Advanced Magnetic Materials for Energy and Power Conversion Applications: Additive Manufacturing of Magnetic Materials
Sponsored by: TMS Functional Materials Division, TMS: Magnetic Materials Committee
Program Organizers: Daniel Salazar, BCMaterials; Alex Leary, NASA Glenn Research Center; Markus Chmielus, University of Pittsburgh; Ryan Ott, Ames Laboratory; Arcady Zhukov, University of the Basque Country
Thursday 2:00 PM
February 27, 2020
Room: Del Mar
Location: Marriott Marquis Hotel
Session Chair: Kevin Byerly, National Energy Technology Laboratory
2:00 PM
Have it Your Way: Manufacturing of Permanent Magnets by Laser Powder-bed Fusion, Cold Spray, Extrusion: Alexander Baker1; Matt Worthington1; Sarah Baker1; Christine Orme1; Scott McCall1; 1Lawrence Livermore National Laboratory
Many Additive manufacturing approaches for permanent magnets have been developed, driven by the promise of low-loss net-shape fabrication. Direct-ink write approaches have used anisotropic particles to bring energy products into the 15 MGOe range. However, challenges such as achieving full density, good fracture toughness or high coercivity remain, due to the complex microstructural engineering required. Here, we will survey recent successes in a variety of AM processes. Extrusion of ink-bound oxide particles enables highly coercive SmCo ( >60 kOe). Laser AM achieves close to full density and a high saturation magnetization. Cold-spray operates below the melting point of the materials to preserve microstructure. Matching the strengths of each approach to the usage is crucial for applications. We will discuss magnetometry, microscopy and structural characterization of the samples throughout the fabrication process, as well as other opportunities enabled by AM techniques.Prepared by LLNL under Contract DE-AC52-07NA27344.
2:20 PM
Understanding the Role of Particle Size in the Development of Flexible Permanent Magnet-polymer Filaments: Ester Palmero1; Daniel Casaleiz1; Javier Rial1; Javier de Vicente1; Alberto Bollero1; 1IMDEA Nanoscience
Advanced 3D-printing attracts much interest for fabricating high-performance and complex permanent magnets (PMs). The challenge is developing magnets with a high filling factor (FF), while avoiding the deterioration of their magnetic properties. Composites (PM particles/polymer) based on NdFeB, hybrid (NdFeB/Sr-ferrite) powders (mean particle size: 5-50 μm) and τ-MnAlC (industrial collaboration with Höganäs AB, Sweden) were analyzed. The different composites (FF>85%) allowed for obtaining filaments (length over 10 m) with coercivity ranging between 1.5-10 kOe [1,2]. Particle size was crucial for extruding flexible filaments, with fine particles (< 20 μm) based composites leading to filaments with maintained FF and coercivity [2]. Extrusion effectiveness and FF were enhanced by optimizing the fine-to-coarse particles ratio [1], showing that composites can be efficiently synthesized for developing PM filaments for 3D-printing. [1] Palmero et al., Sci. Technol. Adv. Mater. 19, 465 (2018); Submitted (2019).[2] Palmero et al., IEEE Trans. Magn. 55, 2101004 (2019).
2:40 PM Invited
Additive Manufacturing of NiZnCu-ferrite Soft Magnetic Composites: Caleb Andrews1; Kathryn Small1; Megan Chatham2; Samantha Dorman2; Mitra Taheri1; 1Johns Hopkins University; 2Drexel University
Soft magnetic composites (SMCs) are a class of magnetic materials that have the potential to create lighter and more efficient electronic devices. SMCs provide high electrical resistivity while providing high magnetic permeability. Until recently, with advances in powder metallurgy, devices needing materials with these properties have been made by complex and geometrically limited laminations or press-and-sinter methods. However, additive manufacturing can serve as a potential manufacturing route for SMCs, presenting new device designs opportunities, cost savings, and reduction in material usage. This talk discusses the use of laser-based 3D printing methods to produce SMCs that exhibit lower or equivalent core loss than that of SMCs with similar composition but produced by conventional powder metallurgy methods. The magnetic properties of these 3D printed SMCs are discussed in the context of microstructural and compositional characterization. Our results highlight both the advantages and limitations of 3D printing for SMC development.
3:05 PM Invited
Composite Magnetic Filaments for Additive Manufacturing: A Novel Procedure for Laboratory Scale Production: Victorino Franco1; Álvaro Díaz-García1; Ana Bellido-Correa1; Agustín Cota1; Joaquín Ramírez-Rico1; Jia Yan Law1; 1Universidad de Sevilla
The production of filaments composed of polymer with embedded magnetic particles is usually performed by mechanical mixing the polymer and the functional material (i.e. with a kneader, which requires large scale equipment) or purchasing pellets of composites, which limits the compositional possibilities to those provided by industrial suppliers. In order to be able to fabricate parts with uniform characteristics, filaments with uniform distribution of particles are needed. One of the major limitations at the laboratory scale is the loss/agglomeration of magnetic powder in the hopper. We propose an original procedure to prepare composite filaments using customized polymer capsules filled with soft magnetic steel particles as the initial feedstock for the extrusion of the composite filaments. This method, not only limited to the addition of metallic particles, does not require a sophisticated machinery and allows desired compositions at the laboratory scale with good control of the amount of particles being added.
3:30 PM Break
3:50 PM
Additive Manufacturing Method to Fabricate Crack-free Highly Dense Fe-6 wt.% Si Soft Magnets: Parans Paranthaman1; Corson Cramer1; Peeyush Nandwana1; Jiaqiang Yan1; Samuel Evans1; Amy Elliott1; Chins Chinnasamy2; 1Oak Ridge National Laboratory; 2Carpenter Technology Corporation
High silicon (Si) electrical steel has the potential for efficient use in applications with cost-effective in processing, but it is difficult to manufacture. Increasing the Si content beyond 3 wt.% improves magnetic and electrical properties, with 6.5 wt.% being achievable. The main goal of this work is to design, develop, and implement a scalable additive manufacturing process to fabricate Fe with 6.5 wt.% Si (Fe-6Si) steel with high magnetic permeability, high electrical resistivity, low coercivity, and low residual induction that other methods cannot achieve because of manufacturing limitations. Additive manufacturing (AM) was used to achieve near full densification. We will report in detail about the properties AM enabled Fe-6Si soft magnets.
4:10 PM
Advances in Directed Energy Deposition (DED) of Fe-Co Based Alloys and Functional Gradients: Samad Firdosy1; Peter Dillon1; John Paul Borgonia1; Ryan Conversano1; Bryan McEnerney1; Andrew Shapiro1; 1Jet Propulsion Laboratory
Fe-Co alloys, known for their high magnetic saturation and low coercivity, are often used in high performance applications such as electric motors, generators, and transformers. NASA is interested in these alloys for magnetic shielded Hall thrusters. 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 (AM), or 3D printing, can aid manufacturability of these alloys, potentially reducing manufacturing cost and lead-time. Additionally, since more than one alloy can be deposited at a time via most directed energy deposition (DED) systems, the fabrication of compositional gradients to stronger, more ductile, and/or weldable engineering alloys is possible. In this talk, advances in DED based AM of Fe-Co based alloys and gradients to improve strength, ductility, and/or weldability will be discussed.
4:30 PM
Low Temperature Additive Manufacturing of Metamagnetic Shape Memory Alloys for Magnetocaloric Applications: Bosco Rodriguez1; Daniel Salazar1; Volodymyr Chernenko1; 1BCMaterials
The current social challenges demand new energy-efficient technologies. Recent progress in caloric materials (magneto- or elasto-caloric) as part of the next generation energy saving devices open new possibilities 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 (>300 ºC). High performance NiMnSn-based magnetocaloric alloys and powders were synthesized and processed for the obtention of the filler material. Inks and filaments were developed under different parameters and conditions in order to find the best ones for their implementation in the fabrication of heat exchangers by low-temperature additive manufacturing techniques.