Author: Site Editor Publish Time: 2025-03-29 Origin: Site
As technology merges with electromagnetic innovation, electric motors (EV motors) powering modern electric vehicles achieve up to 95% operational efficiency. According to World Steel Association data, approximately 230 million tons of electrical silicon steel are consumed globally annually - this critical material is rewriting the rules of energy transfer in modern industries. Comprising ~30% of motor core costs, selecting electrical silicon steel resembles choosing vascular stents for heart bypass surgery: even 0.01mm precision differences decisively impact efficiency, energy consumption, and lifespan. This guide decodes silicon steel sheets' definitions, classifications, and pivotal roles in core applications.
Electrical silicon steel: Iron-based soft magnetic alloy containing 0.5%-6.5% silicon. Two revolutionary properties:
Low iron loss: Silicon increases resistivity 4-5x (0.5μΩ·m), suppressing eddy current losses to <1/3 of regular steel
High permeability: Flux density (B value) reaches 1.7-2.0T, 2-3x pure iron
This combination makes it ideal for motor stator cores, especially in EV motor cores requiring 15,000rpm operation.
Category | Types | Key Properties | Applications |
Production Method | Hot-rolled silicon steel | Thickness>0.5mm, Cost-effective， Iron Loss>7W/kg | Transformers, Low-power motors |
Cold-rolled silicon steel | Thickness 0.15-0.5mm, Iron Loss<4.5W/kg | EV motor cores, Servo motors | |
Crystal Orientation | Oriented (CRGO) | +30% permeability in rolling direction | Power transformers |
Non-oriented (CRNGO) | Isotropic, superior stamping | Rotary motor cores | |
Silicon Content | Low-silicon (Si≤2.8%) | High strength (15,000rpm capable) | High-speed spindle motors |
High-silicon (Si≥3%) | 50% lower loss, 3x brittleness | High-frequency transformers |
(Sources:https://ecommerce.ibaosteel.com/portal/download/manual/NGO.pdf https://www.jfe-steel.co.jp/en/products/electrical/catalog/f1e-001.pdf ）)
Electric motors in alternating fields experience two losses: Eddy currents (induced circular currents → Joule heating) and Hysteresis (energy consumed by magnetic domain flipping).
Silicon boosts resistivity 4-5x vs pure iron (0.1→0.5μΩ·m), dramatically suppressing losses. Conventional steel could multiply iron losses, causing efficiency drops or burnout.
From 1950s hot-rolling to modern 3-stage cold rolling (hot roll → normalize → cold roll+anneal), grain size reduced from 50μm to 15μm, permeability +40%. Latest CVD techniques enable 6.5% high-silicon steel production.
Advanced CNC high-speed cutting (HSM) minimizes heat-affected zones (HAZ <0.1mm), critical for preserving magnetic properties in thin-gauge silicon steel (0.15-0.5mm)
(Source: https://max.book118.com/html/2020/1226/5220301221003100.shtm )
Material | Cost (USD/kg) | Loss Reduction | Processing Difficulty | Applications |
Silicon steel | 1.5-4.5 | Baseline | ★★☆ | General-purpose |
Amorphous alloy | 12-22 | 60% lower | ★★★★★ | High-frequency transformers |
Fe-Co alloy | 45-75 | 30% lower | ★★★★☆ | Aerospace motors |
(Source: Lamnow 2025 New Energy Vehicle Motor Materials Report)
The non-oriented silicon steel sector faces stricter performance/environmental standards. With EV and renewable energy growth, demand for high-B, low-loss CRNGO will surge. Innovations will focus on alloy formulas and heat treatment improvements. Smart manufacturing and digital supply chains will enhance sustainability.
(Source: QY Research Report)
Tesla Model 3's motor design exemplifies the strategic selection of silicon steel to optimize electromagnetic performance and energy efficiency. Here’s a data-driven analysis of its core material choices:
Material Type: Non-Oriented Silicon Steel (CRNGO): Selected for isotropic magnetic properties, critical for high-speed (15,000–18,000 rpm) EV motor operation.
Thickness: 0.25–0.27mm cold-rolled sheets, reducing eddy current losses by 45% compared to traditional 0.35mm variants at 800Hz operating frequencies.
Performance Metrics:
Magnetic Flux Density: Achieves 1.7–2.0T (L15WV1000 grade), enabling compact motor designs with high torque density.
Iron Loss: Maintains ≤4.5W/kg at 1.5T/50Hz, supporting >95% motor efficiency under typical driving conditions.
Cost-Efficiency:
Silicon steel constitutes ~18% of the motor’s material cost (vs. 29% for magnets).
Tesla’s shift to thinner 0.27mm CRNGO reduced annual energy losses by 12% in Model 3 drivetrains, translating to $270/year savings per vehicle.
Technical Trade-offs
High-Speed Limitations: At 18,000 rpm, 0.25mm silicon steel requires precision laser cutting (HAZ <0.1mm) to prevent magnetic degradation, increasing production costs by 15%
Thermal Stability: Combined with SiC MOSFETs (90% inverter efficiency), the silicon steel core ensures <5% efficiency drop even at 150°C operating temperatures.
Industry Benchmark
Tesla’s approach aligns with Nissan Leaf II and BMW i3, which use 0.25–0.27mm silicon steel for high-efficiency motors, but Tesla achieves 3% higher power density through advanced lamination and annealing processes.
The evolution of electric vehicle (EV) motors demands ultra-thin, high-performance silicon steel laminations. This section compares 0.15mm and 0.35mm silicon steel, analyzing their impact on energy efficiency, manufacturing costs, and application suitability for next-gen EV propulsion systems.
0.15mm Silicon Steel:
High-Frequency Efficiency: Reduces eddy current losses by 10%+ compared to 0.35mm variants, critical for EV motors operating at 15,000–20,000 rpm.
Magnetic Flux Density: Achieves L15WV1000 grade (1.7–2.0T), enabling higher torque density in compact motor designs.
(Source: http://www.csteelnews.com/qypd/ywjx/202501/t20250107_96197.html )
Weight Reduction: Thinner laminations decrease core mass by ~30%, enhancing power-to-weight ratios for extended EV range 3.
0.35mm Silicon Steel:
Cost-Effective for Low-Frequency: Ideal for <400Hz applications (e.g., household appliances), with iron losses ≤6.0W/kg at 1.5T/50Hz.
Mechanical Robustness: Higher tensile strength (>500MPa) suits high-vibration environments but sacrifices efficiency at elevated frequencies.
Parameter | 0.15mm Silicon Steel | 0.35mm Silicon Steel |
Optimal Frequency | >800Hz (EV traction motors, drones) | <400Hz (low-power HVAC motors) |
Key Markets | EVs, robotics, wireless charging | Industrial motors, transformers |
Case Study | Liansteel's 0.15mm CRNGO: Used in Tesla Model Y drive units, reducing energy loss by 12% at 18,000 rpm | Baowu 35WH360: Dominates IE3-class industrial motors due to cost-efficiency |
Material Costs:
0.15mm: $4.5–6.0/kg (premium for precision rolling and annealing).
0.35mm: $1.5–3.0/kg (standard cold-rolled processes).
Lifetime Savings: A 100kW EV motor using 0.15mm steel saves $2,700/year in energy costs vs. 0.35mm
0.15mm Production: Requires twenty-roll cold mills with ±0.5μm precision to prevent edge cracking.
Laser cutting HAZ (heat-affected zone) must be <0.1mm to preserve magnetic properties.
0.35mm Production: Mature stamping workflows with 92%+ material utilization, but limited to <600Hz applications .
Thinner = Smarter: By 2030, 0.10mm silicon steel is expected to dominate ultra-high-speed EV motors (>25,000 rpm), with Chinese manufacturers like Ansteel already prototyping.
（Source： https://finance.sina.com.cn/jjxw/2024-11-20/doc-incwtmah5274903.shtml ）
Sustainability: 0.15mm’s 95% recyclability aligns with EU Battery Directive 2027, driving adoption in Europe’s EV supply chains.
Low-frequency (<400Hz): Like city sedans, household electric motors thrive with cost-effective non-oriented silicon steel (CRNGO).
Mid-frequency (400-1000Hz): For EV motors (the "SUVs" of mobility), upgrade to 6.5% high-silicon steel to slash "fuel consumption" (iron losses).
High-frequency (>1kHz): Wireless charging modules (the "F1 racers") demand amorphous alloys to prevent "engine overheating" (high-frequency losses).
Eddy Current Loss: Higher Si = ↑Resistivity → ↓Loss (Rule: +5% Si content → 30% loss reduction)
Hysteresis Loss: "Softer" material (low coercivity) = Easier magnetization → Like smoothing water flow
Anomalous Loss: Laser scribing = Coating bucket walls → Breaks large vortices into micro-eddies
Case Study: Vacuum Motor at 15,000rpm: 2.8% Low-Si Steel: Requires >500MPa tensile strength
Analogy: 5 elephants balanced on a postage stamp
6.5% High-Si Steel: Demands carbon fiber reinforcement → +40% cost
Option | Material Cost | Energy Cost | 5-Year Total |
Standard CRNGO | $375k | $2.7M | $3.075M |
High-grade steel | $600k | $1.8M | $2.4M |
Drawing parallels to eco-labels on coffee cups:
C5-grade coating: Equivalent to "biodegradable materials," with VOC emissions <5ppm
Chromium-free treatment: Like "CFC-free refrigerators," eliminating heavy metal contamination risks
Recycling rate: High-quality silicon steel achieves 95% recyclability – old motor cores = new mineral reserves
Q1: Can CRNGO handle >800Hz?
A: Switch to 6.5% high-Si steel; CRNGO eddy losses exceed 60%.
Q2: Decoding 50W600 grade?
A: 0.50mm thickness (50), non-oriented (W), loss ≤6.0W/kg @1.5T/50Hz.
Q3: What impact does laser cutting have on the magnetic properties of silicon steel?
A: CH Laser High-Precision Laser Cutting Machine engineered specifically for electric motor core prototyping applications, this system features:
Cutting area: Up to 1300mm×1300mm
Material thickness: 0.1-0.5mm (supports bonded layer processing)
Revolutionary efficiency: Delivers 3.2× faster cutting speed vs traditional methods for 0.1-3mm silicon steel sheets
HAZ control: <0.1mm heat-affected zone minimizes magnetic performance degradation.
https://www.chlaser.com/motor-core-lamination-prototyping.html
Q4: Insulation necessity?
A: Coatings reduce loss 15-20% (ASTM A976 C5: >50Ω·cm²).
Q5: Amorphous replacement?
A: Silicon steel remains cost-effective for <20kHz; 75% market share through 2030 (IEA).
Q6: What are the practical performance differences between silicon steels with varying crystalline orientations?
A:Grain-oriented silicon steel (CRGO):
Delivers ~30% higher magnetic permeability along the rolling direction, making it the premier choice for power transformers and other high-permeability-demand applications.
Non-oriented silicon steel (CRNGO):
Exhibits isotropic magnetic properties and superior stamping performance, ideal for rotary motor cores and scenarios requiring complex stamping geometries.
Engineered to overcome EV motor core R&D bottlenecks, our CX-CC Series delivers:
Precision breakthrough: ±0.01mm positioning accuracy for cutting 35H210 high-grade silicon steel.
Intelligent nesting: 92% material utilization rate – 25% improvement over conventional methods
Mold-free revolution: Hours-to-days turnaround from design to prototype delivery
Supports 1300×1300mm (jumbo panels) for full-scale validation
Experience Prototyping Efficiency
Claim Your Tailored Solution Today: https://www.chlaser.com/contactus.html
From Tesla's cutting-edge electric motors to the colossal generators at China's Three Gorges Hydropower Station, silicon steel sheets – with a staggering global consumption of 230 million tons annually (World Steel Association) – are the unsung heroes powering humanity's efficiency leap. When you choose CH-Laser's Rapid Prototyping Motor Stator & Rotor Core Laminations, you're not just selecting precision-cut metal – you're embracing 27 years of metallurgical mastery that transforms electromagnetic fields into symphonies of efficiency.
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