Additive Manufacturing and Innovative Powder Processing of Functional and Magnetic Materials: Soft Magnetic Materials
Sponsored by: TMS Functional Materials Division, TMS Materials Processing and Manufacturing Division, TMS: Additive Manufacturing Committee, TMS: Magnetic Materials Committee, TMS: Powder Materials Committee
Program Organizers: Emily Rinko, Honeywell Fm&T; Iver Anderson, Iowa State University Ames Laboratory; Markus Chmielus, University of Pittsburgh; Emma White, DECHEMA Forschungsinstitut; Deliang Zhang, Northeastern University; Andrew Kustas, Sandia National Laboratories; Kyle Johnson, Sandia National Laboratories
Wednesday 8:30 AM
March 2, 2022
Room: 262C
Location: Anaheim Convention Center
Session Chair: Kyle Johnson, Sandia National Laboratories
8:30 AM Introductory Comments
8:35 AM
Laser Additive Manufacturing of Fe-Co and Fe-Si Based Soft Magnetic Alloys: Andrew Kustas1; Donald Susan1; Todd Monson1; Kyle Johson1; Mark Wilson1; Erin Barrick1; Jonathan Pegues1; Shaun Whetten1; Raymond Puckett1; 1Sandia National Laboratories
Soft magnetic alloys possess favorable functional properties, including high permeability/saturation induction, and low coercivity/core loss, which are beneficial for a variety of electromagnetic applications. However, many of these alloys suffer from poor mechanical properties that impede their manufacturing with conventional hot- and cold-working processes. We explore metal additive manufacturing (AM) as a rapid solidification method for producing bulk forms of magnetic alloys with unconventional compositions based in the Fe-Co-B-Cu-Zr and Fe-Si-Nb-B-Cu systems. Microstructure and composition of the AM-processed soft magnetic alloys, along with resultant mechanical and magnetic properties, are characterized and compared with conventionally processed materials. Implications of utilizing AM for developing next-generation soft magnetic materials and components will be discussed.SNL is managed and operated by NTESS under DOE NNSA contract DE-NA0003525
8:55 AM Invited
Structure-processing-magnetic Property Interrelationships in Additively Manufactured FeCo-2V and Fe-80Ni-5Mo Soft Magnetic Alloys: Samad Firdosy1; Nick Ury1; Andrew Kustas2; Jay Carroll2; Dan Tung2; Donald Susan2; J.P. Borgonia1; Ryan Conversano1; Bryan Mcenerney1; Vilupanur Ravi3; Robert Dillon1; 1NASA Jet Propulsion Laboratory; 2Sandia National Laboratories; 3California State Polytechnic University
Fe-Co and Fe-Ni based alloys, known for their high permeability, high magnetic saturation and low coercivity, are used in electric motors, generators, magnetic shielding and other high performance applications. Although these alloys have excellent magnetic properties for these applications, their mechanical properties can make them challenging to fabricate components with complex geometries. Using additive manufacturing, or 3D printing, can aid manufacturability of these alloys, potentially reducing manufacturing cost and lead time. Additionally, the use of blown powder directed energy deposition processes enables the possibility of functionally grading magnetic alloys to optimize functional and mechanical properties with location specificity. In this talk, progress in directed energy deposition based additive manufacturing of Fe-Co and Fe-Ni based alloys will be discussed through the lens of developing magnetic shielding for Hall Effect thrusters and spacecraft magnetic shielding. SNL is managed and operated by NTESS under DOE NNSA contract DE-NA0003525
9:25 AM
Reduction of Power Losses in SLM Printed FeSi6.5 Alloy by Geometry Optimizing: Przemyslaw Zackiewicz1; Adrian Radon1; Bartosz Jozwik1; Lukasz Hawelek1; Marcin Polak1; Magdalena Steczkowska-Kempka1; Adam Pilsniak1; Aleksandra Kolano-Burian1; 1Lukasiewicz IMN
Silicon steels are one of the best researched materials mainly due to their widespread use in energy devices for energy conversion. The ease of making elements of various shapes and sizes makes it a widely used material, and research is still being conducted to produce magnetic elements with more complex geometry. One of the main areas is the ability to make magnetic parts/cores using additive manufacturing technologies. Unfortunately, there is still a limitation of the applicability of the elements from FeSi powders according to their ultrahigh intrinsic stresses. These stresses result in the delamination and cracking of the printed elements. According to that, as a part of the work, cores made of FeSi6.5 material of various shapes and degrees of filling were produced and tested. Additionally, magnetic inserts were made from FeSi6.5 powders with the ULTIMEG resin in order to reduce the dispersion of the magnetic flux in air gaps.
9:45 AM Invited
NOW ON-DEMAND ONLY - X-ray and Neutron Scattering Reveals Insights into the Formation and Thermal Stability of Metastable Disordered Phases in FeCo and FeSi: Chris Fancher1; Andrew Kustas2; 1Oak Ridge National Laboratory; 2Sandia National Laboratory
Fe-Co and Fe-Si alloys are ubiquitous soft-magnetic materials in applications due to their superior properties. Compositions with optimal magnetic and electrical properties suffer from poor ductility that prohibits their use in commercial deformation processing. Metal additive manufacturing (AM) shows promise as an alternative method for producing bulk components using challenging to process materials. Researchers have demonstrated the viability of directed energy deposition and laser powder bed fusion methods for fabricating Fe-Co and Fe-Si. The printability of these brittle materials was attributed to the stabilization of the high-temperature disordered BCC structure. Despite these promising results, there remains a notable knowledge gap in the process-structure-mechanical relationships at the atomic scale for AM processed Fe-Co and FeSi alloys. In this paper, diffraction and small-angle scattering was utilized to determine the effect of AM process parameters on forming a metastable BCC phase and subsequent thermal stability with heating.