Enhanced fully processed electrical steels for automotive ... - ABM

Enhanced fully processed electrical steels for 

automotive traction applications 

Sigrid Jacobs on behalf of the ES team July 2008

Contents 

• Introduction to AM in general and specifically Electrical Steels 

– People 

– Volumes 

– Production Units 

• General requirements in terms of Electrical Steels of machine performance 

improvements 

– Loss reduction 

– Flux increase 

• ArcelorMittal’s Product Range for enhanced machines 

– Induction machines 

– Synchronous machines 

• Technical Support 

04/08/2008 Confidential 1

ArcelorMittal: Leader in steel 

The world’s only truly global steel maker 

No 1 in 

North America 

77% 

Market position and market share estimates by region* 

23% 

No 1 in 

South America 

76% 

24% 

No 1 in 

Western Europe 

74% 

26% 

No 1 in Africa 

No 1 in Eastern 

Europe and CIS 

04/08/2008 Confidential 2 

53% 

Number 1 in 5 regions and 4 continents 

A global steel production of 116 million tonnes (2007) 

47% 

*Source: ArcelorMittal estimates, based on IISI crude steel production 

89% 

11% 

ArcelorMittal 

Other

ArcelorMittal in figures* 

Sales of US $105.216 billion 

EBITDA of US $19.4 billion 

Operating income of US $14.83 billion 

Net income of US $10.368 billion 

Shipment of 109.7 million tonnes 

116 million tonnes of steel produced 

310,000 employees 

in 60 different countries 

An integrated leader of the metal and mining sector 


7% 

*2007 pro forma figures 

16% 

13% 

6% 

16% 

25% 

17% 

EU15 

Rest EU (EU27) 

Other European countries 

North America 

South America 

East Asia 

Africa

ArcelorMittal: Our identity 

We know that our position in the steel industry brings unique responsibilities. 

We are committed to setting globally recognized standards with the needs of 

future generations in mind. 

transforming tomorrow 

ArcelorMittal brand values: 

� Sustainability 

� Quality 

� Leadership 


ArcelorMittal is committed to 

Corporate Responsibility 

Signatory to universal guidelines and memberships 

• United Nations Global Compact 

• United Nations Universal Declaration on Human Rights 

• International Labor Organization tripartite core conventions 

• World Business Council for Sustainable Development (WBCSD) 

• Constituent of the FTSE4Good Index Series 

Our commitments to transform tomorrow 


A three dimensional strategy 

ArcelorMittal is the 

only producer offering, 

leveraging and 

developing the full 

range of steel products 

and services 

Product 

From commodities to 

value added products, 

from long products to flat 

products, from standard to 

speciality products, from 

carbon steel to stainless 

steel and alloys 

Value Chain 

ArcelorMittal 

ArcelorMittal is not only a steel 

producer but an integrated 

Metals and Mining leader 

capturing opportunities along the 

value chain 

From mining to distribution, 

transformation and trading of finished 

products 

Geography 

ArcelorMittal is the only 

truly global producer 

Leadership position in 

4 continents and 5 regions 

Not only the largest steel producer but a unique Metals & Mining leader 


AM Hamilton, 

Dofasco (CRML) 

AM Hennepin 

(CRML) 

KEY FIGURES 2007 : 

ArcelorMittal 

Production sites of Electrical Steels 

VOLUME : ca. 800kt produced in 9 plants 

AM Gent AM Eisenhüttenstadt 

AM Florange 

AM St.-Chély AM Frýdek Místek (mostly GO) 

AM Bilbao 

AM Inox Brasil 

(also producing GO steels) 

A WIDE RANGE of GRAIN ORIENTED as well as NON ORIENTED ELECTRICAL STEELS from basic 

COLD 04/08/2008 ROLLED over SEMI-PROCESSED Confidential (CRML) to the HIGHEST GRADES of FULLY PROCESSED 7 

DEDICATED COMMERCIAL and TECHNICAL ASSISTANCE TEAM

Rotating machines 

• Large 

– Generators 

– Traction 

• Medium size 

– Industrial motors 

– Hermetic Motors (Compressors) 

– Automotive traction 

• Small 

– Household appliances 

– Automotive 

Market segmentation 

Static machines 

• Transformers 

– Large Distribution type 

– Industrial transformers and selfs 

– Small transformers 

– Ballasts 

• Electrical apparatus 

– Contactors 

– Meters 

• Shielding (electro smog) 


Product groups 

ROTATING MACHINES 

FULLY 

PROCESSED 

Supplied with 

GUARANTEED 

MAGNETIC 

PROPERTIES 

NON-ORIENTED 

isotropic 

Produced in most ES PLANTS 

SEMI 

PROCESSED 

Final heat treatment 

required for DEVELOPING 

the GUARANTEED 

MAGNETIC PROPERTIES 

GRAIN-ORIENTED 

anisotropic 

Produced in AMIB / AMFM 

LARGE TRANSFORMERS 


Grade designation for NO 

• IEC, EN: 

(JIS, ASTM similar) 

M400-50A 5 

Gauge mm x 100 

= 0.50 mm 

IEC for 50Hz 

Magnetic Steel A = Non-Oriented Fully 

Processed grade 

Maximum iron losses 

K = Non-Oriented Semi- 

@1.5T and 50Hz : 

Processed grades 

x 100 

= 4,0 W/kg 


Global CO2 data 

• In the industrialised countries, the transport sector is responsible 

for about a fifth of CO2 emissions 

– ’10 worldwide estimate of the EC: 5461 million t CO2 for 

transport of the global 29055 Mt (source WETO-H2) 

• Automobile has a 96% dependence on petroleum so alternatives are 

needed not only for the environment but also as strategy. 

– There are 700 million vehicles on our planet. 

– Worldwide 70 million vehicles were sold in ‘07 → 94 million units by 

‘16, so by ‘20 15% of the global population will have its own car. In 

‘07, 35% of the world energy need comes from petroleum, with est. 

2% growth/year. 


Are biofuels the green solution ? 

• EU has set the target of having 10% of overall fuel supply for transport in the 

form of biofuels by 2020. 

• 1st generation biofuels 

– are receiving more opposition from green NGOs than any other transport 

fuel. 

– USA produces 16 million cubic metres annually and Brazil 15 

– Production cost of bioethanol: 0.15-0.16 €/l 

– 1 l of ethanol is equivalent to 0.671 l of gasoline regarding energy content 

– This will reduce petrol dependency 

– But is not completely carbon neutral, e.g. Brazil example 

• Flash burning the sugar cane fields for manual harvest, results in air pollution and 

ashes: no longer used 

• Mechanised harvest alternative produces GHG and takes away jobs from the very poor 

– Other EU dilemma’s: Food or fuel ? Forest or fuel ? 

• 2nd generation biofuels 

– BiomassToLiquid should overcome most of these problems 

– Should be available by 2015 


New CO2 Regulations 

• EU 

EU Commission would like to cap average fleet emissions at 130g/km by 2012 

Parliament on its side has proposed to reduce them further down to 125g/km (5.2l/100km 

in gasoline & 4.7l/100km in diesel) but by 2015. 

Legislation framework under discussion : Target may vary depending on Vehicle Mass or 

Vehicle Foot Print or both. 

Europe’s Council of Ministers will make the final decision this year 

• USA 

The energy bill signed December 2007 requires automakers to raise the fuel economy of 

cars and light trucks by 40% industry wide to 35 mpg by 2020 (from current 27.5mpg for 

cars & 22.2mpg for light trucks). 

Increases must begin in the 2011 model year. Cars and light trucks, which have current 

standards of 27.5 mpg and 22.5 mpg, respectively, will retain separate standards. 

Rules for each category will be indexed by size and weight. 

• Japan 

METI has proposed to decrease Passenger car Fuel Consumption by 23.5% between 

2004 (7.35l/100km) and 2015 (6.0l/100km) 

There is a Reinforcement of CO2 legislation in Mature Countries 


Impact of car weight and fuel type 

Source: Global Insight 

• 2000 → 2007: average CO2 emissions 

for all EU25 produced vehicles 

– Despite a significant 12% increase in total vehicle mass, 

technological advancements have permitted to reduce the 

average CO2 emissions to 162g/km in ‘07 

– Essential impact was the transition from 30% diesel in ’00 to 

50% in ’07 

• 2007 → 2012: CO2 forecast based on vehicle types announced 

for production 

– -1% mass for diesel and gasoline 

– 143g/km CO2 for average ’12 

production forecast so >130… 


Petrol consumption and CO2 

• Linear relationships have been determined, between gasoline or diesel 

consumption and CO2 emissions (mixed cycle). Source: Journal of 

chemical education 

• 140gCO2/km = 5,8l gasoline or 5,3l diesel /100km 

• Reducing to 130gCO2/km requires 7% less fuel consumption 

• The hybrid solutions offer this reduction potential 

• Ex. BMW series 1: introduction of micro hybrid reduces CO2 from 124 

to 115g/km 


Impact of the first oil crisis in the ’70s 


Labelling cars 

C 

G 

In application of EU Directive 99/94/EC, Several Countries (Denmark, 

NL, BE...) have selected the above format for Car Labelling 


Fuel Savings Potential of the various 

technologies 

Fuel Savings Cost Availability Application 

Engine Downsizing 5 to 7%

CO2 Reduction Technologies 

OEM Program 

BMW EfficientDynamics 

Stop & 

Start 

Engine 

Downsizing 

Mild & Full 

Hybrid Fuel Cell 

Diesel Hybrid 

under Dvlpt 

Daimler BlueEfficiency SOP end 08 

Fiat (Aria) 

Ford ECOnetic 

GM ecoFLEX 

Honda 

Hyundai 

Blue Lion 

PSA 

Airdream 

Better Place 

Renault eco2 

Suzuki 

Toyota 

VW BLUEMOTION 

Mass Prod 

by 2012/15 

Gas. Hybrid Fuel Cell Fleet 

in USA under test 

Gas. Hybrid Fuel Cell Fleet 

in USA under test 

Gas. Hybrid FCX Clarity 

in JPN offered in 2008 

Mass Prod First model by 

by 2009 

Diesel Hybrid 

under Dvlpt 

Work on 

Electric 

2012 

Gas. Hybrid 

in JPN 

Diesel Hybrid 

under Dvlpt 

Mass Prod 

by 2015 

Longer Gear 

Ratios 

Aerodynamic 

Changes 

Low Roll 

Resistance 

Tyres Equipments 

Brake Ener. 

Recycling 

Better Ener. 

Management 

Source : Press Releases 

Most of OEMs have programs designed to experiment fuel saving 

technologies for mass market: 

Stop & Start, Gear Ratios, Aerodynamic Changes, Green Tyres 


Weight 

Reduction 

Lighter 

materials

Hybridisation technologies and markets 

• Europe’s high efficiency diesel history requires a different hybrid 

solution than the US and Japan 


Overview: hybrid systems 

- starter (DC-machine; 1-2.5 kW) starts ICE 

- generator (Lundell, clawpole-alternator; 

1-3kW) power supply for electrical 

equipment, charges battery 

- starter-generator combines starting and 

power supply operation (2-3 kW) 

- functionality: 

- fast start/stop of ICE 

- generator operation 

- electrical machine (10-15 kW) integrated in 

the drivetrain 

- functionality 

- start/stop 

- generator operation 

- boost operation 

- recuperation 


Overview: hybrid systems 

- ICE in optimal operating point 

- several transformations of energy 

� lower overall efficiency 

- drive without ICE is possible 

� „zero emission“ 

- good weight arrangement is possible, 

due to separate arrangement of the 

machines and the engine 

- ICE mechanically connected to the wheels (� gear) 

- less transformations of energy 

� better overall efficiency than series system 

- four operating points available: 

- electrical traction 

- ICE-traction 

- ICE-traction + charging of battery 

- electrical- and ICE-traction („boost” at peak load) 

- continuous combination of series and parallel 

hybrid system 

� overall efficiency like parallel hybrid system 

- “down-sizing” is possible 

� less frictional losses 

� better overall efficiency 


Electrical Steels in Automotive Drive Systems 

• Standard solution: Start motor + Alternator 

starter alternator 

alternator stator laminations 

• Higher efficiency: Starter-Alternator featuring Start/Stop 


stator laminations of higher performance ES

Electrical Steels in Automotive Drive Systems 

• Further efficiency increase: hybrid traction 


Orion VII diesel-electric hybrid transit bus 

internal 

combustion 

engine and 

e-machine 

battery

Overview: typically used machines 

ASM SRM PMSM / BLDC 

motor converter motor converter motor converter 

efficiency + - - / 0 0 + + 

reliability + 0 - 

power density - - 0 0 + + 

torque ripple + - 0 

overload capicity + - / 0 0 

size - 0 / + + 

cost + - 0 0 / + - 0 / + 

max. revolution 0 + - 

controler complexity 

IEEE AES Systems Magazine 

- / 0 + - / 0 

DC ASM PMSM SRM 

max. efficiency (%) 85-89 94-95 95-97 90 

efficiency (load 10%) (%) 80-87 79-85 90-92 78-86 

max. revolution (rpm) 4000-6000 9000-15000 4000-10000 15000 

cost/torque ($/kW) 10 8-12 10-15 6-10 

cost of controller 1 3.5 2.5 4.5 

reliability good best good good 

Nippon Steel Technical Report 

DC ASM PMSM SRM 

power density 2,5 3,5 5 3,5 

efficiency 2,5 3,5 5 3,5 

controllability 5 5 4 3 

reliability 3 5 4 5 

technolocical maturity 5 5 4 4 

cost 4 5 3 4 

examples of 

several evaluations 

- some differences 

- distinctive similarities 

points: 1 – 5 

(ascending better) 

IEEE Transactions on Vehicular Technology 


Our hybrid offer today 

Micro Hybrid 

• Stop/Start 

• -5% energy/CO2 

•

Non-Oriented 

Fully Processed Electrical Steel range 

Thickness 0.35mm or 0.0140inch 0.50mm or 0.0185inch 0.65mm or 0.0250inch 1.00mm 

ASTM 

denisity 

IEC 60404-8-4 ASTM A677 IEC 60404-8-4 ASTM A677 IEC 60404-8-4 ASTM A677 IEC 60404-8-4 

M195-35A* 

M210-35A 

M235-35A 5 M230-50A 5 

M250-35A 5 36F145 (M15) M250-50A 5 

M270-35A 5 36F155 (M19) M270-50A 5 

M300-35A 5 36F165 (M22) M290-50A 5 47F165 (M19) 

36F175 (M27) M310-50A 5 47F180 (M22) M310-65A 5 

M330-35A 5* 36F185 (M36) M330-50A 5* 47F190 (M27) M330-65A 5 64F200 (M19) 

36F195 (M43) M350-50A 5* 47F200 (M36) M350-65A 5 64F210 (M22) 

36F205 (M45) M400-50A 5* 47F210 (M43) M400-65A 5 64F235 (M36) 

M470-50A 5 47F240 (M45) M470-65A 5* 64F250 (M43) 

M530-50A 5 47F280 (M47) M530-65A 5 64F275 (M45) 

M600-50A 5 M600-65A 5 64F320 (M47) M600-100A 5 

M700-50A 5 47F400 M700-65A 5 M700-100A 5 

M800-50A 5 47F450 M800-65A 5 M800-100A 5 

M940-50A 5 64F500 M900-100A 5 

M1000-65A 5 64F550 M1000-100A 5 

M1300-100A 5 

• Correspond with: EN 10106, JIS C 2552, GB/T 2521, ASTM A 677 

• Grades marked with * exist also in extra high permeability version 

• Grades marked in italic are not included in the standard 

• Other Fully Processed grades available on request (e.g. 0,30mm) 


Other AM Electrical Steels 

Non-Oriented 

• Thin Fully Processed grades for medium frequencies (IEC 60404-8-8) 

– 0,20 mm thickness 

• Fully Processed grades with increased yield strength (AM guarantee) 

– 0,50 and 0,65mm thickness 

• Semi-Processed grades non-alloyed and alloyed (IEC 60404-8-3) 

– Exist also in extra high perm version (AM guarantee) 

• Cold-Rolled Magnetic Laminations (no IEC, ASTM A 726) 

• Steel with specified mechanical properties and magnetic permeability 

(IEC 60404-8-5) 

– Hot-Rolled and Cold-Rolled versions 

• Steel with guaranteed punchability (AM guarantee) 

Grain-Oriented 

• Conventional Fully Processed grades (IEC 60404-8-7) 


Core 

Loss 

Product Segmentation - NO 

ArcelorMittal Group focus on the High and Ultra High Grades used in energy 

efficient machines. 

High Core 

Loss 

Ultra low 

Core Loss 

Low 

Grade 

M940 - 50A 

M800 – 50A 

M700 – 50A 

M600 – 50A 

Medium 

Grade 

M530 – 50A 

M470 – 50A 

M400 – 50A 

High 

Grade 

M350 – 50A 

M330 – 50A 

M310 – 50A 

Ultra High 

Grade 

M290 – 50A 

M270 – 50A 

M250 – 50A 

M230 – 50A 


Electro-magnetic flux generation 

Magnetic field 

(A/m) 

i 

Magnetic flux 

Φ = B.S 

Stack of 

Electrical Steel 

sheets 

B5000 (T) 

Principal role of electrical 

steels: to generate / 

concentrate magnetic 

flux 

Induction 

- For torque generation in a 

motor 

- For current generation in an 

alternator / generator 

- For transforming electric 

power to a lower/higher 

voltage level in a transformer 

with minimal losses 

- Since losses imply efficiency 

reduction and thermal issues 


5000 A/m 

Magnetic 

field

The basics: Losses 

P = 

P + P + P = W π σ 

+ σ 

hyst 

class 

exc 

(Giorgio Bertotti, IEEE Trans. Magn. 24, 621, 1988) 

• The material parameters Wh and V0 are a function of Imax and 

are defined by the material’s microstructure and texture, so 

through them the steel producer has an impact on the hysteresis 

(hyst) and the excess (exc) losses. 

• The electrical conductivity σ and the lamination thickness d are 

the parameter set the steel producer can change for reducing 

the eddy current, Foucault or classical losses (class). 

• Finally in this equation: G = 0,1357. 

2 2 2 2 

h ( I max ) f + d I max f m / 6 8 GSV0 

( I max f m 


) 

3 2

Measures taken by the steel producers to 

reduce the hysteresis impact 

Domain wall mobility 

# DWs 

Reduce impurities 

Larger Grains 

Easier magnetisation Improved Texture 


Measures taken by the steel producers to 

reduce the eddy current impact 

Resistivity 

Gauge 

Fe-Si 

Laminations 

Insulation between sheets 

Varnish, oxydes 


The basics: Losses 

P = 

P + P + P = W π σ 

+ σ 

hyst 

class 

exc 

(Giorgio Bertotti, IEEE Trans. Magn. 24, 621, 1988) 

• For low frequency applications, the relative importance of 

hysteresis losses is predominant, so optimisation concerns 

essentially the steel microstructure and texture 

– EN10106 describes 50Hz FP grades 

• For high frequency applications, the relative importance of eddy 

current losses is predominant, so optimisation concerns the 

steel resistivity, thickness and microstructure 

– EN10303 describes 400Hz FP grades 

2 2 2 2 

h ( I max ) f + d I max f m / 6 8 GSV0 

( I max f m 

→ ArcelorMittal has developed specific loss combinations for 

specific frequency ranges, down to very low losses 


) 

3 2

Hybridisation: machines → steel grades 

• Hybridisation utilises specific electrical machines, translating to 

specific electrical steel demands 

• The following slides show how ArcelorMittal’s offer includes the 

appropriate materials 

• For each machine type, we can offer the most suited grade 


Machine challenge 

Starter-Generator 

• Machine requirements 

(Integrated or belt driven type 

determines a.o. rotational 

speed) 

– Optimal efficiency at a wide 

frequency range 

– Minimal heat dissipation 

– Maximal specific power 

– Electrical machine design 

optimised together with power 

electronics 

• Machine types 

– Claw-pole (essentially EU) 

– Induction (essentially EU) 

– Permanent Magnet (essentially 

JP) 

Motor Generator 




– Maximal torque / power 


– Minimal weight / volume 

(specificity of wheel hub 

motors) 




JP) 


Some specific steel solutions 

Claw-pole and induction machines 

High Permeability – High Thermal Conductivity Fully Processed 

grades with medium loss levels 

• At moderate polarisation levels, higher efficiency achieved 

• Higher saturation polarisation permits better material use 

• Easier heat evacuation 

• Higher tool life in punching process 

• (very thin grades bring no substantial benefit to claw-pole 

machines) 


Example: M400-50A 5 

(47F210 or M43) 

Magnetic advantage of high 

perm grades 

• Same air gap flux with lower 

magnetising current 

• Better saturation behaviour 

• Thermal Conductivity 

increased with 22% 

• For similar loss levels 

Especially beneficial at low 

frequencies 


J 

Polarisation magnétique ( Tesla ) 

2,1 

2,0 

1,9 

1,8 

1,7 

1,6 

1,5 

1,4 

1,3 

1,2 

1,1 

1,0 

0,9 

0,8 

0,7 

0,6 

0,5 

0,4 

0,3 

0,2 

0,1 

à 50 Hz 

400XP - 50 

400 - 50 

0,0 

10 100 1000 10000 

Champ magnétique ( A/m ) 

H

J 

Magnetic polarisation ( Tesla ) 

2,1 

2,0 

1,9 

1,8 

1,7 

1,6 

1,5 

1,4 

1,3 

1,2 

1,1 

1,0 

0,9 

0,8 

0,7 

0,6 

0,5 

0,4 

0,3 

0,2 

0,1 

Example: M400-50A 5 (47F210 or M43) 

perm @ 1,5T (specs US: 800-1750) 

Y 

XP version Ref. J 76565 N 

standard version 

2,1 

µr 

J 50 Hz 1,9 

J 60 Hz 

1,7 

µr 


0,0 

0,0 

10 100 1000 10000 

Magnetic field ( A/m ) 

Y 

7000 

6000 

5000 

4000 

3000 

2000 

1000 

H 

µr 

J 


2,0 

1,8 

1,6 

1,5 

1,4 

1,3 

1,2 

1,1 

1,0 

0,9 

0,8 

0,7 

0,6 

0,5 

0,4 

0,3 

0,2 

0,1 

Ref. T 38727 

7000 

6000 

5000 

4000 

3000 

2000 

1000 

10 100 1000 10000 


µr 

H 

J 50 Hz 

µr 

J 60 Hz 

µr

Texture 

improvement 

methods: 

Special alloy 

& thermal 

treatment 

PHI 

PHI 

0 

10 

20 

30 

40 

50 

60 

70 

0 

1.00 

0 

2.0 

1.00 

5.0 

2.0 

3.0 

0 

3.0 

0 

10.0 

3.0 2.0 

9.0 

6.0 4.0 

8.0 

7.0 

3.0 

2.0 

0 

1.00 

0 

4.0 

0 

6.0 

04/08/2008 0 10 20 30 Confidential 40 50 60 70 80 90 

40 

1.00 

5.0 

7.0 9.0 

80 

1.00 

0 

90 

0 10 20 30 40 50 60 70 80 90 

0 

10 

20 

30 

40 

50 

60 

70 

80 

90 

1.0 

1.0 

2.0 

0 

Constante Phi2 = 45° 

7.0 

1.0 

3.0 

+thermal 

treatment 

Phi1 


4.0 2.0 

6.0 

3.0 

0 

1.0 

2.0 

1.0 

0 

2.0 

1.0 

5.0 3.0 6.0 

Phi1 

Special alloy 

PHI 

Special alloy+treatment 

0 

5.0 

4.0 

4.0 

Special alloy 

PHI 

0 

10 

20 

30 

0 

10 

20 

30 

40 

50 

60 

70 

1.0 

0 

1.0 

4.0 

4.0 



4.0 

2.0 

3.0 

1.0 

3.0 

0 

0 

1.0 

2.0 

3.0 

2.0 

2.0 

1.0 

2.0 

1.0 

80 

90 

2.0 

0 

1.0 2.0 

0 10 20 30 40 50 60 70 80 90 

0 

Phi1 

3.0 

2.0 

1.0 

40 

0 

1.0 

3.0 

50 

60 

2.0 6.0 

2.0 

5.0 

3.0 

4.0 

2.0 

5.0 

70 

1.0 

0 0 

80 1.0 

90 

0 

1.0 

0 

0 10 20 30 40 50 60 70 80 90 

+thermal 

treatment 

Phi1 

0 

0

Thermal treatment improvement ex.: 

5,000 

Hot Band Annealing 

• The reduction obtained 

on the total loss level 

via HBA is clearly due 

to a reduction in 

hysteresis losses 

1,6 

1,2 

0,8 

0,4 

0 

-500 -400 -300 -200 -100 0 100 200 300 400 500 

-0,4 

-0,8 

04/08/2008 -1,2 Confidential 41 

-1,6 

no HBA 

Ptot (W/kg) 

4,500 

4,000 

3,500 

3,000 

2,500 

2,000 

1,500 

1,000 

0,500 

Hot Band Annealed 

Ptot, Hot Band Annealed 

Ptot, no HBA 

Physt, Hot Band Annealed 

Physt, no HBA 

Bp (T) 

0,000 

0,000 0,200 0,400 0,600 0,800 1,000 1,200 1,400 1,600 1,800 

• The impact of HBA on the 

hysteresis loop shape is most 

prominent around the 

deflection point, which reflects 

the impact of texture 

=> The magnetisation loop is 

steeper

Thermal Conductivity 

• Replacing alloying by other product improvement elements, 

allows improving the heat evacuation ease out of the machine 

κ = α p C 

Thermal Conductivity (W/mK) 

50 

45 

40 

35 

30 

25 

20 

Thermal conductivity κ (W/mK) determined via: 

δ 

Diffusivity a (mm²/s): Laser Flash = Transient method. 

Density d (g/cm³): Double Weight test (picnometer). 

Specific heat Capacity Cp (J/gK): Differential Scanning Calorimetry (DSC). 

M400XP-50A 

M400-50A 

0.00 0.50 1.00 1.50 2.00 

Si + Al (%) 

2.50 3.00 3.50 4.00 

162 °C 

124 °C 


85 °C 

50 °C

W 

Specific losses ( W/kg ) 

1000,000 

100,000 

10,000 

Summary: overview of production parameter impact 


1,000 

0,100 

0,010 

Improve hysteresis, eddy currents, excess: 

Texture, Structure, Chemistry, Stresses, 

Surface state 


0,001 

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 


Ref. F 82631 N 

700 Hz 

400 Hz 

200 Hz 

100 Hz 

60 Hz 

50 Hz 

J 

J 


2,1 

2,0 

1,9 

1,8 

1,7 

1,6 

1,5 

1,4 

1,3 

1,2 

1,1 

1,0 

0,9 

0,8 

0,7 

0,6 

0,5 

0,4 

0,3 

0,2 

0,1 

50 Hz 

60 Hz 

100 Hz 

200 Hz 

400 Hz 

700 Hz 

Texture improvement: 

Thermo-mechanical process 

Chemical composition 

Facilitate domain wall movement: 

Chemistry purification 

Internal tension reduction 

Increasing grain size 

0,0 

10 100 1000 10000 


Chemical composition: 

Reduce Si, Al 

Ref. F 82631 N 

H

Compromises to be made 

• Si increases the resistivity, 

so reduces the eddy current losses, 

but in parallel reduces the saturation level 

• Larger grains reduce the hysteresis losses, 

but soften the mechanical properties 

⇒ Specific grades are needed for specific applications 


Machine challenge 

Starter-Generator 


(Integrated or belt driven type 

determines a.o. rotational 

speed) 



– Minimal heat dissipation 


– Electrical machine design 

optimised together with power 

electronics 


– Claw-pole (essentially EU) 



JP) 

Motor Generator 




– Maximal torque / power 


– Minimal weight / volume 

(specificity of wheel hub 

motors) 




JP) 


Wheel-hub motors 

Technology 

• Brushless AC PM motor 

• With gearbox: for high speed, but rotor speed → iron losses → cooling 

• Without gearbox: for direct drive → low speed, higher torque 

• Lowest loss FeSi steels used in 0,35mm or less, higher saturation is beneficial 


Some specific steel solutions 

Permanent magnet machines 

Low loss Fully Processed grades 

• Reduced losses at higher frequencies and in presence of harmonics, 

bringing minimal heat dissipation 

• Thin materials for eddy currents reduction and skin effect minimisation 

– NO20 grade is designed for 400Hz applications 

– Non standardised thicknesses such as 0,3mm 

• Low coercive fields 

• For specific rotor geometries, higher permeability, additionally to the 

low losses, can present an advantage 

• Higher yield strength grades for higher rotational speeds 

– 70MPa Re variation for a given steel grade is easily possible, 

depending on the chosen production process 

• Optimised coatings for maximising tool life in punching process 

– Typically, applying an EC-5 or EC-6 coating reduces the wear with 

80-85%; an EC-3 with 92% 


– Cr-free solution for EU regulations

W 


1000,000 

100,000 

10,000 


(better than 36F145 or M15) 

1,000 

0,100 

0,010 

Improve hysteresis, eddy currents, excess: 

Texture, Structure, Chemistry, Stresses, 

Surface state 


0,001 

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 


Ref. F 82631 N 

700 Hz 

400 Hz 

200 Hz 

100 Hz 

60 Hz 

50 Hz 

J 

J 


2,1 

2,0 

1,9 

1,8 

1,7 

1,6 

1,5 

1,4 

1,3 

1,2 

1,1 

1,0 

0,9 

0,8 

0,7 

0,6 

0,5 

0,4 

0,3 

0,2 

0,1 

50 Hz 

60 Hz 

100 Hz 

200 Hz 

400 Hz 

700 Hz 

Texture improvement: 

Thermo-mechanical process 

Chemical composition 

Facilitate domain wall movement: 

Chemistry purification 

Internal tension reduction 

Increasing grain size 

0,0 

10 100 1000 10000 


Chemical composition: 

Reduce Si, Al 

Ref. F 82631 N 

H

W 


Example: M195P-35A 5 

1000,000 

100,000 

10,000 

1,000 

0,100 

0,010 


0,001 

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 


Grade: M 195 - 35 A 

Typical curves W ( J ) 

Ref. BRMOY12 I 

2500 Hz 

1500 Hz 

1000 Hz 

700 Hz 

400 Hz 

200 Hz 

100 Hz 

60 Hz 

50 Hz 

J 

J 


2,1 

2,0 

1,9 

1,8 

1,7 

1,6 

1,5 

1,4 

1,3 

1,2 

1,1 

1,0 

0,9 

0,8 

0,7 

0,6 

0,5 

0,4 

0,3 

0,2 

0,1 

50 Hz 

60 Hz 

100 Hz 

200 Hz 

400 Hz 

700 Hz 

1000 Hz 

1500 Hz 

2500 Hz 

0,0 

10 100 1000 10000 


Grade: M 195 - 35 A 

Typical curves J ( H ) 

Ref. BRMOY12 I 

H

Non-Oriented 

Fully Processed Electrical Steel range (IEC 60404-8-4) 

Thickness (mm) 0.35 

M195-35A 5* 

ASTM denisity 

M210-35A 5 

0.50 0.65 1.00 

M235-35A 5 M230-50A 5 

M250-35A 5 M250-50A 5 

M270-35A 5 M270-50A 5 

M300-35A 5 M290-50A 5 

M310-50A 5 M310-65A 5 

M330-35A 5* M330-50A 5* M330-65A 5 

M350-50A 5* M350-65A 5 

M400-50A 5* M400-65A 5 

M470-50A 5 M470-65A 5* 

M530-50A 5 M530-65A 5 

M600-50A 5 M600-65A 5 M600-100A 5 

M700-50A 5 M700-65A 5 M700-100A 5 

M800-50A 5 M800-65A 5 M800-100A 5 

M940-50A 5 M900-100A 5 

M1000-65A 5 M1000-100A 5 

M1300-100A 5 

• Correspond with: EN 10106, JIS C 2552, GB/T 2521, ASTM A 677 

• Grades marked with * exist also in extra high permeability version 

• Grades marked in italic are not included in the standard 

• Other Fully Processed grades available on request (e.g. 0,30mm) 


ArcelorMittal can offer you a wide range 

of magnetic materials 

Electrical Steels 

• The heart of an electrical motor 

or generator 

• Determining to a large extent the 

performance of these machines 

– Power output 

– Efficiency 

– Power density 

– Heat dissipation 

Contact 

sigrid.jacobs@arcelormittal.com 

www.arcelormittal.com/fcs (not a 

global catalogue yet, but technical information 

on all AM products can be easily discussed) 

Special alloys FeNi FeCo 

• For outstanding performance of 

sensors and actuators 

– Sensitivity 

– Reliability 

• Linked with specific application 

demands 

– Dynamic behaviour 

– High Power density 

– High temperature 

– Corrosion 

Contact 

herve.fraisse@arcelormittal.com 

www.imphyalloys.com 


ArcelorMittal 

Main R&D Centers for Electrical Steels 

AM Timóteo 

AM Gent 


AM Electrical Steel Research Centres 

• Product development and optimisation 

– Pilot lines for small scale ES 

substrate and coating production 

– Modelling tools for steering 

production processes 

– Texture control (XRD, EBSD) 

– Precipitate control (SEM, TEM, 

quantification methods) 

– Chemical composition (spectro, 

combustion, GDOES, XPS, Auger) 


Precipitated Mass Fraction (ppm) 

50 

40 

30 

20 

10 

0 

500 

600 

700 

800 

900 

1000 

Temperature (°C) 

TiN TiS Ti4C2S2 MnS 

TiC AlN NbC VC 

1100 

1200 

1300 

1400


• Production support 

– Magnetic measurements 

• In-line: process control 

• Off-line: advanced characterisation 

– Mechanical measurements 

• Tensile tests under low – high 

temperatures 

• Fatigue 

– Coating systems 

• Curing control 

• Mechanical property development 

– Electrical Conductivity 

• Coating 

• Steel low-high temperatures 

– Thermal Conductivity 

3rd and 5th harmonic 


2D


• Customer Technical Support 

– Modelling tools 

• FEM machine modelling 

• Annealing process modelling for 

Semi-Processed products 

– Punching expertise 

– Sample characterisation for 

process optimisation 

• Welding 

• Deformation 

Punch 

streamer 

Planishing 

machine 

Feeder & 

Lubrification 

60 T PRESS 


Edge 

rounding 

Front 

face 

wear 

Lateral 

wear 

Tool

AM can provide you with Electrical Steels 

• For the e-machines required for 

– On-board electricity provision 

– Traction assistance / pure electric traction 

– Additional safety / comfort features 

• With a wide range of electrical steel types including the highest 

performance types 

– Excellent compromise of higher permeability, higher thermal 

conductivity at medium loss levels for Induction Machines 

– Lower loss dissipation and Improved high frequency 

behaviour via thin low loss grades for Permanent Magnet 

Machines 


Conclusions 

• By ’12 CO2 needs to reduce from an average 162 to 130g/km in EU, which is 

another 20% 

• Hybridisation of the traction drive train is one of the unavoidable steps to get 

there, if we are not prepared to switch to smaller, less sporty cars 

• ArcelorMittal is ready to supply a wide product 

range 

• We assist you with a highly skilled team for 

technical support and co-engineering 

• Thanks to our global presence we are able to 

support our global customers

Enhanced fully processed electrical steels for automotive ... - ABM

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