Search Results (60)

This study presents a design and optimization methodology to enhance the power density and efficiency of wound field synchronous machines (WFSMs) by selectively applying grain-oriented electrical steel (GOES). Unlike conventional non-grain-oriented electrical steel (NOES), GOES exhibits significantly lower core loss along its rolling direction, making it suitable for regions with predominantly alternating magnetic fields. Based on magnetic field analysis, four machine configurations were investigated, differing in the placement of GOES within stator and rotor teeth. Finite element analysis (FEA) was employed to compare electromagnetic performance across the configurations. Subsequently, a multi-objective optimization was conducted using Latin Hypercube Sampling, meta-modeling, and a genetic algorithm to maximize power density and efficiency while minimizing torque ripple. The optimized WFSM achieved a 13.97% increase in power density and a 1.0% improvement in efficiency compared to the baseline NOES model. These results demonstrate the feasibility of applying GOES in rotating machines to reduce core loss and improve overall performance, offering a viable alternative to rare-earth permanent magnet machines in xEV applications. Full article

The ongoing electrification process also requires improvements in the efficiency of power transmission devices, such as transformers, the main part of which is the magnetic core. Despite great progress in the development of core material, losses and audible noise during their operation is still a critical issue to be solved. Currently, a magnetic material used to produce the transformer core is amorphous steel, which is gaining popularity. Compared to traditionally used grain-oriented silicon electrical steel, a significantly larger number of very thin amorphous ribbons is needed to produce the core, which is due to the fact that they are about an order of magnitude thinner, making mechanical stability a challenge. The presented article describes the preparation of a hybrid binder for amorphous steel based on the two types of silanes, tetraethyl orthosilicate and 1,2-bis(triethoxysilyl)ethane, for which their anticorrosive character and good dielectric properties were confirmed. Using the obtained binders, model toroidal cores were produced and their magnetic and acoustic properties were tested. The obtained results indicate that the applied silane-based hybrid binders improved important functional properties by reducing the magnetic no-load losses and audible noise. Full article

History-dependent hysteresis models can potentially describe magnetization curves of all orders accurately. This property is essential for modeling magnetization and power loss in magnetic components subjected to distorted excitation waveforms, which result in complex magnetization patterns such as offset minor loops. The basic Zirka–Moroz history-dependent hysteresis model offers a good balance between the model’s complexity and accuracy. However, estimating the model’s parameters can be challenging. This research provides insight into the parameter estimation procedure for the discussed hysteresis model. Based on the measured first-order reversal curves, the fundamental two-step parameter estimation procedure was employed and analyzed for two non-oriented and one grain-oriented electrical steel types used widely in contemporary electric drives and electromagnetic devices. For each sample evaluated, two sets of parameters were estimated and compared to the reference parameters recommended for non-oriented electrical steels. The performed analysis is essential for gaining a comprehensive understanding of the capabilities, challenges, requirements, and limitations associated with estimating the parameters and performance of the analyzed model for specific electrical steel types. Full article

The Magnetic Barkhausen Noise (MBN) is a non-destructive testing method, which, due to its high sensitivity to changes in the microstructure of the material, is increasingly being applied with success as a tool for evaluation of magnetic material state and properties. However, it is no less difficult to analyze the measurement signals and their correct interpretation due to the complex, non-deterministic and stochastic nature of the Barkhausen phenomenon. Depending on the material to be examined, a signal with different characteristics can be observed. Frequently, a signal with multi-phase Barkhausen activity characteristics is obtained, like in the case of grain-oriented electrical steels. Due to the increased computational capabilities of computers, more and more advanced signal analysis methods are being used and artificial intelligence is being involved as well. Recently, the time–frequency (TF) approach for MBN signal analysis was introduced and discussed in several papers, where short-time Fourier Transform (STFT) found frequent application with promising results. Due to the automation of the search for diagnostic patterns, the stage of selecting transformation parameters becomes extremely important in the process of preparing training data for evaluation algorithms. This paper investigates the influence of the STFT computational window size on the material state evaluation results obtained using convolutional neural network (CNN). The studies were performed for MBN signals obtained from grain-oriented electrical steel with anisotropic properties. The carried out work made it possible to draw connections on the importance of the choice of the window during the implementation of CNN network training. Full article

The presence of island grains in the initial finished sheets of grain-oriented electrical steel is inevitable in the preparation of ultra-thin strips. Owing to their distinctive shape and size effects, their deformation behavior during rolling differs from that of grain-oriented electrical steels of conventional thickness. This study focuses on the orientation evolution and deformation heterogeneity of island grains during rolling. Four types of island grains with orientations of {210}<001>, {110}<112>, {114}<481>, and {100}<021> were selected and modeled within the Goss-oriented matrix using full-field crystal plasticity finite element (CPFEM) simulation under plane strain compression. The results are then compared with corresponding experimental measurements. The results reveal that orientation rotation and grain fragmentation vary among the island grains of different orientations, with the first two orientations exhibiting more significant deformation heterogeneity compared to the latter two. Additionally, the orientations of the island grains significantly affect the distribution of residual Goss orientations within the surrounding matrix. Pancake-like island grains exhibit a higher degree of orientation scatter and greater deformation heterogeneity in the central layer compared to their spherical counterparts. The initial {210}<001> island grains can form a cube orientation, which can be optimized by subsequent process control to enhance magnetic properties. Full article

The fatigue behavior of a fully processed, non-oriented electrical steel sheet is investigated in dependence on shear-cutting parameters and a subsequent heat treatment. For this, stress-controlled fatigue tests are performed before and after annealing at 700 °C for a total of six different shear-cutting settings. For all parameters, the fatigue strength of shear-cut sheets is improved by the heat treatment. This is due to reduction in a large part of the strain hardening region as well as the reduction in tensile residual stresses. Both were introduced during shear cutting and act detrimental to the fatigue strength. However, the intensity of this improvement depends on the shear-cutting parameters. This is related to the corresponding edge surfaces characteristically being formed during shear cutting. Specimens cut with a worn cutting tool show a more pronounced increase in fatigue life. In contrast, specimens produced with a sharp-edged cutting tool and high cutting clearance hardly benefit from the heat treatment. This appears to be caused by differences in surface topography, in particular coarse topographical damage in the form of grain breakouts. If these occur during shear cutting, the crack formation is not significantly delayed by additional annealing. Full article

This paper explores the effects and impacts of the metallurgical process of quenching on grain-oriented strips of electrical steel. Experimental findings reveal that quenching resulted in increased hardness and an increased Young’s modulus. An analysis of the material structure post-quenching indicates significant alterations in grain spacing and reduced height differences between grains. However, the magnetic properties of the steel deteriorated following quenching. Full article

This study investigates multiple cyclic loading scenarios of non-oriented electrical steel sheets through both experimental and numerical approaches. The numerical simulations were conducted using Representative Volume Elements generated with DRAGen. DRAGen allowed for the generation of Representative Volume Elements with a non-cubic shape to cover the complete sheet thickness and enough grains to represent the material’s texture. The experimental results, on the other hand, are utilized to calibrate and validate a prediction model, highlighting the significance of accumulated plastic slip as a suitable parameter correlated with fatigue life. Using the accumulated plastic slip from the simulations, a fatigue fracture locus is introduced, which describes a 3D surface dependent on the maximum stress, fatigue life, and the fatigue stress ratio. The study shows reliable results for the fatigue life prediction using the calibrated fatigue fracture locus. While substantial progress has been made in predicting the fatigue life at multiple fatigue stress ratios, notable disparities between experimental and simulation results suggest the need for further investigations regarding the influence of the surface quality. This observation motivates ongoing research efforts aimed at refining simulation methodologies to better incorporate surface roughness effects. In summary, this study presents a validated model for predicting fatigue life in non-oriented electrical steel sheets, offering valuable insights into material behavior at different loading scenarios and informing future research directions for enhanced structural performance and durability. Full article

Grain-oriented (GO) electrical steel (ES) laminates are still very important in industrial applications due to their remarkable crystallographic properties. Cores of large electrical machines and transformers are built from ES. The performances of these devices are significantly influenced by the properties of ES. The improvement of ES properties has been the subject of considerable research for many years. The phenomenon of magnetic anisotropy is highly non-linear, and it should be taken into account by the designers of magnetic circuits. The article proposes a modified model for calculating the angular properties of specific total loss of ES. The modeling takes into account the isotropic component (from classic eddy currents) and the anisotropic component, which is the sum of hysteresis and excess losses. For the directional loss modeling, the Boltzmann function was used. An analysis of the dependency of model coefficients on the frequency is presented. Full article

Grain-oriented electrical steel (GOES) has been used for many years for application in transformed cores due to its excellent magnetic properties. Magnetic properties are strongly influenced by obtaining a texture with a certain orientation (110) [001] for BCC structure. This is related to the easy direction of magnetization [001]. So far, the main research has been focused on obtaining a strong texture in the last stages of the process. The aim of the present study was to additionally trace textural changes for a slab after the continuous casting (CC) process and for a sheet after the hot rolling process. The scope of such an analysis has not been conducted before. With regard to the state after continuous casting (CC), the texture was related to measurements of the anisotropy of Barkhausen magnetic noises and the macrostructure of the slab. Based on the X-ray diffraction examinations that compared the texture intensity calculated from the texture coefficient of the slab, the hot rolled steel and the final product of grain-oriented electrical steel contained 3.1% of Si. The studies performed with the material taken from three different production steps showed high differences in the values of textural intensity indicating the occurrence of a crystallization texture, especially in the area of the columnar crystal zone; textural weakness after the hot rolling process and high texturing in the final product for textural components corresponding to the desired Goss texture. Full article

This paper presents a newly proposed domain wall energy-based model of the 2D strain dependence of relative magnetic permeability in highly grain-oriented anisotropic electrical steels. The model was verified utilizing grain-oriented M120-27s electrical steel sheet samples with magnetic characteristics measured by an automated experimental setup with a magnetic yoke. The model’s parameters, identified in the differential evolution-based optimization process, enable a better understanding of the interaction between stress-induced anisotropy and magnetocrystalline anisotropy in electrical steels. Moreover, the consequences of the simplified description of grain-oriented magnetocrystalline anisotropy are clearly visible, which opens up the possibility for further research to improve this description. Full article

A grain-oriented steel containing 6.5% Si, characterized by a notable Goss texture, was effectively manufactured through the rolling technique, incorporating both intrinsic inhibitors and additional inhibitors. This investigation focuses on tracking the development of texture and magnetic properties during the manufacturing process and delineates the mechanism underlying secondary recrystallization. The empirical findings clearly demonstrated the significant influence of nitriding duration and quantity on the secondary recrystallization process. In instances where additional nitrogen is absent, the intrinsic inhibitors alone do not lead to secondary recrystallization. However, when the nitriding duration is 90 s and the nitriding amount is 185 ppm, a complete secondary recrystallization structure with a strong Goss texture enables the finished products have excellent magnetic properties. The preferential growth of Goss grains is mainly governed by the enhanced mobility of high-energy (HE) grain boundaries. With the increase in annealing temperature, the occurrence of 20°–45° HE grain boundaries with Goss grains becomes more progressively frequent. At the secondary recrystallization temperature of 1000 °C, the frequency of 20°–45° HE grain boundaries with Goss grains reaches 62.7%, providing favorable conditions for the abnormal growth of Goss grains. This results in a secondary recrystallization structure predominantly characterized by a strong Goss texture. In light of these observations, the present study provides fundamental theoretical insights and serves as a valuable procedural guideline for the industrial manufacturing of 6.5% Si grain-oriented electrical steels. Full article

Solid-state transformer (SST) is an emerging technology that integrates with transformer power electronics converters and control. The most noticeable advantages of SST are the size and weight reduction compared with low-frequency transformers. Since this device is used in many devices such as smart grids, traction systems, systems with renewable energy sources (RESs) and electric vehicle charging devices, it is important to build a high-efficiency device at a low cost. The article evaluates a medium frequency transformer (SST) operating at a frequency of 500 Hz to 6000 Hz with coils wound with aluminum foil or Litz windings and of a grain-oriented electrical steel (GOES) core. The calculations were made using the 3D field method using the numerical finite element method, and the results were compared with the tests of the real model. The measurement method based on the Fourier analysis of real signals was used for the research. Full article

This paper focuses on the effect of rapid annealing on Non-Grain Oriented Electrical Steel (NGO) in terms of microstructure, mechanical properties, and magnetic properties. The Ultra-Fast Heating (UFH) tests were performed by a transversal induction heater on NGO electrical steel samples (cold rolled down to 0.5 mm), varying the heating power (80 kW and 90 kW) and the speed of the strip through the induction heater. This allowed us to exploit heating rates (HR) in the range of 200–300 °C/s and targeting peak temperature (T_peak) up to a maximum of 1250 °C. The comparison between the microstructure as obtained by conventional annealing and the ultra-fast heating process highlights a clear effect in terms of grain size refinement provided by the UFH. In particular, the average grain size as obtained by UFH ranges two/three times lower than by a conventional process. The results show the possibility of applying UFH to NGO steels, targeting mechanical properties such as those obtained by the standard process, combined with the benefits from this innovative heat treatment in terms of green energy and the minimization of CO₂ emissions. Magnetic characterization performed by a single sheet tester (30 × 90 mm) showed that the values of core losses are comparable with conventional NGO grades. Full article

The magnetic domains of non-oriented electrical steel bearing cumulative thermal compressions made by a Gleeble 3500 Thermal System were observed using an atomic force microscope (AFM). The component forces, comprising the magnetic forces between the AFM probe and magnetic domains of the samples, along the freedom direction of the probe, were measured, and they formed the value fluctuation of the magnetic domains. The fluctuations of the magnetic domains were analyzed by examining the power spectral density (PSD) curves. The hysteresis curves of the samples were measured using a highly sensitive magnetic measurement system. An analysis of the magnetic force microscope (MFM) maps suggested that some magnetic domains were compressed into crushed and fragmented shapes, similar to the microstructure of deformed grains. Meanwhile, some were reconstructed within the thermal compressions, like dynamic recrystallization microstructures. Meaningfully, the MFM probe moved and deformed the proximal magnetic domains of tested samples within the region of its weak magnetic field. The peak positions of the magnetic domains with a high deformation rate were shifted and moved during the measuring processes by the weakly polarized probe. Both windward and leeward sides simultaneously expressed a slope towards each co-adjacent valley in the MFM maps and induced a statistical throbbing within a narrow band in the PSD curves. Thus, the MFM scanning mode was also analyzed and improved to obtain accurate MFM maps with low disturbances from the weak magnetic field of the probe. Swapping the order positions of the middle processes in the MFM scanning and adding a gliding step between them could offset the peak skewing of magnetic domains caused by the weakly polarized probe during MFM measurement process without incurring excessive replacement costs. Accumulative compression at a high rate (10 s⁻¹) would crush magnetic domains into irregularly decreasing sizes with messy boundaries. This investigation provides an example of the complete relationships among deformations, magnetic domains, and magnetic properties. Full article