40.5 Armored Remova

1.Core Material Selection Standards

①Core Materials: Amorphous alloys (Fe-Si-B series, thickness 0.02-0.03mm) or nano-crystalline alloys (nano-crystalline ribbons, saturation magnetic flux density ≥1.8T) are preferred, which must meet the requirement of no-load loss ≤0.1W/kg (50Hz); traditional silicon steel sheets use high-magnetic-induction oriented silicon steel such as 30Q130, with iron loss ≤1.3W/kg.

②Winding Conductors: High-purity oxygen-free copper wires (oxygen content ≤0.003%) or copper foils (thickness 0.5-3mm) are used, with electrical conductivity ≥98% IACS and tensile strength ≥300MPa; for special scenarios (e.g., high-corrosion environments), tinned copper wires or aluminum-magnesium alloy wires can be used (with supporting anti-corrosion treatment).

③Insulation Materials: Materials with temperature resistance ≥180℃ are selected according to the insulation class (Class H or Class C), such as Nomex paper, polyimide film, and epoxy glass cloth board, which must pass the UL94 V-0 fire certification and have UV resistance and anti-aging properties (no cracking after accelerated aging test ≥1000 hours).

2.Preprocessing Technology

①Conductor Preprocessing: Copper wires/foils are annealed in a continuous annealing furnace (temperature 400-500℃, nitrogen protection) to eliminate stress and improve ductility; the surface is phosphated (to form an oxide film) or tinned (thickness 5-10μm) to enhance adhesion to the insulation layer.

②Insulation Material Preprocessing: Insulation paper/film is vacuum-dried (80-100℃, vacuum degree ≤10Pa) to remove moisture (moisture content ≤0.5%); glass fiber cloth needs to be pre-impregnated with glue (epoxy resin content 30-40%) to ensure uniform curing in subsequent processes.

③Auxiliary Material Preprocessing: Aluminum profiles (radiators) used in the cooling system undergo anodization (film thickness ≥15μm) or fluorocarbon spraying (thickness 50-80μm), passing a salt spray test ≥1000 hours; oil tank steel plates (Q235B) are derusted by sandblasting (Sa2.5 level) to improve paint film adhesion.