Electrical Steel:-

➢ Also called Lamination Steel OR Silicon electrical steel OR transformer steel, is a special steel, designed to
produce certain magnetic properties
➢ It has specific proportion of Silicon upto about 6.5%, which increases the electrical resistivity of steel and
reduces hysteresis loss and eddy current loss in steels. Commercial electrical steels have upto 3.2% Si.
Properties of Electrical Steel:-
➢ Hysteresis Loss is low i.e. on application of A.C current, the magnetic domains in the steel, easily get aligned
in one or other directions and less electrical energy is required for the process
➢ Magnetic permeability is high i.e. the steel easily allows formation and accumulation of magnetic field within
➢ Electrical resistance is high, to prevent eddy current losses (Current that flows on the surface as a result of
magnetic induction in any core coil)
Magnetic Hysteresis Loss:- Phenomenon of lagging of magnetic flux density (B) behind the magnetizing force
(H) in a magnetic material, subject to a cycle of magnetization, (i.e. it is magnetized first in one direction and then
in the other) is called magnetic hysteresis. Hysteresis Loss result rom this irreversible magnetization process

➢ The shape and size of Hysteresis loop depends on the nature of material

Silicon Steel (Electrical Steel):- Hard Steel (Permanent Magnets):- Wrought Iron (Electromagnets):-
Smaller area of Hysteresis Loop Larger area of Hysteresis Loop Moderate area of Hysteresis Loop
Less Hysteresis Loss Greater Hysteresis Loss Faily good Hysteresis Loss

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Eddy Current Loss:- These are circulating currents generated in a magnetic material due to induced EMF
when it experiences a changing magnetic field, on application of Alternating Current. These currents produce a
loss (I2R) In the magnetic material known as Eddy Current Loss, and increase the temperature of the magnetic
material.

Eddy current mechanism is shown in the fig. When an AC current flows through the coil, it sets
up a magnetic flux in the magnetic material. The magnetic flux also links to the core material and
induces EMF at various points of the core. This potential difference causes closed loop
circulating currents in the core, called Eddy Current

Eddy current loss is proportional to:-
▪ Square of Eddy Current (I2)
▪ Resistance of the Core (R)
Eddy current loss = k x I2R
Higher is the current, higher is the Eddy Current Loss
Any solid core has a higher cross sectional area, hence
lower resistance and therefore higher current
➢ Eddy Current Losses can be reduced by reducing
current
➢ Current reduces with increase in core resistance
➢ Core resistance can be increased by
(1) Use of thin laminated sheets in the core
(2) Use high resistivity Silicon Steel for core making

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Types of Electrical Steels:-

➢ Grain Oriented Steels

➢ Non-Grain oriented Steels

Grain Oriented Steels CRGO

➢ These are Magnetically Anisotropic and have superior magnetic properties in direction of rolling
➢ The special magnetic properties are due to (i) certain special chemical composition, containing
upto 3.5% Silicon (ii) Rolling practise (iii) Heat Treatment process
➢ CRGO (Cold Rolled Grain Oriented) steels have rolling done in one direction, with emphasis on
crystal orientation / texture, so that grains elongate in one direction
➢ These are mostly used in distribution and power transformers

Non-Grain Oriented Steels

➢ These are Magnetically Isotropic and have same magnetic properties in all directions
➢ These can be supplied in fully processed OR semi processed form CRNGO
➢ Fully processed Non Grain Oriented Steels are subjected to De-Carburizing annealing followed by an
organic or inorganic lamination coating, to achieve the desired magnetic properties
➢ Semi processed Non Grain Oriented steels, are those where further heat treatment operation, after
rolling, is carried out at stamping manufacturers end.
➢ Semi processed non grain oriented steels can be supplied in un-alloyed form (Silicon Free) or alloyed
form (containing Silicon)
➢ Alloyed Steel with high Silicon Content (upto 6.5% Si) are very hard and brittle
➢ CRNGO (Cold Rolled non Grain Oriented) steels are rolled without any special emphasis to control
the crystal orientation / texture
➢ These are mostly used in generators with moving parts and electric motors.

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 Huge applications in the
manufacturing of Electric Motors,
Electric Generators and Electrical
Power transmission units

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How to achieve magnetic properties in Electrical Steels – Goss Texture

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Nomenclature and Designations of Electrical Steels(As per different Specs) :-
CRNGO:- ( As per IS 648) CRGO:- (As per IS 3024)
The complete symbol for grade of CRNGO magnetic sheet The complete symbol for grade of CRGO magnetic sheet and strip Shall be as
and strip shall be as following:- following:-

Example:- Designation of Cold Rolled Non-Oriented, finally annealed

Magnetic strip of a grade symbolized by 50C470 means:- thickness
0.50mm, having total specific core loss (Ps) at Magnetic Flux Density
Of 1.5T will not exceed 4.70 W/Kg

*** Note:- The nomenclature for CRNGO steel as per other

Specifications will be different

EN 10106 – for CRNGO, fully finished steel *** Note:- The nomenclature for CRGO steel as per other Specifications will be
EN 10126 / EN 10107 – for CRNGO semi finished steel different
EN 10107 – for CRGO steel

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Process Path Flow for Electrical Steel:-
CRNGO:-

CRGO:-

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Facility Requirements for Electrical Steel Production:-
(1) CRNGO (SEMI PROCESSED):-
Process Steps Process Requirement
HR Coil Receiving Si Grade Steel from Hot
Rolling Mill suppliers as per
Specification (IS 648 )
Pickling Surface Scale removal
Cold Rolling Thickness as per
requirement
Batch Annealing Proper Annealing Cycle for
Recrystallization
Temper Rolling / Skin Pass Shape improvement and
Luder bands elimination
improvement after stress
relief annealing
Facility requirement Critical Process Measurement Facility
Control requirement Requirement
Not Applicable Chemistry as per MTC (% Portable Optical Emission
Si, % Al most important) Spectrometer
Pickling Line Hcl Concentration Content Chemical Laboratory
in Acid, Temperature of
Acid, Rinse Water PH,
Rinse Water Conductivity,
Rinse Water Temp., Dryer
Temp.
6 Hi, Reversing Cold Rolling Thickness and flatness Chemical Laboratory
Mill control
Emulsion Control:-PH,
Conductivity, Total Oil,
Tramp Oil, Scum in Oil, SAP
value, ESI, Chlorides ppm,
Fe content
Batch Annealing Furnace Process display of complete Tensile Testing Machines
cycles, temperature, gas (Physical Testing Lab)
flow rates, base fan speeds.
Mechanical Properties
achieved
Skin Pass Mill Thickness and flatness Tensile Testing Machines
control (Physical Testing Lab)
Mechanical Properties
achieved in Annealing
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Facility Requirements for Electrical Steel Production:-
(2) CRNGO (FULLY PROCESSED) …contd.. from previous page :-
Process Steps
HR Coil Receiving
Pickling
Cold Rolling
Electrolytic Cleaning
Decarburization in Hydrogen
and Nitrogen atmosphere in
furnace
Recrystallization Annealing in
Nitrogen atmosphere in
furnace
Process Requirement
Si Grade Steel from Hot
Rolling Mill suppliers as per
Specification (IS 648 )
Surface Scale removal
Thickness as per requirement
Coil Surface cleaning from
emulsion
Reduce Carbon PPM in steel
to avoid Carbon Aging, by
reacting Carbon with Oxygen
Recrystallization of cold Rolled
grains and restrict grain
growth during primary
recrystallization by Aluminium-
Nitride formation
Facility requirement
Not Applicable
Pickling Line
6 Hi, Reversing Cold Rolling
Mill
Decarburizing, Annealing and
Insulation Coating Line, with
Electrolytic Cleaning Section
at Entry
Critcal Process Measurement Facility
Control requirement Requirement
Chemistry as per MTC (% Si, Portable Optical Emission
% Al most important) Spectrometer
Hcl Concentration Content in Chemical Laboratory
Acid, Temperature of Acid,
Rinse Water PH, Rinse Water
Conductivity, Rinse Water
Temp., Dryer Temp.
Thickness and flatness control Chemical Laboratory
Emulsion Control:-PH,
Conductivity, Total Oil, Tramp
Oil, Scum in Oil, SAP value,
ESI, Chlorides ppm, Fe
content
Alkali Concentration, rectifier Chemical Laboratory
current, Rinse water PH and
Conductivity,
Carbon PPM in steel is Less LECO – Carbon ppm checking
than 30 PPM, O2 % between LECO – Oxygen % checking
0.1 – 0,115%,
Mix gas atmosphere control in
furnace zones (N2 & H2 %),,
Humidifier section control,
Dew point control inside
furnace sections
N2 % in steel is between LECO – Nitrogen % checking
0.022 – 0.026%
N2 % control in furnace Zones
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Facility Requirements for Electrical Steel Production:-
(3) CRNGO (FULLY PROCESSED) …contd.. from previous page :-
Process Steps
Insulation Coating, Curing and
Drying
On Line Watt Loss Tester in
Decarb, Annealing and
Insulation Coating Line
Process Requirement
Insulation Coating to reduce
Eddy Current Loss by
increasing Resistivity between
Laminations
Measurement of On Line Watt
Loss / Core Loss (Permeability
of Magnetic Properties) for
Process Control on Magnetic
Properties achieved
Facility requirement
Decarburizing, Annealing and
Insulation Coating Line, with
Electrolytic Cleaning Section at
Entry
On Line Watt Loss Tester with
continuous strip test chart
available
Critical Process Measurement Facility
Control requirement Requirement
Insulation Resistivity, Coating Magnetics Laboratory with all
thickness, Thermal effect on testing facilities as per IS 648
coating, Resistance to Heat,
Resistance to Solvents
(Xylene), Resistance to De-
Greasing
agents(Trichloroethylene),
Resistance to Transformer
Oils, Ductility (Bend Test),
Adherence (Reverse Bending
Test)
Control on Density and Chemical Testing Lab
Viscosity of Insulation Coating
material
Control of Maximum Core Loss Brockhaus MPG on line Single
(W/kg) at AC Magnetization of Sheet Tester for Watt Loss
50 Hz frequency, Magnetic Measurement
Flux Density of 1.5 T and
Minimum Magnetization Value
requirement (B Max) as per
Spec.
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Facility Requirements for Electrical Steel Production:-
(4) CRGO
Process Steps
HR Coil Receiving
Pickling
Cold Rolling with Interpass
Aging facility and Auto Flatness
Control
Electrolytic Cleaning
Decarburization in Hydrogen
and Nitrogen atmosphere in
furnace
Recrystallization Annealing in
Nitrogen atmosphere in furnace
Process Requirement
Si Grade Steel from Hot Rolling
Mill suppliers as per
Specification (IS 3024)
Surface Scale removal
• Thickness as per
requirement
• Flatness as per requirement
• Improve magnetic property
in high permeability CRGO
steel by increasing amount
of 110〈001〉 component in
the primary recrystallization
texture
Coil Surface cleaning from
emulsion
Reduce Carbon PPM in steel to
avoid Carbon Aging, by
reacting Carbon with Oxygen
Recrystallization of cold Rolled
grains and restrict grain growth
during primary recrystallization
by Aluminium-Nitride formation
Facility requirement
Not Applicable
Pickling Line
6 Hi, Reversing Cold Rolling
Mill
Decarburizing, Annealing and
Insulation Coating Line, with
Electrolytic Cleaning Section at
Entry
Critcal Process Measurement Facility
Control requirement Requirement
Chemistry as per MTC (% Si, Portable Optical Emission
% Al most important) Spectrometer
Hcl Concentration,Fe Content Chemical Laboratory
in Acid, Temperature of Acid,
Rinse Water PH, Rinse Water
Conductivity, Rinse Water
Temp., Dryer Temp.
Thickness and flatness control Chemical Laboratory
Emulsion Control:-PH,
Conductivity, Total Oil, Tramp
Oil, Scum in Oil, SAP value,
ESI, Chlorides ppm, Fe content
Alkali Concentration, rectifier Chemical Laboratory
current, Rinse water PH and
Conductivity,
Carbon PPM in steel is Less LECO – Carbon ppm checking
than 30 PPM, O2 % between LECO – Oxygen % checking
0.1 – 0,115%,
Mix gas atmosphere control in
furnace zones (N2 & H2 %),,
Humidifier section control, Dew
point control inside furnace
sections
N2 % in steel is between 0.022 LECO – Nitrogen % checking
– 0.026%
N2 % control in furnace Zones
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Facility Requirements for Electrical Steel Production:-
(5) CRGO .. contd.. from previous page :-
Process Steps
On Line Watt Loss Tester in
Decarb, Annealing and
Insulation Coating Line
Magnesium Oxide Coating
Secondary Recrystallization
through high temperature
annealing
Process Requirement Facility requirement Critical Process Measurement Facility
Control requirement Requirement
Measurement of On Line Watt On Line Watt Loss Tester with Control and improvement of Brockhaus MPG on line Single
Loss (Permeability of Magnetic continuous strip test chart Maximum Core Loss (W/kg) at Sheet Tester for Watt Loss
Properties) for Process Control on available AC Magnetization of 50 Hz Measurement
Magnetic Properties achieved frequency, Magnetic Flux
Density of 1.5 T and Minimum
Magnetization Value (B Max)
• Prevent interwrap sticking Magnesium Oxide Coating line Control on MgO Coating Weight Thermogravimetric Analyzer
during Secondary with IR fired drying and Air Control on moisture content in (TGA) to check Loss of moisture
Recrystallization in Tunnel Cooling MgO coating ignition (%) at 1000 Deg C
Furnace
• Reaction of MgO coating with
fayelite layer (Fe2SiO4) on the
strip, during secondary
recrystallization in Tunnel
furnace, to form forsterite
(Mg2SiO4) layer which is called
“Glass Film” or “Mill Glass” or
“Mill Anneal” coatings which
acts as insulation coating
• Secondary Recrystallization to Tunnel Furnace Control on Nitrogen % at Entry NA
obtain large secondary and Exit Chamber of furnace
recrystallized grain structure to Control of Hydrogen % and
minimize Core Loss temperature inside Tunnel
• Formation of forsterite layer during process
(Mg2SiO4) with MgO coating
from MgO line, which is called
“Glass Fil” and acts as
insulation coating
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Facility Requirements for Electrical Steel Production:-
(6) CRGO .. contd.. from previous page :-
Process Steps
Cleaning of excess MgO coating
powder after Tunnel Furnace
Pickling of sheet with Ortho
Phosphoric Acid and then rinsing
with Water
• Application of Tension
Insulation coating (Phosphate +
Colloidal Silica based coating),
• Curing in Drying Furnace
• Electrical heating for stress
relieving and thermal flattening
through flattening rolls inside
furnace
• Jet cooling
On Laser Scribing in Heat
Flattening and Insulation Coating
Line
On Line Watt Loss Tester in Heat
Flattening and Insulation Coating
Line with continuous strip test chart
Process Requirement
Scrubbing with Brush roll and
rinsing with DM water
Cleaning of Strip before
application of Insulation
Coating Layer
Insulation Coating application
to reduce further Core Loss
Domain Refining to Reduce
further core loss through laser
scribing
Measurement of On Line Watt
Loss (Permeability of Magnetic
Properties) for Process Control
on Magnetic Properties
achieved
Facility requirement Critical Process Measurement Facility
Control requirement Requirement
NA
Control on Acid Concentration Chemical Laboratory
• Insulation Resistivity, Coating Magnetics Laboratory with all
thickness, Thermal effect on testing facilities as per IS 648
coating, Resistance to Heat,
Resistance to Solvents
(Xylene), Resistance to De-
Greasing
Heat Flattening and agents(Trichloroethylene),
Insulation Coating Line Resistance to Transformer
Oils, Ductility (Bend Test),
Adherence (Reverse Bending
Test)
• Control on Density of Coating Chemical Laboratory
Material
• Control on Viscosity of
Coating Material
Measurement of Improvement in Brockhaus MPG, Single Sheet
Core Loss (W/Kg) after Laser Tester for measurement of Core
Scribing Loss in the steel
Control of Maximum Core Loss Brockhaus MPG on line Single
(W/kg) at AC Magnetization of Sheet Tester for Watt Loss
50 Hz frequency, Magnetic Flux Measurement in Lab
Density of 1.5 T and Minimum (Magnetics Lab)
Magnetization Value requirement
(B Max) as per Spec.
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Line Flow Diagrams of Main Processing Facilities which are needed for Electrical Steel Making :-
Decarburizing and Annealing Line for CRGO

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Line Flow Diagrams of Main Processing Facilities which are needed for Electrical Steel Making :-

Magnesium Oxide Coating Line for CRGO

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Line Flow Diagrams of Main Processing Facilities which are needed for Electrical Steel Making :-

Tunnel Furnace for Secondary Recrystallization Annealing - CRGO

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Line Flow Diagrams of Main Processing Facilities which are needed for Electrical Steel Making
:-
Heat Flattening and Insulation Coating Line for CRGO

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Main Testing facilities which will be required for Electrical Steel Making :-

Brockhaus MPG 100 D – For measurement of magnetic magnetic Core Losses in Electrical Steels

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Main Testing facilities which will be required for Electrical Steel Making :-
Insulation Resistivity testers Stacking Factor testing machine

Insulation Coating Thk. measurement

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Main Testing facilities which will be required for Electrical Steel Making :-
LECO O2-N2 Anlyser LECO C-S Anlyser

Loss of moisture on Ignition – MgO coating

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Main Testing facilities which will be required for Electrical Steel Making :-
Adherence Tester for CRGO sheets (Full Width)

Adherence Class Chart for CRGO Sheet

Adherence Tester for CRGO sheets (Full Width)

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Main Testing facilities which are needed for Electrical Steel Making :-

Grain Viewer – For assessment of Grain Size uniformity across full width of the coil

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CRGO applications

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CRGO applications

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CRNGO applications

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CRNGO applications

Laminated Stamping

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Electrical Steel Suppliers in India – TKES (Thyssen Krupp Electrical Steels India Ltd

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Electrical Steel Suppliers in India – TKES (Thyssen Krupp Electrical Steels India Ltd

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