Abstract
In the planar flow casting (PFC) process, the cooling rate significantly affects the structure and properties of a cast ribbon. The influence of the thermal conductivity of the cooling wheel substrate on cooling rate was simulated by a numerical method, and it is shown that a higher thermal conductivity of the cooling wheel substrate leads to a higher cooling rate in the PFC process. Two copper-beryllium (Cu-2Be) rings with thermal conductivities of 175.3 W/m·K and 206.5 W/m·K were manufactured and installed onto a wheel core as the substrate of the cooling wheel. The effects of cooling rate on the soft magnetic properties of Fe-Si-B amorphous ribbons were investigated by pragmatic ribbon casting. The results show that the increment in the thermal conductivity of the cooling wheel substrate from 175.3 W/m·K to 206.5 W/m·K lowered the coercive force of amorphous ribbon from 2.48 A/m to 1.92 A/m and reduced the core losses at 1.4 T and 50 Hz by up to 22.1%.
Highlights
Fe-based amorphous ribbons play an important role in high-efficiency energy conversion devices, and have been widely used in the fields of electric power, power electronics and renewable energy as distribution transformers [1,2,3], medium-frequency inductors [4], reactors [5], and motors [6,7], etc
To estimate the influence of the thermal conductivity of the cooling wheel substrate on the cooling rate of solidified alloy in the puddle region, the planar flow casting (PFC) process was simulated and thermal conductivities of 175.3 W/m·K and 206.5 W/m·K were used for the Cu-2Be rings as a substrate of the cooling wheel
The influence of the thermal conductivity of the cooling wheel substrate on the cooling rate in the PFC process was simulated by a numerical method, and the results show that the increase in the thermal conductivity of the cooling wheel substrate from 175.3 W/m·K to 206.5 W/m·K led to an increase in cooling rate from 1.2 × 106 K/s to 1.44 × 106 K/s during the PFC process
Summary
Fe-based amorphous ribbons play an important role in high-efficiency energy conversion devices, and have been widely used in the fields of electric power, power electronics and renewable energy as distribution transformers [1,2,3], medium-frequency inductors [4], reactors [5], and motors [6,7], etc. Fe-based amorphous ribbon materials are characterized as energy-saving materials, due to the one-step energy-saving production process of planar flow casting (PFC) [8], and the novel properties arising from their unique microstructure as well as the thin ribbon gauge [9]. The configuration parameters mainly include nozzle configuration parameters, such as the slot width of the nozzle, inclination angle of nozzle, parallelism of the nozzle to the axis of the cooling wheel, etc., and cooling wheel configuration parameters such as the cooling wheel dimensions, thickness of the cooling wheel substrate and thermal conductivity of cooling wheel substrate, etc. The casting process parameters mainly include the temperature of molten alloy, applied pressure of the molten alloy to the bottom of the nozzle, the nozzle–wheel distance, velocity of cooling wheel substrate, and temperature and flow rate of coolant in the cooling wheel. PFC processes have been the subject of numerous studies by a number of scientists and engineers, with the emphases mainly focused on puddle formation [11,12] and process stability [13,14], as well as the influences of processing parameters and processing conditions on materials structure [15,16], ribbon thickness [17,18], and ribbon surface topography [19,20]
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