Additive Manufacturing of Functional and Energy Materials: Magnetic Materials
Sponsored by: TMS: Additive Manufacturing Committee
Program Organizers: Sneha Prabha Narra, Carnegie Mellon University; Markus Chmielus, University of Pittsburgh; Mohammad Elahinia, University of Toledo; Reginald Hamilton, Pennsylvania State University
Thursday 8:30 AM
February 27, 2020
Room: 7B
Location: San Diego Convention Ctr
Session Chair: Markus Chmielus, University of Pittsburgh
8:30 AM Invited
When Additive Manufacturing Meets Magnetic Materials: Advanced Processing for Green Technologies: Daniel Salazar1; 1BCMaterials
The shortage of raw materials required for the development of advanced magnetic materials for energy applications drives the search of new alloys with reduced content of critical elements and performance similar to the current ones. Recent progress in magnetocaloric materials for solid-state refrigeration and high-energy permanent magnets open new opportunities to explore future technological developments in additive manufacturing. Metamagnetic shape memory alloys are promising candidates for magnetic refrigeration due to their high entropy change around the first-order martensitic transformation but their crystalline phase is unstable at high temperatures (>300ºC). Novel nitride ThMn12-based permanent magnets are good option to replace the conventional Nd-Fe-B magnet. Nd(Fe,Mo)12Nx showed high performance but they can degrade at temperatures above 400ºC when Nitrogen starts to leave the interstitial sites of the ThMn12-type structure. Different inks and filaments were developed to study the best parameters in the fabrication of complex structured materials by screen- and 3D-printing.
9:00 AM
Effect of Post-process Heat Treatment on Microstructure and Properties of a Ni-Mn-Ga Alloy Deposited Using Laser Powder Bed Fusion: Ville Laitinen1; Alexei Sozinov1; Andrey Saren1; Antti Salminen1; Kari Ullakko1; 1LUT University
In this study, a Ni-Mn-Ga based magnetic shape memory (MSM) alloy was deposited using laser powder bed fusion (L-PBF), and a systematic design of experiments approach was used for investigating the effects of post-process chemical homogenization and structural ordering heat treatment on microstructure and properties of the deposited material. The experiments were implemented using temperature and duration of the heat treatment as varied parameters. The phase transformation and Curie temperatures of each sample were determined using low-field ac magnetic susceptibility method and differential scanning calorimetry, whereas the microstructures of the samples were characterized using SEM, X-ray diffraction and atomic/magnetic force microscopy. The results show that grain growth, recrystallization, and transition of the crystal structure from the mixed martensite structure of the as-deposited material to single martensite phase occurred during the heat treatment. Consequently, the deposited material showed recovery of the typical narrow phase transformations and ferromagnetic properties.
9:20 AM
Advanced Additive Manufacturing for Functional Magnetic Materials: Markus Chmielus1; Pierangeli Rodriguez De Vecchis1; Aaron Acierno1; Danielle Brunetta1; Tyler Paplham1; Runbo Jiang1; Katerina Kimes1; Erica Stevens1; Jakub Toman1; 1University of Pittsburgh
Additive manufacturing (AM) methods, ranging from laser metal deposition to 3D ink and binder jet 3D printing, have been investigated as alternative manufacturing methods for functional magnetic materials over the past few years. These manufacturing methods hold the promise of enabling complex and currently impossible internal and external geometries, designed porosity, and varying or constant composition and properties, among others. While each new method brings new opportunities, considerations with regards to feedstock material characteristics, manufacturing, and post-processing parameters must be made to produce parts with microstructure and properties that result in functional responses to an applied magnetic field. In this talk, different additive manufacturing techniques will be compared for Ni-Mn-based magnetic shape memory alloys and magnetocaloric materials. Furthermore, modifications to the AM methods, processes, and post-processes will be described, leading to magnetically aligned printing and beneficial microstructures and properties, including multi-material printing and epitaxial resolidification.
9:40 AM
Experimental Investigation of Melt Pool Geometry, Microstructure, and Texture in NiMnGa Fabricated via Laser Powder Bed Fusion: Yao Xu1; Sneha Narra1; 1Worcester Polytechnic Institute
Polycrystalline NiMnGa has been fabricated by laser powder bed fusion (LPBF). However, the major disadvantage of polycrystalline NiMnGa is the low magnetic-field-induced-strain because of the strain incompatibility. One possible solution is to attain a microstructure with textured columnar grains. Hence, it is critical to map the effect of primary deposition parameters on NiMnGa solidification microstructure. In this work, single-bead melt tracks were deposited at different power, velocity, and spot size combinations to investigate the available processing space for LPBF processes. Grain size, orientation, composition, and melt pool geometry information were studied using SEM and optical microscopy. NiMnGa melt tracks with textured columnar grains can be achieved by altering the solidification conditions and melt pool geometry. In addition, grain size and evaporation are also a function of processing parameters. This work establishes a comprehensive understanding of the effect of primary deposition parameters on the as-fabricated NiMnGa microstructure.
10:00 AM Break
10:20 AM
Additive Manufacturing of Rare Earth Bonded Permanent Magnets: Prospects and Challenges: Parans Paranthaman1; 1Oak Ridge National Laboratory
Additive manufacturing (AM) or 3D printing is well known for producing parts without any tooling required, offering a promising alternative to the conventional injection molding method to fabricate near-net-shaped functional magnets. We compare two 3D printing technologies, namely binder jetting and material extrusion, to determine their applicability in the fabrication of Nd-Fe-B bonded magnets. Prospects and challenges of these state-of-the-art technologies for large-scale industrial applications will be discussed. This work was supported by the Critical Materials Institute, an Energy Innovation Hub funded by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office.
10:40 AM
Microstructural Characterization of Alnico Alloy Fabricated by Selective Laser Melting: Paul Rottmann1; Andrew Polonsky2; McLean Echlin2; Michael Krispin3; Gotthard Rieger3; Stefan Lampenscherf3; Tresa Pollock2; Carlos Levi2; 1University of Kentucky; 2University of California, Santa Barbara; 3Siemens AG, Corporate Technology
Alnico alloys have regained increased interest in recent years as an alternative to rare earth containing permanent magnets to alleviate issues of supply instability and sustainability. The ability to additively manufacture permanent magnets additionally promises to increase sustainability by reducing material waste while expanding capabilities to enable system integration and production of novel geometries. The magnetic properties of alnico depend on a refined microstructure, so there is the substantial hurdle of understanding the complex processing—thermal history—microstructure relationships to achieve viability. The microstructural characterization of an alnico 8 alloy fabricated by selective laser melting will be presented. Characterization was performed by TEM and using the TriBeam system at UCSB for 3D analysis. The microstructure is comparable to conventionally-produced alnico, but the presence of αγ precipitates indicates that further process tuning is needed to achieve an optimal microstructure. Preliminary results from magnetic characterization conducted at Siemens will also be presented.
11:00 AM Cancelled
Additive Manufacturing of Magnetic Materials for Advanced and Transparent Electronic Applications: Pedro Martins1; Rita Policia1; Ana Catarina Lima1; Nélson Pereira1; Esther Calle2; Manuel Vázquez2; Senetxu Lanceros-Mendez3; 1Universidade do Minho; 2Instituto de Ciencia de Materiales de Madrid; 3BCMaterials, Basque Center for Materials, Applications and Nanostructures
The demand of transparent magnetic smart materials is leading to substantial advances in principles, material combinations and technologies. Particularly, the development of optically transparent magnetoelectric (ME) composites will extend the range of applications to disruptive directions in the field of magneto-optics. In this work, a flexible and optically transparent ME composite, composed of piezoelectric P(VDF–TrFE) (piezoelectric modulus coefficient of 25 pC/N) and magnetostrictive Fe72.5Si12.5B15 microwires (magnetostriction coefficient of 35 ppm) exibits a ME voltage response 70 mV/cm/Oe and a optical transmittance of 80% suitable for transparent touch displays, actuators, sensors and coatings.
11:20 AM
Additive Manufacturing of Soft Magnetic Alloys: Mohan Sai Kiran Nartu1; Varun Chaudhary2; Sriswaroop Dasari1; Srinivas Aditya Mantri1; Raju Ramanujan2; Rajarshi Banerjee1; 1University of North Texas; 2Nanyang Technological University
While there has been substantial effort focused on additive manufacturing of structural alloys over the past couple of decades, there have been rather limited efforts on AM of functional alloys, such as magnetic materials. The present study will focus on laser additive processing of magnetic alloys using the laser engineered net shaping (LENS) process that falls under the category of directed energy deposition processes. Soft and semi-hard magnetic alloys of different types based on Fe-Co & Fe-Ni binary systems have been processed using LENS. Systematic changes in the laser-power and the travel speed have been correlated to the phase stability in the deposits of these alloys, and the consequent magnetic properties. LENS technique can also be effectively used to process compositionally-graded alloys by varying the flow rates from individual powder hoppers that comprise the feedstock for this AM process. This work shows feasibility of AM processing of soft magnetic materials.