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Determination of the Structure-Processing-Properties Relationship of Fe-6.5Wt%Si

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Determination of the Structure-Processing-Properties Relationship of Fe-6.5Wt%Si Iowa State University Capstones, Theses and Graduate Theses and Dissertations Dissertations 2019 Determination of the structure-processing-properties relationship of Fe-6.5wt%Si Chad Richard Macziewski Iowa State University Follow this and additional works at: https://lib.dr.iastate.edu/etd Part of the Materials Science and Engineering Commons, and the Mechanics of Materials Commons Recommended Citation Macziewski, Chad Richard, "Determination of the structure-processing-properties relationship of Fe-6.5wt%Si" (2019). Graduate Theses and Dissertations. 17737. https://lib.dr.iastate.edu/etd/17737 This Dissertation is brought to you for free and open access by the Iowa State University Capstones, Theses and Dissertations at Iowa State University Digital Repository. It has been accepted for inclusion in Graduate Theses and Dissertations by an authorized administrator of Iowa State University Digital Repository. For more information, please contact [email protected]. Determination of the structure-processing-properties relationship of Fe-6.5wt%Si by Chad Macziewski A dissertation submitted to the graduate faculty in partial fulfilment of the requirements for the degree of DOCTOR OF PHILOSOPHY Major: Materials Science and Engineering Program of Study Committee: Jun Cui, Major Professor Iver Anderson Scott Chumbley Matthew Kramer Frank Peters The student author, whose presentation of the scholarship herein was approved by the program of study committee, is solely responsible for the content of this dissertation. The Graduate College will ensure this dissertation is globally accessible and will not permit alterations after a degree is conferred. Iowa State University Ames, Iowa 2019 ii DEDICATION I would like to dedicate this dissertation to my wife Brittany and my son Rowan without whose support I would not have been able to accomplish my dream of obtaining my doctorate. I would also like to extend my sincere thanks to all my friends and family for their wisdom and guidance during my time writing this work. iii TABLE OF CONTENTS Page ACKNOWLEDGEMENTS ........................................................................................... vi ABSTRACT .................................................................................................................. vii CHAPTER 1 INTRODUCTION ........................................................................................ 1 1.1. History of Fe-6.5wt%Si and its use as a soft magnetic material ........................... 1 1.2. Effect of Wheel Speed on Magnetic and Mechanical Properties of Melt-spun Fe-6.5wt%Si high silicon steel ............................................................ 4 1.3. Effects of Melt-spinning on Material Properties of Fe-6.5wt%Si ........................ 5 1.4. Thermodynamic and Kinetic analysis of the melt-spinning process of Fe-6.5wt%Si alloy................................................................................ 6 1.5. In-situ cooling rate analysis of melt-spun Fe-6.5wt%Si ....................................... 8 1.6. Determining B2-D03 Ordering in a Fe-6.5wt%Si Alloy ...................................... 8 1.7. Construction of the TTT Curve ........................................................................... 10 CHAPTER 2 A REVIEW OF FE-6.5WT%SI HIGH SILICON STEEL – A PROMISING SOFT MAGNETIC MATERIAL FOR SUB-KHZ APPLICATION .... 11 Abstract ......................................................................................................................... 11 2.1. Introduction ......................................................................................................... 11 2.2. History of high silicon steel ................................................................................ 18 2.3. Structure of high silicon steel .............................................................................. 19 2.3.1. Effect of silicon in steel ................................................................................... 19 2.3.2. Ordering in high silicon steel........................................................................... 20 2.3.3. Suppression of ordering in silicon steel ........................................................... 22 2.4. Properties of high silicon steel ............................................................................ 24 2.4.1. Magnetic properties ......................................................................................... 24 2.4.2. DC magnetic properties ................................................................................... 24 2.4.3. AC magnetic properties (iron loss) .................................................................. 24 2.4.4. Iron loss management ...................................................................................... 27 2.4.5. Lamination and near-net shape processing ...................................................... 29 2.4.6. Mechanical properties...................................................................................... 31 2.5. Processing of high silicon steel ........................................................................... 34 2.5.1. Thermal mechanical processing ...................................................................... 35 2.5.2. Rapid solidification.......................................................................................... 35 2.5.3. Deposition/diffusion annealing........................................................................ 39 2.5.4. Comparison of magnetic properties ................................................................. 41 2.6. Application .......................................................................................................... 42 2.6.1. Electricity conversion ...................................................................................... 42 2.6.2. Electric machine .............................................................................................. 43 2.6.3. Sensors ............................................................................................................. 43 2.6.4. Electromagnetic interference (EMI) prevention .............................................. 44 2.6.5. Electronic components .................................................................................... 45 2.6.6. Others............................................................................................................... 45 2.7. Summary ............................................................................................................. 45 iv CHAPTER 3 EFFECT OF WHEEL SPEED ON MAGNETIC AND MECHANICAL PROPERTIES OF MELT SPUN FE-6.5WT%SI HIGH SILICON STEEL .................... 47 Abstract ......................................................................................................................... 47 3.1. Introduction ......................................................................................................... 47 3.2. Experiment .......................................................................................................... 49 3.3. Results and discussion ......................................................................................... 49 3.4. Conclusion ........................................................................................................... 55 CHAPTER 4 EFFECTS OF WHEEL SPEED ON THE MATERIAL PROPERTIES OF FE-6.5WT%SI .................................................................................................................. 56 Abstract ......................................................................................................................... 56 4.1. Introduction ......................................................................................................... 56 4.2. Methods ............................................................................................................... 56 4.3. Results ................................................................................................................. 58 4.4. Discussion ........................................................................................................... 58 CHAPTER 5 THERMODYNAMIC AND KINETIC ANALYSIS OF MELT SPINNING PROCESS OF FE-6.5WT%SI ALLOY ........................................................................... 60 Abstract ......................................................................................................................... 60 5.1. Introduction ......................................................................................................... 60 5.2. Experiments ......................................................................................................... 61 5.3. Thermodynamic and kinetic analysis .................................................................. 63 5.4. CALPHAD data .................................................................................................. 64 5.5. Solidification simulation ..................................................................................... 66 5.6. Growth of the bcc_B2 antiphase domain ............................................................ 70 5.7. Conclusions ......................................................................................................... 73 CHAPTER 6 IN-SITU COOLING RATE ANALAYSIS OF MELT-SPUN FE- 6.5WT%SI USING THERMAL IMAGING TECHNIQUES .......................................... 74 Abstract ........................................................................................................................
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