Soft Magnetic Iron, Electro Magnetic Iron, Pure Iron
Leading Importer And Stockholder of Soft Magnetic Iron, Electro Magnetic Iron, Pure Iron Rods, Bars, Sheets, Plates, Strips, Coils, Foils, Bands, Wires, Billets, Ingots Fe-99.9% Fe-99.95% Fe-99.96% Fe-99.97% Fe-99.98% Fe-99.99%
SOFT IRON BASE ALLOYS Soft Iron Base Alloys Soft magnetic alloys are ferromagnetic materials that are easily magnetized and de-magnetized. To provide optimal magnetic performance, these alloys possess very low levels of carbon, nitrogen, and oxygen. They rely on various additions of phosphorus, nickel, and silicon to optimize magnetic induction, permeability, and coercive force. The magnetic properties of all of these alloys benefit from high temperature sintering (HT) above 2200 F (1200 C) in hydrogen, as compared to the standard PM sintering process (ST) in metal mesh belt furnaces at nominally 2050 F (1120 C). Density and grain size increases, while residual levels of carbon, oxygen, and nitrogen are reduced. Typical applications include tone wheels, relays, cores, sensor probes, armatures, solenoid components, and pole pieces. SUY-1 is a soft steel with ultra-low carbon and low impurities. The grade is defined in the standard, “JIS C 2504 Soft Magnetic Iron,” and is generally referred to as “pure iron.” There are four SUY grades from SUY-0 to SUY-3. The suffix indicates the material’s magnetic properties with grade 0 providing the best magnetic properties. SUY-1 has less carbon content and lower impurities than carbon steel. It also features good drawability and good properties as a soft magnetic material. SUY-1 is mainly used in motor applications, but is recently being used more and more as magnetic shielding. It has high flux density and coercive force, and these magnetic properties can be maximized if the material is re-subjected to magnetic annealing after the cold-rolling process. High purity soft iron suitable for the manufacture of frames, yokes, armatures, cores etc in telephone relays, solenoids, magnetic clutches, magnetic brakes and all stationary parts of magnetic circuits carrying a direct flux. Many other applications in the electrical and electronic equipment industry. Also used for Sacrificial Anodes, for example in the protection of condensers and pumps for the electricity generation and shipping industries and in water de-salination plants. Whilst strategic stock sizes are held, semi finished material is always available to enable further processing to satisfy individual customer requirements. Heat Treatment The heat treatment required to produce these typical electromagnetic properties, consists of full annealing from 920ºC (ie 920º C soak, furnace cool at 50º C/hour max to 600º C, furnace cool to room temperature). In order to avoid scaling, this treatment should be carried out in a neutral or slightly reducing atmosphere. Typical hardness after annealing 95-110 B.H.N. Annealing is normally done after any significant machining work, but can be arranged on request. Electromagnetic Properties Normally conforming to MoD specifications DTD 5092 and DTD 5102, which although obsolete, are commonly used as a basis for the typical electromagnetic properties which are expected to be achieved following the annealing process. In order to develop the optimum electromagnetic properties, the material must be subjected to the above annealing treatment, preferably after rough machining. ELECTRICAL AND MAGNETIC PROPERTIES The purity of a metal determines its electrical conductivity. This is why materials that are as pure as possible are used for all conducting parts. Electrical conductivity is affected even by very low proportions of C, Si, P, S, Mn and Cu, and these proportions are higher in the usual commercial grades of steel. PURE IRON FE, on the other hand, is sure to provide significantly better conductivity than other soft, unalloyed types of steel. Experience has shown that the specific resistance of PURE IRON FE, at 20° C temperature of the material, is ≈ 0.11 Ohm x mm²/m. Because of its high magnetic permeability, PURE IRON FE is also a material of choice for DC magnetisation of solid parts. It has a saturation of approx. 21,000 Gauss, and can thus be used wherever maximum induction is required. Particularly noteworthy characteristics of the pure and soft PURE IRON FE are its high permeability and very low coercive force. It also has outstanding magnetic properties, such as high magnetic saturation, low coercivity, high permeability, as well as excellent conductivity, especially in medium induction ranges. Each cold working process leads to stresses in the microstructure of the material, and thus to a deterioration of its magnetic properties. That is why finished parts generally need to undergo annealing when they are in final form. You will find an example on the following pages. However, our experience shows that PURE IRON FE reaches the magnetic values required by customers even without a final annealing in various applications. This is due to its high grade of purity. Precise values for specific applications can be demonstrated in experiments. The following values should be taken as guidelines: Initial permeability: 300-500, Max. permeability: 2.000-20.000, Coercive force: 15-160 A/m, Saturation induction: 2.15 T. APPLICATION CHARACTERISTICS Corrosion The purer the iron, the greater its resistance to electrolytic self-destruction, which occurs at the interfaces between the iron crystals and the accumulated alloying elements. Chemical interactions PURE IRON FE is partially resistant to acids, bases, and salt solutions, which react with the element Fe. Although PURE IRON FE cannot completely replace other rust- and acid-resistant materials, it offers advantages where certain chemical degradation of unalloyed metallic materials is acceptable. Compared to unalloyed steels, the homogeneous structure and high purity of PURE IRON FE makes it more resistant to many corroding chemicals. Oxidation he purer the iron, the better its oxidation behavior (scaling). It plays a major role particularly in thermal processing and other thermal applications. Oxidative scaling not only prevents the transfer of heat; it also has a destructive effect by reducing the thickness of the material. PURE IRON FE features increased resistance due to its firmly adhering, protective layers of scale. FROM ELECTROMAGNETIC APPLICATIONS UP TO HARDENING Because of its 99,9% pure iron PURE IRON FE can be used in a large scope of application. From high-technology up to various handcrafts. MACHININGTurning PURE IRON FE can be machined using both high-speed steel tools and carbide tools. It is extremely important that the tools are sharpened and the cutting data is carefully selected, otherwise PURE IRON FE will lubricate. Small feed rate and deep cutting will ensure most efficient rough turning. With fine turning, the feed rate should not exceed 0.1 mm if optimal surface quality and dimensional accuracy are required. When cutting data is properly selected, the turned surface appears bright; otherwise it is matt. Extremely fine-grained cutting surface is also important. Tip: Generous cooling and lubrication are essential to protect the tool and the workpiece. It is recommended to use a mineral oil with 1-1.5% sulphur and 5% grease. Milling For a fine surface, use hobbing cutters with lead angles of 45-52°. Radial rake angle: 30°. For optimal cutting speed of 25 – 45 m/min at 19 – 32 mm/min feed rate. Radial rake angle when working with side milling cutters: 10°. Tip: Check that the clearance hole of the tools is correct. For cooling and lubricating, observe the same instructions as for turning. Drilling Generally, high-speed steel drills with an acute angle of 100° provide satisfactory results. Lead angle at the cutting edge: approx. 12°. Cutting speed 20-30 m/min at a feed rate of 0.02-0.1 mm/revolution. Threading Tip: Select a slightly larger core diameter of the thread than usual. This will greatly reduce the risk of taps breakage, and ensure a clean thread. Non-cutting thread forming is recommended. Rake angle: approx. 15-20° Cutting speed: 4 6 m/min. NON-CUTTING PROCESSING Non-cutting forming Due to its mechanical properties, PURE IRON FE offers exceptional advantages in cold working with a high degree of deformation. During there is minimal compressive stress and resistance to deformation. That ensures high levels of deformation. With a controlled deformation, the tensile strength can reach twice the initial value. Tip: Hot working by rolling, forging, bending, flanging, and pressing must not take place in the red-short area from 850 to 1.050°.
High-purity iron with purity of 99.987 wt.% was prepared employing a process of direct reduction–melting separation–slag refining. The iron ore after pelletizing and roasting was reduced by hydrogen to obtain direct reduced iron (DRI). Carbon and sulfur were removed in this step and other impurities such as silicon, manganese, titanium and aluminum were excluded from metallic iron. Dephosphorization was implemented simultaneously during the melting separation step by making use of the ferrous oxide (FeO) contained in DRI. The problem of deoxidization for pure iron was solved, and the oxygen content of pure iron was reduced to 10 ppm by refining with a high basicity slag. Compared with electrolytic iron, the pure iron prepared by this method has tremendous advantages in cost and scale and has more outstanding quality than technically pure iron, making it possible to produce high-purity iron in a short-flow, large-scale, low-cost and environmentally friendly way. We can produce the special type which you ask Applications High purity iron is used largely as the basic material for (re-)melting of low-carbon, Stainless and acid-resistant steels, materials with a high nickel content, magnetic alloys as well as stainless and heat resistant steel castings in induction and vacuum furnaces. High purity iron is also used in many applications of aviation construction, nuclear Technology, the production of magnets (pole cores, yokes and armatures), in automotive construction, as magnetic shielding, as welding rods and fuse wire, as gasket in the chemical and petrochemical industry, power station construction, as anti-corrosion anode and as galvanizing tank including equipment. Mechanical properties Brinell hardness (hb) High purity iron Max. Typical Cold-rolled strip / sheet 105 90 Hot-rolled strip / plate 105 90 Quarto plate 100 90 Round bar 110 95 Electrical and magnetic properties Characteristics typical values Initial permeability 300 – 500 Permeability 3500 – 6000 Coercive force 60 – 120 a/m Saturation induction 2.15 t Density at 20 °c 7.86 kg/dm³ Melting point 1536 °c Linear expansion coefficient Temperature range 0 – 100 °c 12×10-6 1/°c Modulus of elasticity 207 kn/mm² Pure iron, which refers to iron with very few impurities, has excellent properties such as low coercivity, high ductility, soft texture as well as good performance in thermal conductivity and electrical conductivity. High-purity iron is widely used in aerospace, radio engineering, the atomic industry and other fields. It is an important raw material for the production of precision alloys, superalloys, advanced heat-resistant alloys, amorphous alloys, soft magnetic materials, permanent magnet alloys and other materials. In recent years, pure iron has been paid more and more attention due to its extensive use and high added-value. Pure iron is generally categorized as electrolytic iron and technically pure iron. Electrolytic iron can be prepared by electrolytic refining of high purity ferrous salt solution obtained by ion exchange or solvent extraction. The purity of a conventional electrolytic iron is about 99.9 wt.%, containing gaseous impurities such as carbon, nitrogen, oxygen, hydrogen, sulfur and chlorine of more than 500 mass ppm in total. To obtain higher-purity products, zone refining, electromagnetic levitation melting and vacuum induction melting are used to further purify electrolytic iron. Since a single purification method cannot meet the requirements of preparing ultra-high-purity iron, it is necessary to combine various purification methods. The common process is ion exchange + solvent extraction → electrolytic refining → cold-crucible melting → zone refining. Many efforts have been devoted to the preparation of high-purity iron. succeeded in making ultra-high-purity iron of 99.999 wt.% from pure iron by electron beam zone refining in an atmosphere of ultra-high vacuum. et al. [3–5] made a 7.5 kg ultra-high-purity iron ingot by careful refining of high purity electrolytic iron. The purity of the purified iron was determined to be 99.9988 wt.% by chemical analysis of 33 elements. et al. [6] developed a process consisting of anion exchange in a HCl solution, hydrogen reduction and plasma arc melting for the production of semiconductor grade high-purity Fe with 99.998 wt.% purity. After improving the refining efficiency, the purity of Fe achieved 99.9993 wt.% At present, the pure iron that has been produced and applied industrially is called technically pure iron, with purity ranging from 99.6% to 99.8%. As a raw material for smelting various special alloys such as superalloys, heat-resistant alloys, precision alloys and maraging steel, technically pure iron has been widely used in metallurgical industry. Technically pure iron is produced by pyrometallurgy. Firstly, iron ore is reduced to pig iron in a blast furnace, then excessive carbon is removed by the basic oxygen furnace (BOF) or electric arc furnace (EAF), and impurities are further eliminated via a secondary refining route, through which the required purity level is achieved. During the past few years, the demands for high-quality materials have grown more and more. Some alloys (e.g., heat-resistant alloys) use technically pure iron in smelting raw materials, but the impurities such as oxygen, phosphorus and sulfur in technically pure iron are not invariably low. These impurities cannot be eliminated readily during the alloy smelting process, leading to the situation that the alloy cannot achieve the desired performance [8]. The quality improvement of technically pure iron produced by hot metal from a blast furnace is hindered by impurity elements. Besides removing the impurities such as silicon, manganese and phosphorus, oxygen is injected to remove excess carbon in hot metal. Blowing oxygen causes an excess of oxygen to be brought into the hot metal, after which it is necessary to add aluminum or strictly control the C–O reaction using a vacuum for further deoxidation. This lengthy and complicated process, which revolves around decarbonization and deoxidation, violates the original intention of purification and makes it difficult to produce pure iron with high cleanliness. On the other hand, the concentrations of gas impurities (C+N+H+O+S) in common commercial electrolytic iron are generally high. Further refining would increase the cost and make it difficult to achieve an efficient production. The high-purity iron or ultra-high-purity iron with 99.99–99.999% purity is too expensive ($7000–200,000 US dollars/tonne) to be used on a large scale. Research and development of high-purity iron is still in the small-scale laboratory stage, and the supply cannot meet the demand. Therefore, the manufacture of pure iron has great market potential and profit margin. How to use short-process, low-cost and environmentally friendly manufacturing technology to produce high-quality pure iron is the future direction of research. In this study, an approach of producing high-purity iron is proposed via a direct reduction of iron ore–melting separation–refining process, by which high-purity iron with purity up to 99.987% can be produced on a large scale with low cost. The process mainly includes three major steps: Step 1, the iron ore after pelletizing and roasting is reduced by hydrogen, and direct reduced iron (DRI) that is carbon-free is obtained. Some impurities such as carbon, sulfur, silicon, manganese, titanium and aluminum cannot be reduced or get into iron in this step. Step 2, the direct reduced iron is separated into gangue (slag) and metal by melting. In this step, the composition of slag is adjusted to dephosphorize, if necessary. Step 3, the high basicity slag is dosed to refining for deoxidation. Similar to the process investigated in this study, researchers have studied the process of smelting pure iron with DRI in an induction furnace, which has delivered good results. However, these results still have the capacity to improve the impurities removal in pure iron, especially in solving the problem of deoxidation of pure iron, so the purity has not reached a high grade. As a comparison, the chemical compositions of pure iron in this work, typical technically pure iron and typical commercial electrolytic iron, are shown in Table 1. The purity of pure iron produced by the process has exceeded that of commercial electrolytic iron and technically pure iron. When the purity of pure iron reaches 3N level or above, it is very difficult to further improve the purity, and the increase of cost and price brought by this is an exponential growth. The pure iron obtained by this method has tremendous advantages in cost and scale compared with electrolytic iron and has more outstanding quality than technically pure iron. This is because this process takes full advantage of the purity advantage of DRI and solves the problem of deoxidization of pure iron in the context of large-scale production. This paper mainly expounds upon the experimental process and related mechanism of producing high-purity iron by this method, as well as the feasibility of industrialization.
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