Additive Manufacturing and Innovative Powder/Wire Processing of Multifunctional Materials: Hard and Soft Magnets
Sponsored by: TMS Functional Materials Division, TMS Materials Processing and Manufacturing Division, TMS: Magnetic Materials Committee, TMS: Additive Manufacturing Committee, TMS: Powder Materials Committee
Program Organizers: Daniel Salazar, BCMaterials; Markus Chmielus, University of Pittsburgh; Emily Rinko, Honeywell Fm&T; Emma White, DECHEMA Forschungsinstitut; Kyle Johnson, Sandia National Laboratories; Andrew Kustas, Sandia National Laboratories; Iver Anderson, Iowa State University Ames Laboratory
Tuesday 2:30 PM
March 21, 2023
Room: 23C
Location: SDCC
Session Chair: Daniel Salazar, BCMaterials
2:30 PM Invited
In Situ Analysis of the Phase Evolution in AlNiCo: Emily Rinko1; Andrrew Chuang2; Emma White3; Jordan Tiariks1; Iver Anderson4; Matthew Kramer4; 1Iowa State University; 2Argonne National Laboratory; 3DECHEMA Forschungsinstitut; 4Ames Laboratory
Developing alloys for Additive Manufacturing requires understanding of the time-temperature-transformation properties near the extremes of conventional cooling rates. The temporal and spatial varying conditions of AM builds can also lead to high residual stresses not normally found in conventional processes. Thus, adapting existing alloys, especially functional alloys like permanent magnets, to AM is a challenge. AlNiCo is an interesting functional alloy since its magnetic properties are controlled by the shape anisotropy, dictated by growth and the subsequent time-temperature pathway during cooling below the spinodal temperature. We tracked the phase evolution of AlNiCo using concurrent small-angle and wide-angle diffraction at the Advanced Photon Source at Argonne National Laboratory. These data reveal the sensitivity of the cooling rate and hold times as well as the interfacial strain that develops during cooling. These results will be compared to AM builds to try to understand the rate controlling processes for optimizing the magnetic properties.
2:55 PM Invited
Structural Magnetic Materials Build by Cold Spray Additive Manufacturing: Fabrice Bernier1; Jean-Michel Lamarre1; 1National Research Council Canada
Novel magnetic applications often require materials combining high functional and structural properties. While most additive manufacturing techniques allow for increased design flexibility and complex shape components, their deployment is limited by high electrical losses and insufficient mechanical performance. Cold spray additive manufacturing (CSAM) allows high deposition rate fabrication of magnetic components without the need for assembly. Using tailored powder feedstocks, it is possible to build components with improved mechanical properties surpassing conventional and other additive manufacturing techniques. In this presentation, recent CSAM developments on the fabrication of high integrity anisotropic NdFeB magnets and iron based soft magnetic materials will be detailed. The link between the powder mix characteristics (size distribution, shape, composition, magnetic loading), the process parameters (gas temperature and pressure), and the final properties will be analyzed. More specifically, functional material properties were optimized in terms of magnetic and mechanical performance to demonstrate their potential for future applications.
3:20 PM
Powder Fabrication and Directed Energy Deposition of AlNiCo Permanent Magnets: Saikumar Dussa1; Sameehan Joshi1; Narendra Dahotre1; Rajarshi Benerjee1; 1University of North Texas
The AlNiCo-5,8H and 9 elemental powders are mechanically alloyed by ball milling. the mechanically alloyed mixture was fed into Tekna for plasma spheroidization at different feed rate and power to study the amount of alloying. XRD was performed to analyze the phase evolution of the alloy powder. Particle size and composition of the alloy powders were analyzed by Scanning Electron Microscopy and Laser Diffraction. Alloyed powders were subjected to additive manufacturing via direct energy deposition to examine the manufacturability. The magnetic properties of the AlNiCo samples such coercivity, remanence and maximum energy product(BHmax) were compared with cast and sintered AlNiCo magnetic properties. Effect of magnetic annealing was brought out as well
3:40 PM Invited
Alignment of Magnetic Particles during Additive Manufacturing of Anisotropic Bonded Permanent Magnets: Ikenna Nlebedim1; 1Ames National Laboratory, US-DOE
Additive manufacturing (AM) of near-net-shaped bonded magnets can help address the criticality of rare earths due to waste minimization and opportunity to reuse feedstock materials. In addition to high volumetric filling fraction of magnetic powder in a polymer binder, high-performance bonded magnets need alignment of the anisotropic magnetic particles. Although post-printing magnetic alignment has been considered, integration of magnetic field sources into AM systems for in-situ alignment will open new horizons for manufacturing complex bonded magnets. This talk will focus on the considerations for achieving high-degree of magnetic field-induced alignment in 3D printing of polymer bonded magnets. The presentation will include the resultant degree of alignment due to competing effects including alignment temperature, applied magnetic field, magnetic particles interactions, loading fraction, and the thermo-rheological state of the polymer. Hence, the talk will shed light into how processing parameters can be tuned for high-performance AM bonded magnets development.
4:05 PM Break
4:20 PM Invited
Magnetocaloric Composites for Fused Filament Fabrication: Victorino Franco1; Álvaro Díaz-García1; Luis M. Moreno-Ramírez1; Jorge Revuelta1; Jia Yan Law1; 1Universidad de Sevilla
Additive manufacturing techniques of magnetocaloric materials are limited by the fact that melting the magnetocaloric phase has deleterious effects on the functionality of printed parts. In fact, laser melting techniques make the active phase transform, reducing the magnetocaloric response of the sample. In this talk we present a physical method for the production of uniform polymer based composite filaments for fused filament fabrication. The presence of functional fillers in the composite alters the transformation temperatures of the polymer and modifies the printing conditions. A comparison between the magnetocaloric response of the fillers (Heusler alloys and hydrogenated La(FeSi)13 powders) and that of the filaments and printed parts demonstrate that this printing technique does not affect the functionality of the active material.Supported by Grant PID2019-105720RB-I00 funded by MCIN/AEI/10.13039/501100011033, Consejería de Economía, Conocimiento, Empresas y Universidad de la Junta de Andalucía (grant P18-RT-746), and US Air Force Office of Scientific Research (FA8655-21-1-7044).
4:45 PM
Electrohydrodynamic 3D Printing of Magnetic Composites: Ander Reizabal1; 1BCMaterials - Basque Center for Materials, Applications and Nanostructures
Aqueous solutions electrowriting shows great potential for high-resolution microscale printing while bringing new opportunities for new materials processing. To boost its visibility, current research brings the combination of new technology, sustainable inks, and composites development to fulfill advanced applications. A cryogenic stage allows the freezing of EHD jets, to facilitate the 3D growth of structures. Highly viscous silk fibroin aqueous solutions, bring microfibers of around 30 µm which can be successfully stacked on each other to achieve complex micro-structures. The further combination with magnetic nanoparticles allows the scaffolds to respond to magnetic fields. The obtained structures, show excellent biological response and capacities for cell guidance, but also the potential for soft robotics and actuators. With this approach, the suitability of a new type of 3D-printed material is achieved, as the time that the complexity and requirements of the new technology are tested.
5:05 PM
Effect of Chromium Content on the Magnetic Behavior of Direct Energy Deposited FeNiCo Alloys: Madhavan Radhakrishnan1; Michael McKinstry1; Sai Kiran Nartu1; Varun Chaudhary2; Raju Ramanujan2; Rajarshi Banerjee1; Narendra Dahotre1; 1University of North Texas; 2Nanyang Technological University
The soft magnetic behavior and microstructures of direct energy deposited (FeNiCo)1-xCrx high entropy alloys has been investigated as a function of chromium content using VSM and electron microscopy. The saturation magnetization of the ternary FeNiCo at room temperature monotonously decreased as the concentration of Cr increased, and the magnetic behavior transformed to paramagnetic at the equiatomic composition. High temperature magnetic measurements revealed that the Curie transition temperature of the ferromagnetic FeNiCo alloy gradually decreased with Cr content, while the paramagnetic equiatomic alloy showed a transition temperature of 85 K. Our results indicate that the magnetic behavior of FeNiCo alloy can be systematically tuned with the addition of non-magnetic solute element, the finding which could be promising for applications demanding gradient magnetic coatings and alloys. The talk would focus on the effects of composition and heat treatment conditions on the DED processed microstructures, local chemistry and observed magnetic behavior.
5:25 PM
Process-microstructure-property Relationships in Additively Manufactured Fe-Si-B-Nb-Cu Soft Magnetic Alloy: Erin Barrick1; Andrew Kustas1; Joseph Boro1; Eric Theisen2; Todd Monson1; Levi Van Bastian1; Frank Delrio1; Jonathan Pegues1; Matthew Jones3; Carl Frick4; 1Sandia National Laboratories; 2Metglas Inc.; 3University of Wyoming; 4Colorado School of Mines
Soft magnetic alloys exhibit high magnetic permeability/saturation induction and low coercivity/energy loss, yet they are limited by poor mechanical properties except in the nanocrystalline grain size regime, which is difficult to access via conventional manufacturing processes. In this study, additive manufacturing (AM) was used as a rapid solidification technique for producing bulk forms of an Fe-Si-B-Nb-Cu soft magnetic alloy that is traditionally manufactured as melt-spun amorphous/nanocrystalline ribbons. Pre-alloyed powder feedstock in the form of micron-scale flakes was ball milled from nanocrystalline ribbons. Compact metallurgical specimens were fabricated using both laser directed energy deposition (L-DED) and laser powder bed fusion (L-PBF) AM processes. Alloy microstructure, mechanical properties, and magnetic properties were characterized and rationalized based on differences in the AM processes and compared to conventionally processed product ribbons. SNL is managed and operated by NTESS under DOE NNSA contract DE-NA0003525
5:45 PM Cancelled
Development of Additively Manufactured FeCo-2V and Fe-80Ni-5Mo Soft Magnetic Alloys for Spacecraft Magnetic Shielding Applications: Samad Firdosy1; Nicholas Ury1; Katherine Dang1; Pablo Narvaez1; Vilupanur Ravi2; R. Peter Dillon1; 1Nasa Jet Propulsion Laboratory; 2California State Polytechnic University, Pomona
Magnetic shielding for flight hardware has increasingly been an important aspect of controlling magnetic interference between highly sensitive instruments such as magnetometer sensors and co-located engineering subsystems containing mechanisms and motors (e.g., Reaction Wheel Assemblies, Scanning Mechanisms, Cryogenic Coolers, etc.). One way of minimizing magnetic interference is to shield these noisy magnetic sources. Operating highly sensitive instruments concurrently with these engineering subsystems has become a challenge due to the difficulty and complex nature of the manufacturability of very effective magnetic shields. In this talk we report on the development of additively manufactured magnetic shielding materials and prototypes using high permeability (Fe-80Ni-5Mo) and high saturation (FeCo-2V) alloys with magnetic shielding performance that meets or exceeds shields manufactured using traditional wrought magnetic shielding alloy products.