Soft magnetic steels Dr Roger West Cogent Surahammars Bruks AB
Transcription
Soft magnetic steels Dr Roger West Cogent Surahammars Bruks AB
Cogent Power Ltd Soft magnetic steels Dr Roger West Cogent Surahammars Bruks AB Presented at the Magnetic Materials in Electrical Machine Applications 2009 Pori, Finland 4-6 November 2009 Cogent Power Ltd – Owners Tata Group 350000 empl. 63 BUSD Tata Steel UK Ltd 100% Corus 100% Tata Steel 80000 empl. 27 mill tpa No 6 in world Corus Group 20 mill tpa 42000 empl Cogent Power Ltd 100% Orb Electrical Steels Ltd Surahammars Bruks AB Cogent Power Ltd 900 empl. Cogent Power Inc Cogent Power Ltd Use of Corus Distribution network Cogent Power Inc., Canada Transformer cores Steel Service Centre Orb Electrical Steels, UK GO 80 kt p.a. Worldwide electrical steel supplier - 85 % export Europe 155 kt 10 kt Americas Africa 4 kt Asia 25 kt Australasia 1 kt Our Key Global Clients Include • • • ABB Siemens Alstom Surahammars Bruk, Sweden NO fully processed 115 kt p.a. Surahammars Bruks AB Short facts Small NO electrical steel: 80 kt Flexible Grain oriented GO : 3 kt Specialised Turnover (MEUR): Employees: 90 170 Cogent Surahammars Bruks AB is specialized in electrical steels. Small in terms of total volume - But big (~10% of world market) in high Si low loss and thin grades Surahammars Bruks AB - Short History 1627 Chancellor Axel Oxenstierna acquires two estates in Surahammar and erects a hammer 1866 The production of railway wheels starts 1897 The first Swedish car is made in Surahammar 1916 ASEA acquires Surahammars Bruk 1917 First delivery of hot rolled electrical steel 1986 Svenskt Stål AB (SSAB) buys Surahammars Bruk 1991 Surahammars Bruk is incorporated into European Electrical Steels Ltd, EES 2001 Cogent Power Ltd is formed SSAB-Luleå SSABLuleå Hot rolling at SSAB - Borlänge Processing of Electrical Steels at Surahammar Electrical Steels • How to make low losses ? • Thinner gauge, in general thinner gauges gives lower losses for a given chemistry. (1.0)– 0.65– 0.50– 0.35– 0.27– 0.20– 0.10mm • Increasing the electrical resistance of the steel by alloying with silicon and aluminium. Electrical Steels • What can be done additionally to make low losses ? • Low content of oxygen, sulphur, carbon and nitrogen, (lowest possible amount of particles in the steel) 10-30 ppm • Coarse grain size, high temperature is important • Stress free material, no deformation of the material after the final anneal. Electrical Steels • Electrical steels are graded according to their power losses. Lower loss materials are better (and more expensive). • The power losses occurs in the steel when the magnetic field changes direction and magnitude 100 times per second (50 Hz). • The power losses generates heat in the steel. Electrical Steels • Important Terms • Losses, measured in W/kg at 1.5 T and 50 Hz • Permeability Materials Expertise Production Know-how All standard grades of electrical steels Wide range of coatings World class expertise on electrical steels Access to specialists on magnetics and materials both in-house and via external partners 1.5 Specialised in thin grades for high frequency applications 1 0.5 0 -0.5 -1 -1.5 -300 Responsive Willing and able to modify processes to meet customer requirements Small Flexible Flexible Specialised Can make small batches for e.g. special machines or development purposes Fast e.g. NO 27 development took ~3 months from idea to commercial product -100 0 100 200 300 16 Loss at 400Hz . -200 15 Latest development: Thin gauge grade NO 27 with the same loss as NO 20 but 35 % thicker (= 35 % higher productivity in stamping) 14 13 12 0.1 0.15 0.2 0.25 0.3 Thickness mm Full range of electrical steels Non-oriented fully processed electrical steels Grade EN 10106 Thickness Max specific total loss at 50 Hz J = 1,5 T 1,0 T** W/kg W/kg 2.10 0.85 M210-27A mm 0.27 M235-35A M250-35A M270-35A M300-35A M330-35A 0.35 0.35 0.35 0.35 0.35 2.35 2.50 2.70 3.00 3.30 0.95 1.00 1.10 1.20 1.30 M250-50A M270-50A M290-50A M310-50A M330-50A M350-50A M400-50A M470-50A M530-50A M600-50A M700-50A M800-50A M940-50A 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 2.50 2.70 2.90 3.10 3.30 3.50 4.00 4.70 5.30 6.00 7.00 8.00 9.40 1.05 1.10 1.15 1.25 1.35 1.50 1.70 2.00 2.30 2.60 3.00 3.60 4.20 M310-65A M330-65A M350-65A M400-65A M470-65A M530-65A M600-65A M700-65A M800-65A M1000-65A 0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65 3.10 3.30 3.50 4.00 4.70 5.30 6.00 7.00 8.00 10.00 1.25 1.35 1.50 1.70 2.00 2.30 2.60 3.00 3.60 4.40 M600-100A M700-100A M800-100A M1000-100A 1.00 1.00 1.00 1.00 6.00 7.00 8.00 10.00 2.60 3.00 3.60 4.40 Full range of electrical steels Thin non-oriented fully processed Grade Thickness electrical steels NO27 NO20 NO18 NO12 NO10 mm (inch) 0,27 (0.011) 0,20 (0.008) 0,178 (0.007) 0,127 (0.005) 0,10 (0.004) Max specific total loss at 1,0 T 400 Hz 2500 Hz W/kg W/kg 15.0 300 15.0 215 14.3 179 13.5 152 13.0 135 Thin Non-Oriented Fully Processed Electrical Steels Grade Thickness mm (inch) Max specific total loss at 1.0 T Typical specific total loss at 1.0 T 400 Hz W/kg 2500 Hz W/kg 50 Hz W/kg 400 Hz W/kg 2500 Hz W/kg NO27 0.27 (0.011) 15.0 300 0.79 13.0 250 NO20 0.20 (0.008) 15.0 215 0.95 12.2 205 NO18 0.178 (0.007) 14.3 179 1.07 12.3 161 NO12 0.127 (0.005) 13.5 152 1.09 11.8 132 NO10 0,10 (0,004) 13.0 135 1.29 12.1 119 Cogent Power Ltd - Applications HRC from Corus, TKS, SSAB etc Thin Gauge Grades for High Frequency Applications 2500000 2000000 1500000 1000000 500000 0 2000 2002 2004 2006 2008 2010 2012 2014 Surahammars Bruk Vision 2010 Our vision: We shall be known as a Leading Producer of Non oriented electrical steels - specialized in producing: Low core loss values and thin gauges (0.20 mm down to 0.10 mm) Surahammars Bruk Vision and focus How R&D – Own + Corus 950 researchers. Spends € 120M/a ”Best customers” – Healthy companies, good products Quality – Lean Thinking, implementation started 2003 KPI´s, like DTT (min 92 %), delays (max 2 weeks), claims (max 500 ppm) etc… Human relations – Safety (not a single LTA) Inspire to a healthy way of living Cogent Power Ltd Reducing the energy lost in generation, transmission and distribution of electrical energy enables Cogent Power to make a significant contribution to the preservation of natural resources ssttcc55 The first car in Sweden produced in Surahammar 1897 Thank you for your attention! www.sura.se
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