Title of Invention

IMPROVED METHOD FOR PRODUCTION OF NON-ORIENTED ELECTRICAL STEEL STRIP

Abstract This invention discloses a method for producing a non-oriented electrical steel comprising the steps of: (a) preparing a non-oriented electrical steel melt having a composition in weight % comprising: up to 6.5% silicon, up to 5% chromium, up to 0.05% carbon, up to 3% aluminum. up to 3% manganese, and the balance being substantially iron and residuals; (b) casting a steel slab from said steel melt; (c) heating said steel slab to a temperature less than Tmax and greater than Tmin as defined by: Tmin, °C = 921 - 5998(%C) - 106(%Mn) + 135(%P) + 78.5(%Si) + 107(%AI) - 11.9(%Cr) + 896(%N) + 8.33(%Cu) - 146(%Ni) + 173(%Mo) Tmax. °C = 1479 + 3480(%C) + 158(%Mn) - 347(%P) - 121(%Si) - 275(%A1) + 1.42(%Cr) - 195(%N) + 44.7(%Cu) + 140(%Ni) - 132(%Mo) (d) hot rolling said slab to a hot rolled strip wherein said hot rolling provides a nominal strain of at least 700 using the equation: wherein, "n" equals the roll rotational rate in revolutions per second, "D" equals the work roll diameter in millimeters, "t" equals the initial thickness of the cast strip in millimeters, "tf" equals the final thickness of the cast and hot rolled strip in millimeters; and, (e) finish annealing said strip at a temperature less than T as defined by: T, °C = 759 - 4430(%C) - 194(%Mn) + 445(%P) + 181(%Si) + 378(%A1) - 29.0(%Cr) - 48.8(%N) - 68.1(%Cu) - 235(%Ni) + 116(%Mo).
Full Text IMPROVED METHOD FOR PRODUCTION OF
NON-ORIENTED ELECTRICAL STEEL STRIP
CROSS-REFERENCE TO RELATED APPLICATION
This present invention is related to and claims priority from U.S.
Provisional Application No. 60/378,743, Schoen et al., filed May 8,
2002.
BACKGROUND OF THE INVENTION
Non-oriented electrical steels are widely used as the magnetic core
material in a variety of electrical machinery and devices, particularly in
motors where low core loss and high magnetic permeability in all
directions of the sheet are desired. The present invention relates to a
method for producing a non-oriented electrical steel with low core loss
and high magnetic permeability whereby a steel melt is solidified as an
ingot or continuously slab and subjected to hot rolling and cold rolling
to provide a finished strip. The finished strip is provided with at least
one annealing treatment wherein the magnetic properties develop,
making the steel sheet of the present invention suitable for use in
electrical machinery such as motors or transformers.
Commercially available non-oriented electrical steels are typically
broken into two classifications: cold rolled motor lamination steels ,
("CRML") and cold rolled non-oriented electrical steels ("CRNO").
CRML is generally used in applications where the requirement for very
low core losses is difficult to justify economically. Such applications
typically require that the non-oriented electrical steel have a maximum
core loss of about 4 watts/pound (about 9 w/kg) and a minimum
magnetic permeability of about 1500 G/Oe (Gauss/Oersted) measured
at 1.5T and 60 Hz. In such applications, the steel sheet used is typically
processed to a nominal, thickness of about 0.018 inch (about 0.45 mm)
to about 0.030 inch (about 0.76 mm). CRNO is generally used in more
demanding applications where better magnetic properties are required.
Such applications typically require that the non-oriented electrical steel
have a maximum core loss of about 2 watts/pound (about 4.4 w/kg) and a
minimum magnetic permeability of about 2000 G/Oe measured at 1.5T
and 60 Hz. In such applications, the steel sheet is typically processed to a
nominal thickness of about 0.006 inch (about 0.15 mm) to about 0.025
inch (about 0.63 mm).
Non-oriented electrical steels are generally provided in two forms,
commonly referred to as "semi-processed" or "fully-processed" steels.
"Semi-processed" infers that the product must be annealed before use to
develop the proper grain size and texture, relieve fabrication stresses and,
if needed, provide appropriately low carbon levels to avoid aging. "Fully-
processed" infers that the magnetic properties have been fully developed
prior to the fabrication of the sheet into laminations, that is, the grain size
and texture have been established and the carbon content has been reduced
to about 0.003 weight % or less to prevent magnetic aging. These grades
do not require annealing after fabrication into laminations unless so
desired to relieve fabrication stresses. Non-oriented electrical steels arc
predominantly used in rotating devices, such as motors or generators,
where uniform magnetic properties are desired in all directions with
respect to the sheet rolling direction.
The magnetic properties of non-oriented electrical steels can be affected
by thickness, volume resistivity, grain size, chemical purity and
crystallographic texture of the finished sheet. The core loss caused by
eddy currents can be made lower by reducing the thickness of the finished
steel sheet, increasing the alloy content of the steel sheet to increase the
volume resistivity or both in combination.
In the established methods used to manufacture non-oriented electrical
steels, typical but. non-limiting alloy additions of silicon, aluminum.
manganese and phosphorus are employed. Non-oriented electrical
steels may contain up to about 6.5 weight % silicon, up to about
3 weight % aluminum, carbon up to about 0.05 weight % (which must
be reduced to below about 0.003 weight % during processing to
prevent magnetic aging), up to about 0.01 weight % nitrogen, up to
0.01 weight % sulfur and balance iron with other impurities incidental
to the method of steelmaking.
Achieving a suitably large grain size after finish annealing is desired
for optimum magnetic properties. The purity of the finish annealed
sheet can have a significant effect on the magnetic properties since
presence of a dispersed phase, inclusions and/or precipitates may
inhibit normal grain growth and prevent achieving the desired grain
size and texture and, thereby, the desired core loss and magnetic
permeability, in the final product form. Also, inclusions and/or
precipitates during finish annealing hinder domain wall motion during
AC magnetization, further degrading the magnetic properties in the
final product form. As noted above, the crystallographic texture of the
finished sheet, that is, the distribution of the orientations of the crystal
grains comprising the electrical steel sheet, is very important in
determining the core loss and magnetic permeability in the final
product form. The and texture components as defined by
Millers indices have higher magnetic permeability; conversely, the
type texture components have lower magnetic permeability.
Non-oriented electrical steels are differentiated by proportions of
additions such as silicon, aluminum and like elements. Such alloying
additions serve to increase volume resistivity, providing suppression of
eddy currents' during AC magnetization, and thereby lowering core
loss. These additions also improve the punching characteristics of the
steel by increasing the hardness. The effect of alloying additions on
volume resistivity of iron is shown in Equation I:
where p is the volume resistivity, in µ-O, of the steel and %Mn,
%Si, %A1, %Cr and %P are, respectively, the weight percentages of
manganese, silicon, aluminum, chromium and phosphorus in the steel.
Steels containing less than about 0.5 weight % silicon and other
additions to provide a volume resistivity of up to about 20 µO-cm can
be generally classified as motor lamination steels; steels containing
about 0.5 to 1.5 weight % silicon or other additions to provide a
volume resistivity of from about 20 µO-cm to about 30 µO-cm can be
generally classified low-silicon steels; steels containing about 1.5 to
3.0 weight % silicon or other additions to provide a volume resistivity
of from about 30 µO-cm to about 45 µO-cm can be generally
classified as intermediate-silicon steels; and, lastly, steels containing
more than about 3.0 weight % silicon or other additions to provide a
volume resistivity greater than about 45 µO-cm can be generally
classified as high-silicon steels.
Silicon and aluminum additions have detrimental effects on steels.
Large silicon additions are well known to make steel more brittle,
particularly at silicon levels greater than about 2.5%, and more
temperature sensitive, that is, the ductile-to-brittle transition
temperature may increase. Silicon may also react with nitrogen to form
silicon nitride inclusions that may degrade the physical properties and
cause magnetic "aging" of the non-oriented electrical steel. Properly
employed, aluminum additions may minimize the effect of nitrogen on
the physical and magnetic quality of the non-oriented electrical steel as
aluminum reacts with nitrogen to form aluminum nitride inclusions
during the cooling after casting and/or heating prior to hot rolling.
However, aluminum additions can impact steel melting and casting
from more aggressive wear of refractory materials and, in particular,
clogging of refractory components used to feed the liquid steel during slab
casting. Aluminum can also affect surface quality of the hot rolled strip by
making removal of the oxide scale prior to cold rolling more difficult.
Alloying additions to iron such as silicon, aluminum and the like also
affect the amount of austenite as shown in Equation II:

where ?1150oC is percentage of austenite formed at 1150°C (2100°F) and
%Si, %A1, %Cr, %Mn, %P, %Cr, %Ni, %C and %N are, respectively, the
weight percentages of silicon, aluminum, manganese, phosphorus,
chromium, nickel, copper, carbon and nitrogen in the steel. Typically,
alloys containing in excess of about 2.5% Si are fully ferritic, that is, no
phase transformation from the body-center-cubic ferrite phase to the face-
centered-cubic austenite phase occurs during heating or cooling. It is
commonly known that the manufacture of fully ferritic electrical steels
using thin or thick slab casting is complicated because of a tendency for
"ridging". Ridging is a defect resulting from localized non-uniformities in
the metallurgical structure of the hot rolled steel sheet.
The methods for the production of non-oriented electrical steels discussed
above are well established. These methods are typically involve preparing
a steel melt having the desired composition; casting the steel melt into an
ingot or slab having a thickness from about 2 inches (about 50 mm) to
about 20 inches (about 500 mm); heating the ingot or slab to a temperature
typically greater than about 1900°F (about 1040°C); and, hot rolling to a
sheet thickness of about 0.040 inch (about 1 mm) or more. The hot rolled
sheet is subsequently processed by a variety of routings which may
include pickling or, optionally, hot band annealing prior to or after
pickling; cold rolling in one or more
steps to the desired product thickness; and, finish annealing, sometimes
followed by a temper rolling, to develop the desired magnetic properties.
In the most common exemplary method for the production of a non-
oriented electrical steel, a slab having a thickness of more than about 4
inches (about 100 mm) and less than about 15 inches (about 370 mm) is
continuously cast; reheated to an elevated temperature prior to a hot
roughing step wherein the slab is converted into a transfer bar having a
thickness of more than 0.4 inch (about 10 mm) and less than about 3
inches (about 75 mm); and hot rolled to produce a strip having a thickness
of more than about 0.04 inch (about 1 mm) and less than about 0.4 inch
(about 10 mm) suitable for further processing. As noted above, thick slab
casting methods afford the opportunity for multiple hot reduction steps
that, if properly employed, can be used to provide a uniform hot rolled
metallurgical microstructure needed to avoid the occurrence of a defect
commonly known in the art as "ridging". However, the necessary practices
are often incompatible with or undesirable for operation of the mill
equipment.
In recent years, technological advances in thin slab casting have been
made. In an example of this method, a non-oriented electrical steel is
produced from a cast slab having a thickness of more than about 1 inch
(about 25 mm) and less than about 4 inches (about 100 mm) which is
immediately heated prior to hot rolling to produce a strip having a
thickness of more than about 0.04 inch (about 1 mm) and less than about
0.4 inch (about 10 mm) suitable for further processing. However, while
production of motor lamination grades of non-oriented electrical steels has
been realized, the production of fully ferritic non-oriented electrical steels
having the very highest magnetic and physical quality has met with only
limited success because of "ridging" problems. In part, thin slab casting is
more constrained because of the amount of and flexibility in hot reduction
from the as-cast slab to finished hot
rolled strip is more limited than when thick slab casting methods are
employed.
For the above mentioned reasons, there has been a long felt need to
develop a means to produce even the very highest grades of non-oriented
electrical steels using methods which are more compatible with the
capabilities afforded by thick and thin slab casting and which are less
costly to manufacture.
DESCRIPTION OF THE FIGURES
Figure 1. A schematic drawing of the austenite phase field as a function
of temperature showing the critical Tmin and Tmax temperatures.
Figure 2. Photographs of the microstructure of Heat A after the cast slabs
are heated and hot rolled using the reductions shown.
Figure 3. Photographs of the microstructure of Heat A after the cast slabs
are heated and hot rolled using the reductions shown.
Figure 4. A plot of the calculated amount of austenite at various
temperatures characterizing the austenite phase fields of Heats C, D, E.
and F from Table 1.
SUMMARY OF THE INVENTION
The principle object of the present invention is the disclosure of an
improved composition for the production of non-oriented electrical steel
with excellent physical and magnetic characteristics from a continuously
cast slab.
The above and other important objects of the present invention are
achieved by a steel having a composition in which the silicon, aluminum,
chromium, manganese and carbon contents are as follows:
i. SiliconT up to about 6.5%
ii. Aluminum: up to about 3%
iii. Chromium: up to about 5%
iv. Manganese: up to about 3%
v. Carbon: up to about 0.05%;
In addition, the steel may have antimony in an amount, up to about
0.15%; niobium in an amount up to about 0.005%; nitrogen in an
amount up to about 0.01%; phosphorus in an amount up to about
0.25%; sulfur and/or selenium in an amount up to about 0.01%; tin in
an amount up to about 0.15%; titanium in an amount up to about
0.01%; and vanadium in an amount up to about 0.01% with the balance
being iron and residuals incidental to the method of steel making.
In a preferred composition, these elements are present in the following
amounts:
i. Silicon: about 1 % to about 3.5%;
ii. Aluminum: up to about 1%;
iii. Chromium: about 0.1% to about 3%;
iv. Manganese: about 0.1% to about 1%;
v. Carbon: up to about 0.01%;
vi. Sulfur: up to about 0.01 %;
vii. Selenium: up to about 0.01%; and
viii. Nitrogen: up to about 0.005%;
In a more preferred composition, these elements are present in the
following amounts:
i. Silicon: about 1.5% to about 3%;
ii. Aluminum: up to about 0.5%;
iii. Chromium: about 0.15% to about 2%;
iv. Manganese: about 0.1 % to about 0.35%;
v. Carbon: up to about 0.005%;
vi. Sulfur: up to about 0.005%;
vii. Selenium: up to about 0.007%; and
viii. Nitrogen: up to about 0.002%.
In one embodiment, the present invention provides a method, to
produce a non-oriented electrical steel from a steel melt containing
silicon and other alloying additions or impurities incidental to the
method of steelmaking which is subsequently cast into a slab having a
thickness of from about 0.8 inch (about 20 mm) to about 15 inches
(about 375 mm), reheated to an elevated temperature and hot rolled
into a strip of a thickness of from about 0.014 inch (about 0.35 mm) to
about 0.06 inch (about 1.5 mm). The non-oriented electrical steel of
this method can be used after a finish annealing treatment is provided
to develop the desired magnetic characteristics for use in a motor,
transformer or like device.
In a second embodiment, the present invention provides a method
whereby a non-oriented electrical steel is produced from a steel melt
containing silicon and other alloying additions or impurities incidental
to the method of steelmaking which is cast into a slab having a
thickness of from about 0.8 inch (about 20 mm) to about 15 inches
(about 375 mm), reheated and hot rolled into a strip of a thickness of
from about 0.04 inch (about 1 mm) to about 0.4 inch (about 10 mm)
which is subsequently cooled, pickled, cold rolled and finish annealed
to develop the desired magnetic characteristics for use in a motor,
transformer or like device. In an optional form of this embodiment, the
hot rolled strip may be annealed prior to being cold rolled and finished
annealed.
In the practice of the above embodiments, a steel melt containing silicon,
chromium, manganese and like additions is prepared whereby the
composition provides a volume resistivity of at least 20 µO-cm as defined
using Equation I and a peak austenite fraction, ?1150°C, is greater than 0
wt% as defined using Equation II. In the preferred, more preferred, and
most preferred practice of the present invention, ?1150°C is at least 5%,
10% and at least 20%, respectively.
In the practice of the above embodiments, the cast or thin slabs may not be
heated to a temperature exceeding Tmax 0% as defined in Equation IIIa
prior to hot rolling into strip. Tmax 0% is the high temperature boundary of
the austenite phase field at which 100% ferrite is present in the alloy and
below which a small percentage of austenite is present in the alloy. This is
illustrated in Figure 1. By so limiting the heating temperature, the
abnormal grain growth caused by re-transformation of the austenite to
ferrite during slab reheating is avoided. In the preferred practice of the
above embodiments, the cast or thin slabs may not be heated to a
temperature of exceeding Tmax 5% as defined in Equation IIIb prior to hot
rolling into strip. Similarly, Tmax 5% is the temperature at which 95%
ferrite and 5% austenite is present in the alloy, just below the high
temperature austenite phase field boundary. In the more preferred practice,
the cast or thin slabs may not be heated to a temperature of exceeding Tmax
10%. In the most preferred practice of the above embodiments, the cast or
thin slabs may not be heated to a temperature of exceeding Tmax 20% as
defined in Equation IIIc prior to hot rolling into strip. Tmax 10% and Tmax
20% are the temperatures at which 10% and 20% austenite [is] are present
in the alloy, respectively, at a temperature exceeding the peak austenite
weight percent. Tmax 5%, Tmax 10%, and Tmax 20% are also illustrated in
Figure 1.
(IIIa) Tmax 0%, °C = 1463 + 3401 (%C) + 147(%Mn) - 378(%P) -
109(%Si) - 248(%A1) - 0.79(%Cr) - 78.8(%N) + 28.9(%Cu) + 143(%Ni) -
22.7(%Mo)
(IIIb) Tmax 5%, °C = 1479 + 3480(%C) + 158(%Mn) - 347(%P) -
121(%Si) - 275(%A1) + 1.42(%Cr) - 195(%N) + 44.7(%Cu) + 140(%Ni) -
132(%Mo)
(IIIc) Tmax 20%, °C = 1633 + 3970(%C) + 236(%Mn) - 685(%P) -
207(%Si) - 455(%A1) + 9.64(%Cr) - 706(%N) + 55.8(%Cu) + 247(%Ni) -
156(%Mo)
The cast and reheated slab must be hot rolled such that at least one
reduction pass is performed at a temperature where the metallurgical
structure of the steel is comprised of austenite. The practice of the above
embodiments includes a hot reduction pass at a temperature which is
greater than about Tmin 0% illustrated in Figure 1 and a maximum
temperature less than about Tmax 0% as defined in Equation IIIa, illustrated
in Figure 1. The preferred practice of the above embodiments includes a
hot reduction pass at a temperature which is greater than about Tmax 5% of
Equation I Va and a maximum temperature less than about Tmax 5% as
defined in Equation IIIb. The more preferred practice of the above
embodiments includes a hot reduction pass at a temperature which is
greater than about Tmin 10% and a maximum temperature less than about
Tmax 10%, illustrated in Figure 1. The most preferred practice of the above
embodiments includes a hot reduction pass at a temperature which is
greater than about Tmin 20% of Equation IVb and a maximum temperature
less than about Tmax 20% as defined in Equation IIIc.
(IVa) Tmin 5%, °C = 921 - 5998(%C) - 106(%Mn) + 135(%P) +
78.5(%Si) + 107(%A1) - 11.9(%Cr) + 896(%N) + 8.33(%Cu) - 146(%Ni)
+ 173(%Mo)
(IVb) Tmin 20%, °C = 759 - 4430(%C) - 194(%Mn) + 445(%P) +
181(%Si) + 378(%A1) - 29.0(%Cr) - 48.8(%N) - 68.1(%Cu) - 235(%Ni) -
116(%Mo)
The practice of the above embodiments includes at least one hot reduction
pass to provide a nominal strain (enominal) after hot rolling of at least 700
calculated using Equation V as:

The practice of the above embodiments may include an annealing step
prior to cold rolling which annealing step is conducted at a temperature
which is less than Tmin 20% of Equation IVb. The preferred practice of the
above embodiments may include an annealing step prior to cold rolling
which annealing step is conducted at a temperature which is less than Tmin
10%. The more preferred practice of the above embodiments may include
an annealing step prior to cold rolling which annealing step is conducted a
temperature which is less than Tmin 5% of Equation IVa. The most
preferred practice of the above embodiments may include an annealing
step prior to cold rolling which annealing step is conducted at a
temperature which is less than Tmin 0%.
The practice of the above embodiments must include a finishing anneal
wherein the magnetic properties of the strip are developed which
annealing step is conducted at a temperature which is less than Tmin 20%
(Equation IVb). The preferred practice of the above embodiments must
include a finishing anneal wherein the magnetic properties of the strip are
developed which annealing step is conducted at a temperature which is
less than Tmin 10% (illustrated in Figure 1). The more preferred practice of
the above embodiments must include a finishing anneal wherein the
magnetic properties of the strip are developed which annealing step is
conducted at a temperature which is less than Tmin 5%
(Equation IVa). The most preferred practice of the above embodiments
must include a finishing anneal wherein the magnetic properties of the
strip are developed which annealing step is conducted a temperature
which is less than Tmin 0% (illustrated in Figure 1).
Unless otherwise defined, all technical and scientific terms used herein
have the same meaning as commonly understood by one of ordinary
skill in the art. Although methods and materials similar or equivalent to
those described herein can be used in the practice or testing of the
present invention, suitable methods and materials are described below.
All publications, patent applications, patents, and other references
mentioned herein are incorporated by reference in their entirety. In the
case of conflict, the present specification, including definitions, will
control. In addition, the materials, methods, and examples are
illustrative only and not intended to be limiting. Other features and
advantages of the invention will be apparent from the following
detailed description and claims.
DETAILED DESCRIPTION OF THE INVENTION
In order to provide a clear and consistent understanding of the
specification and claims, including the scope to be given such terms,
the following definitions are provided.
The terms "ferrite" and "austenite" are used to describe the specific
crystalline forms of steel. "Ferrite" or "ferritic steel" has a body-
centered-cubic, or "bcc", crystalline form whereas "austenite" or
"austenitic steel" has a face-centered cubic, or "fee", crystalline form.
The term "fully ferritic steel" is used to describe steels that do not
undergo any phase transformation between the ferrite and austenite
crystal phase forms in the course of cooling from the melt and/or in
reheating for hot rolling, regardless of its final room temperature
microstructure.
The terms "strip" and "sheet" are used to describe the physical
characteristics of the steel in the specification and claims being
comprised of a steel being of a thickness of less than about 0.4 inch
(about 10 mm) and of a width typically in excess of about 10 inches
(about 250 mm) and more typically in excess of about 40 inches (about
1000 mm). The term "strip" has no width limitation but has a
substantially greater width than thickness.
In the practice of the present invention, a steel melt containing alloying
additions of silicon, chromium, manganese, aluminum and phosphorus
is employed.
To begin to make the electrical steels of the present invention, a steel
melt may be produced using the generally established methods of steel
melting, refining and alloying. The melt composition comprises
generally up to about 6.5% silicon, up to about 3% aluminum., up to
about 5% chromium, up to about 3% manganese, up to about 0.01%
nitrogen, and up to about 0.05% carbon with the balance being
essentially iron and residual elements incidental to the method of
steelmaking. A preferred composition comprises from about 1% to
about 3.5% silicon, up to about 1% aluminum, about 0.1% to about 3%
chromium, about 0.1% to about 1% manganese, up to about 0.01%
sulfur and/or selenium, up to about 0.005% nitrogen and up to about
0.01% carbon. In addition, the preferred steel may have residual
amounts of elements, such as titanium, niobium and/or vanadium, in
amounts not to exceed about 0.005%. A more preferred steel comprises
about 1.5% to about 3% silicon, up to about 0.5% aluminum, about
0.15% to about 2% chromium, up to about 0.005% carbon, up to about
0.008% sulfur or selenium, up to about 0.002% nitrogen, about 0.1% to
about 0.35% manganese and the balance iron with normally occurring
residuals. The steel may also include other elements such as antimony,
arsenic, bismuth, phosphorus and/or tin in amounts up to about 0.15%.
The steel may also include copper, molybdenum and/or nickel in
amounts up to about 1% individually or in combination. Other elements
may be present either as deliberate additions or present as residual
elements, i.e., impurities, from steel melting process. Exemplary methods
for preparing the steel melt include oxygen, electric arc (EAF) or vacuum
induction melting (VIM). Exemplary methods for further refining and/or
making alloy additions to the steel melt may include a ladle metallurgy
furnace (LMF), vacuum oxygen decarburization (VOD) vessel and/or
argon oxygen decarburization (AOD) reactor.
Silicon is present in the steels of the present invention in an amount of
about 0.5% to about 6.5% and, preferably, about 1% to about 3.5% and,
more preferably, about 1.5% to about 3%. Silicon additions serve to
increase volume resistivity, stabilize the ferrite phase and increase
hardness for improved punching characteristics in the finished strip;
however, at levels above about 2.5%, silicon is known that make the steel
more brittle.
Chromium is present in the steels of the present invention in an amount of
up to about 5% and, preferably, about 0.1% to about 3% and, more
preferably, about 0.15% to about 2%. Chromium additions serve to
increase volume resistivity; however, its effect must be considered in
order to maintain the desired phase balance and microstructural
characteristics.
Manganese is present in the steels of the present invention in an amount of
up to about 3% and, preferably, about 0.1% to about 1% and, more
preferably, about 0.1% to about 0.35%. Manganese additions serve to
increase volume resistivity; however, manganese is known in the art to
slow the rate of grain growth during the finishing anneal. Because of this,
the usefulness of large additions of manganese must be considered
carefully both with respect to the desired phase balance and microstructure
characteristics in the finished product.
Aluminum is present in the steels of the present invention in an amount
of up to about 3% and, preferably, up to about 1% and, more
preferably, up to about 0.5%. Aluminum additions serve to increase
volume resistivity, stabilize the ferrite phase and increase hardness for
improved punching characteristics in the finished strip. However, the
usefulness of large additions of aluminum must be considered carefully
as aluminum may accelerate deterioration of steelmaking refractories.
Moreover, careful consideration of processing conditions are needed to
prevent the precipitation of fine aluminum nitride during hot rolling.
Lastly, large additions of aluminum can cause the development of a
more adherent oxide scale, making descaling of the sheet more
difficult and expensive.
Sulfur and selenium are undesirable elements in the steels of the
present invention in that these elements can combine with other
elements to form precipitates that may hinder grain growth during
processing. Sulfur is a common residual in steel melting. Sulfur and/or
selenium, when present in the steels of the present invention, may be in
an amount of up to about 0.01%. Preferably sulfur may be present in
an amount up to about 0.005% and selenium in an amount up to about
0.007%.
Nitrogen is an undesirable element in the steels of the present
invention in that nitrogen can combine with other elements and form
precipitates that may hinder grain growth during processing. Nitrogen
is a common residual in steel melting and, when present in. the steels of
the present invention, may be in an amount of up to about 0.01% and,
preferably, up to about 0.005% and, more preferably, up to about
0.002%.
Carbon is an undesirable element in the steels of the present invention.
Carbon fosters the formation of austenite and, when present in an
amount greater than about 0.003%, the steel must be provided with a
decarburizing annealing treatment to reduce the carbon level
sufficiently to prevent "magnetic aging", caused by carbide
precipitation, in the finish annealed steel. Carbon is a common residual
from steel melting and, when present in the steels of the present
invention, may be in an amount of up to about 0.05% and, preferably,
up to about 0.01% and, more preferably, up to about 0.005%. If the
melt carbon level is greater than about 0.003%, the non-oriented
electrical steel must be decarburization annealed to less than about
0.003% carbon and, preferably, less than about 0.0025% so that the
finished annealed strip will not magnetically age.
The method of the present invention addresses a practical issue arising
in the present steel production methods and, in particular, the compact
strip production methods, i.e., thin slab casting, for the manufacture of
high grade non-oriented electrical steel sheets.
In the particular case of thin slab casting, the caster is closely coupled
to the slab reheating operation (alternatively referred to as temperature
equalization) which, in turn, is closely coupled to the hot rolling
operation. Such compact mill designs may place limitations both on
the slab heating temperature as well as the amount of reduction in
which can be used for hot rolling. These constraints make the
production of fully ferritic non-oriented electrical steels difficult as
incomplete recrystallization often leads to ridging in the final product.
In the particular case of thick slab casting and, in some cases, with thin
slab casting, high slab reheating temperatures are sometimes employed
to ensure that the steel is at a sufficiently high temperature for rough
hot rolling, during which the slab is reduced in thickness to a transfer
bar, followed by finish hot rolling, during which the transfer bar is
rolled to a hot band. Slab heating must be employed to maintain the
slab at a temperature where the slab microstructure consists of mixed
phases of ferrite and austenite to prevent abnormal grain growth in the
slab prior to rolling. In the practice of the method of the present invention,
the temperature for slab reheating should not exceed Tmax of Equation III.
The rolled strip is further provided with a finishing anneal within which
the desired magnetic properties are developed and, if necessary, to lower
the carbon content sufficiently to prevent magnetic aging. The finishing
annealing is typically conducted in a controlled atmosphere during
annealing, such as a mixed gas of hydrogen and nitrogen. There are
several methods well known in the art, including batch or box annealing,
continuous strip annealing, and induction annealing. Batch annealing, if
used, is typically conducted to provide an annealing temperature of at or
above about 1450°F (about 790°C) and less than about 1550°F (about
843°C) for a time of approximately one hour as described in ASTM
specifications 726-00, A683-98a and A683-99. Continuous strip
annealing, if used, is typically conducted at an annealing temperature at or
above 1450°F (about 790°C) and less than about 1950°F (about 1065°C)
for a time of less than ten minutes. Induction annealing, when used, is
typically conducted to provide an annealing temperature greater than
about 1500°F (815°C) for a time less than about five minutes.
The present invention provides for a non-oriented electrical steel having
magnetic properties appropriate for commercial use wherein a steel melt is
cast into a starting slab which is then processed by either hot rolling, cold
rolling or both prior to finish annealing to develop the desired magnetic
properties.
The silicon and chromium bearing non-oriented electrical steel of one
embodiment of the present invention is advantageous as improved
mechanical property characteristics of superior toughness and greater
resistance to strip breakage during processing are obtained.
In one embodiment, the present invention provides processes to produce a
non-oriented electrical steel having magnetic properties which have a
maximum core loss of about 4 Watts/pound (about 8.8W/kg) and a
minimum magnetic permeability of about 1500 G/Oe measured at 1.5T
and 60 Hz.
In another embodiment, the present invention provides processes to
produce a non-oriented electrical steel having magnetic properties which
have a maximum core loss of about 2 Watts/pound (about 4.4W/kg) and a
minimum magnetic permeability of about 2000 G/Oe measured at 1.5T
and 60 Hz.
In the optional practices of the present invention, the hot rolled strip may
be provided with an annealing step prior to cold rolling and/or finish
annealing.
The methods of processing a non-oriented electrical steel from a
continuously cast slab having a starting microstructure comprised entirely
of ferrite are well known to those skilled in the art. It is also known that
there are significant difficulties in getting complete recrystallization of the
as-cast grain structure during hot rolling. This results in the development
of a non-uniform grain structure in the hot rolled steel strip which may
result in the occurrence of a defect known as "ridging" during cold rolling.
Ridging is the result of non-uniform deformation and results in
unacceptable physical characteristics for end use. Equation II illustrates
the effect of composition on formation of the austenite phase and in the
practice of the method of the present invention, can be used to determine
the limiting temperature for hot rolling, if used, and/or annealing, if used,
of the strip.
The applicants have determined in one embodiment of the present
invention wherein the strip is hot rolled, annealed, optionally cold rolled,
and finish annealed to provide a non-oriented electrical steel having
superior magnetic properties. The applicants have further
determined in another embodiment of the present invention wherein the
strip is hot rolled, cold rolled and finish annealed to provide a non-
oriented electrical steel having superior magnetic properties without
requiring an annealing step after hot rolling. The applicants have further
determined in third embodiment of the present invention wherein the strip
is hot rolled, annealed, cold rolled and finish annealed to provide a non-
oriented electrical steel having superior magnetic properties.
In the research studies conducted by the applicants, the hot rolling
conditions are specified to foster recrystallization and, thereby, suppress
the development of the "ridging" defect. Jn the preferred practice of the
present invention, the deformation conditions for hot rolling were modeled
to determine the requirements for hot deformation whereby the strain
energy imparted from hot rolling was needed for extensive
recrystallization of the strip was determined. This model, outlined in
Equations IV through X, represents a further embodiment of the method of
the present invention and should be readily understood by one skilled in
the art.
The strain energy imparted from rolling can be calculated as:

Whereby W is the work expended in rolling, 9c is the constrained yield
strength of the steel and R is the amount of reduction taken in rolling in
decimal fraction, i.e., initial thickness of the strip (tj, in mm) divided by
the final thickness of the cast and hot strip (t/, in mm). The true strain in
hot rolling can be further calculated as:

Where e is the true strain and K1 is a constant. Combining Equation VI
into Equation VII, the true strain can be calculated as:

The constrained yield strength, ?c, is related to the yield strength of the
cast steel strip when hot rolling. In hot rolling, recovery occurs
dynamically and thus strain hardening during hot rolling is considered
not to occur in the method of the invention. However, the yield
strength depends markedly on temperature and strain rate and thereby
the applicants incorporated a solution based on the Zener-Holloman
relationship whereby the yield strength is calculated based on the
temperature of deformation and the rate of deformation, also termed as
the strain rate, as follows.

Where ?r is the temperature and strain rate compensated yield strength
of the steel during rolling, e is the strain rate of rolling and T is the
temperature, in °K, of trie steel when rolled. For the purposes of the
present invention, ?T is substituted for ?C in Equation VIII to obtain:

where K2 is a constant.
A simplified method to calculate the mean strain rate, em, in hot
rolling is shown in Equation XI:

Where D is the work roll diameter in mm, n is the roll rotational rate in
revolutions per second and K3 is a constant. The above expressions

can be rearranged and simplified by substituting em of Equation IX tor
e of Equation IX and assigning a value of 1 to the constants, K1, K2 and
K3, whereby the nominal hot rolling strain, e nominal, can be calculated as
shown in Equation XII:

In the embodiments of the present invention, the cast slab is heated to a
temperature not greater than Tmax of Equation III to avoid abnormal grain
growth. The cast and reheated slab is subjected to one or more hot rolling
passes, whereby a reduction in thickness of greater than at least about
15%, preferably, greater than about 20% and less than about 70%, more
preferably, greater than about 30% and less than about 65%. The
conditions of the hot rolling, including temperature, reduction and rate of
reduction are specified such that at least one pass and, preferably at least
two passes, and, more preferably, at least three passes, impart a strain,
e nominal of Equation V, greater than 1000, and, preferably, greater than
2000 and, more preferably, greater than 5000 to provide an optimum
conditions for recrystallization of the as-cast grain structure prior to cold
rolling or finish annealing of the strip.
In the practice of the present invention, annealing of the hot rolled strip
may be carried out by means of self-annealing in which the hot rolled strip
is annealed by the heat retained therein. Self-annealing may be obtained
by coiling the hot rolled strip at a temperature above about 1300°F (about
705°C). Annealing of the hot rolled strip may also be conducted using
either batch type coil anneal or continuous type strip anneal methods
which are well known in the art; however, the annealing temperature must
not exceed Tmin of Equation IV. Using a batch type coil anneal, the hot
rolled strip is heated to an elevated temperature, typically greater than
about 1300°F (about 705°C) for a time greater than about 10 minutes,
preferably greater than about
1400°F (about 760°C). Using a strip type continuous anneal, the hot
rolled strip is heated to a temperature typically greater than about
1450°F (about 790°C) fqr a time less than about 10 minutes.
A hot rolled strip or hot rolled and hot band annealed strip of the
present invention may optionally be subjected to a descaling treatment
to remove any oxide or scale layer formed on the non-oriented
electrical steel strip before cold rolling or finish annealing. "Pickling"
is the most common method of descaling where the strip is subjected to
a chemical cleaning of the surface of a metal by employing aqueous
solutions of one or more inorganic acids. Other methods such as
caustic, electrochemical and mechanical cleaning are established
methods for cleaning the steel surface.
After finish annealing, the steel of the present invention may be further
provided with an applied, insulative coating such as those specified for
use on non-oriented electrical steels in ASTM specifications A677 and
A976-97.
Example 1
Heats A and B were melted to the compositions shown in Table I and
made into 2.5 inch (64 mm) cast slabs. Table I shows that Heats A and
B provided a ?1150°c calculated in accordance with Equation II of about
21% and about 1%, respectively. Slab samples from both heats were
cut and heated in the laboratory to a temperature of from about 1922°F
(1050°C) to about 2372oF (1300°C) before hot rolling in a single pass
and a reduction of between about 10% to about 40%. The hot rolling
was conducted in a single rolling pass using work rolls having a
diameter of 9.5 inches (51 mm) and a roll speed of 32 RPM. After hot
rolling, the samples were cooled and acid etched to determine the
amount of recrystallization.
The results from Heats A and B are shown Figs. 2 and 3, respectively.
As Fig. 2 shows, a steel having a composition comparable to Heat A
would provide sufficient austenite to prevent abnormal grain growth at
slab heating temperatures of up to about 2372°F (1300°C). and using
sufficient conditions for the hot reduction step, would provide excellent
recrystallization of the cast structure. As Fig. 3 shows, a steel having a
composition comparable to Heat B, having a lesser amount of austenite,
must be processed with constraints as to the permissible slab heating
temperature, about 2192°F( 1200°C) or lower for the specific case of Heat
B, so as to avoid abnormal grain growth in the slab prior to hot rolling.
Moreover, the desired amount of recrystallization of the cast structure
could only be obtained using much higher hot reductions within a much
narrower hot rolling temperature range. Fig. 3 shows both conditions of
abnormal grain growth and insufficient conditions for hot rolling result in
large areas of unrecrystallized grains which may form ridging defects in
the finished steel sheet.
Example 2:
The compositions of Heats C, D and E in Table 1 were developed in
accordance with the teachings of the present invention and employ a Si-Cr
composition to provide a ?1150oc of about 20% or greater with a volume
resistivity calculated in accordance with Equation I of from about 35 µO-
cm, typical of an intermediate-silicon steel of the art, to about 50 µO-cm,
typical of a high-silicon steel of the art. Heat F, also shown in Table 1,
represents fully ferritic non-oriented electrical steel of the prior art. Table
I shows both the maximum permissible temperature for slab heating and
the optimum temperature for hot rolling for these steels of the present
invention. The results of Table I are plotted in Figure 4. The austenite
phase fields are shown for Heats C, D and E. Figure 4 also illustrates that
Heat F is calculated not have an austenite/ferrite phase field. As Table I
illustrates, a non-oriented electrical steel can be made by the method of the
invention to provide a
volume resistivity typical of intermediate- to high-silicon steels of the
prior art while providing a sufficient amount, of austenite to ensure
vigorous and complete recrystallization during hot rolling using a wide
range of slab heating temperatures and hot rolling conditions.
Moreover, the method taught in the present invention can be employed
by one skilled in the art to develop an alloy composition for maximum
compatibility with specific manufacturing requirements, operational
capabilities or equipment limitations.
Temperatures in °C
* Of the invention
* * Chemistry of the invention
*** Not of the invention
We Claim :
I. A method for producing a non-oriented electrical steel having a volume resistivity of at
least 20µO-cm and a peak austenitc volume fraction, ?1150oC of at least 5 weight % comprising
the steps of:
(a) preparing a non-oriented electrical steel melt having a composition in weight % comprising:
0.5% to 6.5% silicon,
up to 5% chromium,
up to 0.05% carbon,
up to 3% aluminum,
up to 3% manganese, and
the balance being substantially iron and residuals such as herein described;
(b) casting a steel slab from said steel melt;
(c) heating said steel slab to a temperature less than Tmax and greater than Tmin as defined by:
Tmin °C = 921 - 5998(%C) - 106(%Mn) + 135(%P) + 78.5(%Si) + 107(%A1) -
11.9(%Cr) + 896(%N) + 8.33(%Cu) - 146(%Ni) + 173(%Mo)
Tmax. °C = 1479 + 3480(%C) + 158(%Mn) - 347(%P) - 121(%Si) - 275(%A1) +
1.42(%Cr) - 195(%N) + 44.7(%Cu) + 140(%Ni) - 132(%Mo)
(d) hot rolling said slab to a hot rolled strip wherein said hot rolling provides a nominal strain of
at least 700 using the equation:

wherein,
"n" equals the roll rotational rate in revolutions per second,
"D" equals the work roll diameter in millimeters,

"ri"equals the initial thickness of the cast strip in millimeters,
"tf" equals the final thickness of the cast and hot rolled strip in millimeters; and,
(e) finish annealing said strip at a temperature less than T as defined by:
T, °C = 759- 4430(%C) - 194(%Mn) + 445(%P) + 181(%Si) + 378(%A1) -
29.0(%Cr) - 48.8(%N) - 68.1 (%Cu) - 235(%Ni) + 116(%Mo).
2. The method as claimed in claim 1 wherein the finish annealing temperature is less than T
as defined by:
T, °C = 921 - 5998(%C) - 106(%Mn) + 135(%P) + 78.5(%Si) + 107(%A1) -
11.9(%Cr) + 896(%N) + 8.33(%Cu) - 146(%Ni) + 173(%Mo).
3. The method as claimed in claim 1 wherein the non-oriented electrical steel melt
comprises:
1% to 3.5% silicon,
0.1% to 3% chromium,
up to 0.01% carbon,
up to 1 % aluminum,
0.1 % to 1 % manganese,
up to 0.01 % of a metal selected from the group consisting of sulfur, selenium and
mixtures thereof,
up to 0.01% nitrogen, and
the balance being substantially iron and residuals such as herein described.
4. The method as claimed in claim 2 wherein the non-oriented electrical steel melt
comprises:
1 % to 3.5% silicon,
0.1 % to 3% chromium.
up to 0.01% carbon,
up to 1 % aluminum,
0.1% to 1% manganese,
up to 0.01% of a metal selected from the group consisting of sulfur, selenium and
mixtures thereof,
up to 0.01% nitrogen, and
the balance being substantially iron and residuals such as herein described.
5. The method as claimed in claim 1 wherein the non-oriented electrical steel melt
comprises:
1.5% to 3% silicon,
0.15% to 2% chromium,
up to 0.005% carbon,
up to 0.5% aluminum,
0.1 % to 0.35% manganese,
up to 0.005% sulfur;
up to 0.007% selenium;
up to 0.002% nitrogen, and
the balance being substantially iron and residuals such as herein described.
6. The method as claimed in claim 2 wherein the non-oriented electrical steel melt
comprises:
1.5%; to 3% silicon,
0.15% to 2% chromium,
up to 0.005% carbon,
up to 0.5% aluminum,
0.1% to 0.35% manganese,
up to 0.005% sulfur;
up to 0.007% selenium;
up to 0.002% nitrogen, and
the balance being substantially iron and residuals such as herein described.
7. The method as claimed in claim 1 wherein the non-oriented electrical steel melt further
comprises up to 0.15% antimony, up to 0.005% niobium, up to 0.25% phosphorus, up to 0.15%
tin, up to 0.01% sulfur and/or selenium, and up to 0.01 % vanadium.
8. The method as claimed in claim 2 wherein the non-oriented electrical steel melt further
comprises up to 0.15% antimony, up to 0.005% niobium, up to 0.25% phosphorus, up to 0.15%
tin, up to 0.01 % sulfur and/or selenium, and up to 0.01% vanadium.
9. A method for producing a non-oriented electrical steel having a volume resistivity of at
least 20µO-cm and a peak austenite volume fraction, ?1150°c, of at least 5 weight % comprising
the steps of:
(a) preparing a non-oriented electrical steel melt having a composition in weight % comprising:
0.5% to 6.5% silicon,
up to 5% chromium,
up to 0.05% carbon,
up to 3% aluminum,
up to 3% manganese, and
the balance being substantially iron and residuals such as herein described;
(b) casting a steel slab from said steel melt;
(c) heating said steel slab to a temperature less than Tmax and greater than Tmin as defined by:
Tmin,°C= 759-4430(%C)- 194(%Mn) + 445(%P) + 181(%Si) + 378(%A1) -
29.0(%Cr) - 48.8(%N) - 68.1 (%Cu) - 235(%Ni) + 116(%Mo)
Tmax. °C = 1633 + 3970(%C) + 236(%Mn)- 685(%P) - 207(%Si) - 455(%A1) +
9.64(%Cr) - 706(%N) + 55.8(%Cu) + 247(%Ni) - 156(%Mo)
(d) hot rolling said slab to a hot rolled strip wherein said hot rolling provides a nominal strain of
at least 700 using the equation:

wherein,
"n" equals the roll rotational rate in revolutions per second,
"D" equals the work roll diameter in millimeters,
"ti" equals the initial thickness of the cast strip in millimeters,
"tf equals the final thickness of the cast and hot rolled strip in millimeters; and,
(e) finish annealing said strip at a temperature less than Tmin as defined by:
Tmin °C = 759-4430(%C) - 194(%Mn) + 445(%P) + 181(%Si) + 378(%A1) -
29.0(%Cr) - 48.8(%N) - 68.1 (%Cu) - 235(%Ni) + 116(%Mo).
10. The method as claimed in claim 9 wherein the finish annealing temperature is less than T
as defined by:
T, °C = 921 - 5998(%C) - 106(%Mn) + 135(%P) + 78.5(%Si) + 107(%A1) -
11.9(%Cr) + 896(%N) + 8.33(%Cu) - 146(%Ni) + 173(%Mo).
11. The method as claimed in claim 9 wherein the non-oriented electrical steel melt
comprises:
1% to 3.5%- silicon,
0.1 % to 3% chromium,
up to 0.01 % carbon,
up to 1 % aluminum,
0.1% to 1% manganese,
up to 0.01 % of a metal selected from the group consisting of sulfur, selenium and
mixtures thereof,
up to 0.01% nitrogen, and
the balance being substantially iron and residuals such as herein described.
12. The method as claimed in claim 10 wherein the non-oriented electrical steel melt
comprises:
1% to 3.5% silicon,
0.1% to 3% chromium,
up to 0.01% carbon,
up to 1 % aluminum,
0.1% to 1% manganese,
up to 0.01 % of a metal selected from the group consisting of sulfur, selenium and
mixtures thereof,
up to 0.01% nitrogen, and
the balance being substantially iron and residuals such as herein described.
13. The method as claimed in claim 9 wherein the non-oriented electrical steel melt
comprises:
1.5% to 3% silicon,
0.15% to 2% chromium,
up to 0.005% carbon,
up to 0.5% aluminum,
0.1% to 0.35% manganese.
up to 0.005% sulfur;
up to 0.007% selenium;
up to 0.002% nitrogen, and
the balance being substantially iron and residuals such as herein described.
14. The method as claimed in claim 10 wherein the non-oriented electrical steel melt
comprises:
1.5% to 3% silicon,
0.15% to 2% chromium,
up to 0.005% carbon,
up to 0.5% aluminum,
0.1% to 0.35% manganese,
up to 0.005% sulfur;
up to 0.007% selenium;
up to 0.002% nitrogen, and
the balance being substantially iron and residuals such as herein described.
15. The method as claimed in claim 9 wherein the non-oriented electrical steel melt further
comprises up to 0.15% antimony, up to 0.005% niobium, up to 0.25% phosphorus, up to 0.15%
tin, up to 0.01 % sulfur and/or selenium, and up to 0.01% vanadium.
16. The method as claimed in claim 10 wherein the non-oriented electrical steel melt further
comprises up to 0.15% antimony, up to 0.005% niobium, up to 0.25% phosphorus, up to 0.15%
tin, up to 0.01% sulfur and/or selenium, and up to 0.01% vanadium.
17. A method for producing a non-oriented electrical steel having a volume resistivity of at
least 20µO-cm and a peak austcnite volume fraction, ?1150oC, of at least 5 weight % comprising
the steps of:
(a) preparing a non-oriented electrical steel melt having a composition in weight % comprising:
0.5% to 6.5% silicon,
up to 5% chromium,
up to 0.05% carbon,
up to 3% aluminum,
up to 3% manganese, and
the balance being substantially iron and residuals such as herein described;
(b) casting a steel slab from said steel melt;
(c) heating said steel slab to a temperature less man Tmax as defined by:
Tmax, °C= 1463 + 3401 (%C) + 147(%Mn) - 378(%P) - 109(%Si) - 248(%A1) +
0.79(%Cr) - 78.8(%N) + 28.9(%Cu) + 143(%Ni) - 22.7(%Mo)
(d) hot rolling said slab to a hot rolled strip wherein said hot rolling provides a nominal strain of
at least 700 using the equation:

wherein,
"n" equals the roll rotational rate in revolutions per second,
"D" equals the work roll diameter in millimeters,
'ti," equals the initial thickness of the cast strip in millimeters,
"tf' equals the final thickness of the cast and hot rolled strip i n millimeters; and,
(e) finish annealing said strip at a temperature less than Tmin as defined by:
Tmin, °C = 759-4430(%C) - 194(%Mn) + 445(%P) + 181(%Si) + 378(%Al) -
29.0(%Cr) - 48.8(%N) - 68.1 (%Cu) - 235(%Ni) + 116(%Mo).
18. The method as claimed in claim 17 wherein the finish annealing temperature is less than
T as defined by:
T, °C = 921 - 5998(%C) - 106(%Mn) + 135(%P) + 78.5(%Si) +
107(%A1) - 11.9(%Cr) + 896(%N) + 8.33(%Cu) - 146(%Ni) + 173(%Mo).
19. The method as claimed in claim 17 wherein the non-oriented electrical steel melt
comprises:
1% to 3.5% silicon,
0.1% to 3% chromium,
up to 0.01% carbon,
up to 1 % aluminum,
0.1% to 1% manganese,
up to 0.01 % of a metal selected from the group consisting of sulfur, selenium and
mixtures thereof,
up to 0.01% nitrogen, and
the balance being substantially iron and residuals such as herein described.
20. The method as claimed in claim 18 wherein the non-oriented electrical steel melt
comprises:
1% to 3.5% silicon,
0.1 % to 3% chromium,
up to 0.01% carbon,
up to I % aluminum,
0.1% to 1% manganese,
up to 0.01 % of a metal selected from the group consisting of sulfur, selenium and
mixtures thereof,
up to 0.01% nitrogen, and
the balance being substantially iron and residuals such as herein described.
21. The method as claimed in claim 17 wherein the non-oriented electrical steel melt
comprises:
1.5% to 3% silicon,
0.15% to 2% chromium,
up to 0.005% carbon,
up to 0.5% aluminum,
0.1% to 0.35% manganese,
up to 0.005% sulfur;
up to 0.007% selenium;
up to 0.002% nitrogen, and
the balance being substantially iron and residuals such as herein described.
22. The method as claimed in claim 18 wherein the non-oriented electrical steel melt
comprises:
1.5% to 3% silicon,
0.15% to 2% chromium,
up to 0.005% carbon,
up to 0.5% aluminum,
0.1 % to 0.35% manganese,
up to 0.005% sulfur;
up to 0.007% selenium;
up to 0.002% nitrogen, and
the balance being substantially iron and residuals such as herein described.
23. The method as claimed in claim 17 wherein the non-oriented electrical steel melt further
comprises up to 0.15% antimony, up to 0.005% niobium, up to 0.25% phosphorus, up to 0.15%
tin, up to 0.01% sulfur and/or selenium, and up to 0.01 % vanadium.
24. The method as claimed in claim 18 wherein the non-oriented electrical steel melt further
comprises up to 0.15% antimony, up to 0.005% niobium, up to 0.25% phosphorus, up to 0.15%
tin, up to 0.01% sulfur and/or selenium, and up to 0.01 % vanadium.
This invention discloses a method for producing a non-oriented electrical steel
comprising the steps of:
(a) preparing a non-oriented electrical steel melt having a composition in weight %
comprising:
up to 6.5% silicon, up to 5% chromium, up to 0.05% carbon, up to 3% aluminum.
up to 3% manganese, and the balance being substantially iron and residuals; (b) casting a
steel slab from said steel melt; (c) heating said steel slab to a temperature less than Tmax
and greater than Tmin as defined by:
Tmin, °C = 921 - 5998(%C) - 106(%Mn) + 135(%P) + 78.5(%Si) +
107(%AI) - 11.9(%Cr) + 896(%N) + 8.33(%Cu) - 146(%Ni) + 173(%Mo)
Tmax. °C = 1479 + 3480(%C) + 158(%Mn) - 347(%P) - 121(%Si) -
275(%A1) + 1.42(%Cr) - 195(%N) + 44.7(%Cu) + 140(%Ni) - 132(%Mo)
(d) hot rolling said slab to a hot rolled strip wherein said hot rolling provides a nominal
strain of at least 700 using the equation:

wherein,
"n" equals the roll rotational rate in revolutions per second, "D" equals the work roll
diameter in millimeters, "t" equals the initial thickness of the cast strip in millimeters,
"tf" equals the final thickness of the cast and hot rolled strip in millimeters; and, (e) finish
annealing said strip at a temperature less than T as defined by:
T, °C = 759 - 4430(%C) - 194(%Mn) + 445(%P) + 181(%Si) + 378(%A1) - 29.0(%Cr) -
48.8(%N) - 68.1(%Cu) - 235(%Ni) + 116(%Mo).

Documents:

2468-kolnp-2005-granted-abstract.pdf

2468-kolnp-2005-granted-assignment.pdf

2468-kolnp-2005-granted-claims.pdf

2468-kolnp-2005-granted-correspondence.pdf

2468-kolnp-2005-granted-description (complete).pdf

2468-kolnp-2005-granted-drawings.pdf

2468-kolnp-2005-granted-examination report.pdf

2468-kolnp-2005-granted-form 1.pdf

2468-kolnp-2005-granted-form 13.pdf

2468-kolnp-2005-granted-form 18.pdf

2468-kolnp-2005-granted-form 3.pdf

2468-kolnp-2005-granted-form 5.pdf

2468-kolnp-2005-granted-gpa.pdf

2468-kolnp-2005-granted-reply to examination report.pdf

2468-kolnp-2005-granted-specification.pdf

2468-kolnp-2005-granted-translated copy of priority document.pdf


Patent Number 233930
Indian Patent Application Number 2468/KOLNP/2005
PG Journal Number 17/2009
Publication Date 24-Apr-2009
Grant Date 22-Apr-2009
Date of Filing 02-Dec-2005
Name of Patentee AK STEEL PROPERTIES, INC.
Applicant Address INTELLECTUAL PROPERTY SECTION, 705, CURTIS STREET, MIDDLETOWN, OH
Inventors:
# Inventor's Name Inventor's Address
1 SCHOEN, JERRY, W. 6315, GEMSTONE DRIVE, MIDDLETOWN, OH 45044
2 COMSTOCK, ROBERT, JR. 509, SOUTHWICK PLACE, TRENTON, OH 45067
PCT International Classification Number C21D 8/12
PCT International Application Number PCT/US2004/014506
PCT International Filing date 2004-05-10
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10/436,571 2003-05-08 U.S.A.