Soft magnetic steels Dr Roger West Cogent Surahammars Bruks AB

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