の一つとみなす。
したがって、上記のような温度履歴で仕上げ焼鈍の条件を設定していたとしても、コイル内の位置により温度差は大きく異なるので、本発明ではコイル内の各位置(区画)における温度(設定値)を実測やシミュレーションにより把握する必要がある。
なお、シミュレーション手法については、有限差分法、有限要素法など各種提案されている温度シミュレーション手法のいずれの方法を用いてもよい。また、かかるシミュレーションの計算にあたって、コイル各部位に熱電対他温度測定装置を取り付けて測温し計算に加味することは計算精度がさらに高まり望ましい。
なお、方向性電磁鋼板の製品板を積層して使用する場合には、鋼板表面に絶縁被膜を有するものであることが好ましく、特に鉄損特性を重視するときは、絶縁被膜として鋼板に張力を付与する張力付与被膜を適用するのが好ましい。この絶縁被膜の被成は、上記平坦化焼鈍において行ってもよく、あるいは、平坦化焼鈍の前もしくは後の工程で行ってもよい。
100-150×(Fe2SiO4強度比)〔h〕・・・(1)
これを踏まえ、コイル内の温度シミュレートから均一化熱処理終了時点での各コイル位置(コイルの各区画)での均一化熱処理時間の設定候補値(h0、h1、h2…)を選定し、かかる設定候補値h0、h1、h2…から上記式(1)から得られる(最適値)との差±δが±20時間以内となる区画の合計面積が最大となる条件を設定値Hとして、均一化熱処理温度を900℃とした上で、均一化熱処理時間をコイル中巻き部と接する炉床に設置された熱電対を基準に、コイルごとに上記した設定値Hに設定した。
以上のコイルの製造を10回行うに当たり、コイル毎に上記手順に従って設定値Hを設定して均一化熱処理を施した。かくして得られた10コイルについて、表面検査装置により被膜外観を目視判定した。なお、合否判定は、前記実験1の基準に従った。
具体的には、O,Si,Al,Mn,Pのピーク強度をそれぞれP(O), P(Si), P(Al), P(Mn), P(P)としたときに
f(O,Si,Al,Mn,P)= 8.8×P(O)-1.1×P(Si)-11×P(Al)-13×P(Mn)+6.0×P(P)+88(℃/h)・・・(2)
で求められる(最適値)との差±δが±4℃/hとなる区画の合計面積が最大となる条件に設定した。また、昇温速度は、コイル中巻き部と接する炉床に設置された熱電対での測定を基準として設定した。上式(2)が関数f(M)である。
その後、鋼板に残った焼鈍分離剤を除去してからコーティング剤を塗布し、さらに焼き付けを兼ねて平坦化焼鈍を行って、鋼板表面に絶縁被膜(リン酸塩を主体とするガラス被膜)を形成した。
以上のコイルの製造を10回行うに当たり、コイル毎に上記手順に従って設定値Hを設定して950~1100℃間の昇温を行った。かくして得られた10コイルについて、表面検査装置により被膜外観を目視判定した。なお、合否判定は、前記実験1の基準に従った。
Claims (4)
- 方向性電磁鋼板用の鋼素材を熱間圧延した後、1回の冷間圧延または中間焼鈍を挟む2回以上の冷間圧延を施し、さらに、一次再結晶焼鈍を兼ねた脱炭焼鈍を施し、焼鈍分離剤を塗布してコイル状に巻き取ったのち、仕上げ焼鈍を施して下地被膜を形成し、ついで、平坦化焼鈍を施して製品板とする、方向性電磁鋼板の製造工程において、
上記仕上げ焼鈍の条件を決定するに際し、
1)前記脱炭焼鈍後の鋼板を、長手方向および幅方向に複数の区画に区分したときの該区画毎に、前記脱炭焼鈍後の鋼板における内部酸化膜中の濃化成分指標(M)の情報を得ること、
2)前記仕上げ焼鈍条件の決定に先立ち、前記濃化成分に対する、該仕上げ焼鈍の制御項目が前記下地被膜の特性へ与える影響の評価結果に基づいて、前記仕上げ焼鈍の制御項目の前記濃化成分指標(M)に対する最適関数f(M)を導出しておくこと、
3)前記仕上げ焼鈍の制御項目の設定値(H)となる複数の候補値に対する、前記区画毎の制御項目の分布についての、前記鋼板全体における情報を得ること、
4)前記区画毎の制御項目の分布が、前記f(M)に対して所定の許容値(±δ)の範囲内であるかを判別するとともに、前記許容値の範囲内となる区画の合計面積が最大となる制御項目の設定値(H)を前記複数の候補値から選択すること、
を行う方向性電磁鋼板の仕上げ焼鈍条件の決定方法。 - 前記濃化成分指標(M)を、鋼板表面のO濃度、Si濃度、Al濃度、Mn濃度、P濃度、Fe2SiO4強度比、SiO2強度比およびFeO強度比のうちのいずれか1種または2種以上とする請求項1に記載の方向性電磁鋼板の仕上げ焼鈍条件の決定方法。
- 前記仕上げ焼鈍の制御項目を、最終仕上げ焼鈍の950~1100℃間の昇温速度、雰囲気切り替え温度、均一化熱処理時間および均一化熱処理温度のいずれか1種または2種以上とする請求項1または2に記載の方向性電磁鋼板の仕上げ焼鈍条件の決定方法。
- 請求項1から3のいずれか1項に記載の仕上焼鈍条件の決定方法を用いることを特徴とする方向性電磁鋼板の製造方法。
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