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Comprehensive assessment of the magnetic behavior of grain-oriented steel (GO) Fe–Si sheets, going beyond the conventional characterization at power frequencies along the rolling direction (RD), can be the source of much needed information for the optimal design of transformers and efficient rotating machines. However, the quasi-monocrystal character of the material is conducive, besides an obviously strong anisotropic response, to a dependence of the measured properties on the sample geometry whenever the field is applied along a direction different from the rolling and the transverse (TD) directions. In this work, we show that the energy losses, measured from 1 to 300 Hz on GO sheets cut along directions ranging from 0° to 90° with respect to RD, can be interpreted in terms of linear composition of the same quantities measured along RD and TD. This feature, which applies to both the DC and AC properties, resides on the sample geometry-independent character of the RD and TD magnetization and on the loss separation principle. This amounts to state that, as substantiated by magneto-optical observations, the very same domain wall mechanisms making the magnetization to evolve in the RD and TD sheets, respectively, independently combine and operate in due proportions in all the other cases. By relying on these concepts, which overcome the limitations inherent to the semi-empirical models of the literature, we can consistently describe the magnetic losses as a function of cutting angle and stacking fashion of GO strips at different peak polarization levels and different frequencies.

We investigate in theory and experiment the frequency dependence of magnetic losses in Grain-Oriented 0.29 mm thick high-permeability steel sheets up to 10 kHz. Such an unusually broad frequency range, while responding to increasing trends towards high-frequency regimes in applications, is conducive to a complex evolution of the magnetization process, as imposed by increasing frequencies to a non-linear high-permeability saturable material. We show that the concept of loss decomposition, supported by observations of the domain wall dynamics through Kerr experiments, is effective in the assessment of the broadband frequency dependence of the energy loss. By calculating, in particular, the instantaneous and time averaged macroscopic induction profiles across the sheet thickness through the Maxwell’s diffusion equation, the classical loss component Wclass, versus frequency f and peak polarization Jp, is obtained. A simplified theoretical approach is pursued in this case by identifying the normal magnetization curve with the magnetic constitutive equation of the material. While the hysteresis loss Whyst is shown to invariably increase with frequency, the excess loss Wexc, the quantity directly associated with the eddy currents circulating around the moving domain walls, tends to vanish upon increasing both frequency and induction values. The Kerr experiments actually show that, while the oscillating 180° domain walls can adjust to the depth of the induction profile by bowing at low Jp values, the magnetization reversal at high inductions and high frequencies occurs by inward motion of symmetric fronts originating at the sheet surface, according to a classical framework.