About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
External Field-Intensified Materials Processing
|
| Presentation Title |
Magnetic Field-Assisted Additive Manufacturing of Rare-Earth-Free AlNiCo Magnets |
| Author(s) |
Omar Bishop, Anthony Duong, Ian Smith, Kyle Snyder, Everett Carpenter , Radhika Barua |
| On-Site Speaker (Planned) |
Omar Bishop |
| Abstract Scope |
Global supply chain disruptions and geopolitical tensions underscore the urgent need for rare-earth-free permanent magnets. AlNiCo alloys offer thermal stability, corrosion resistance, and domestic sourcing, but conventional methods often yield poor magnetic properties due to limited microstructural control. This study investigates Magnetic Field-Assisted Directed Energy Deposition (MF-DED) to enhance magnetic performance during fabrication. AlNiCo powders were printed using a custom DED system with a Halbach array generating static magnetic fields up to 1600 Oe. Laser power, scan speed, powder flow rate, and toolpath orientation were systematically varied to tailor processing conditions. Results show that thermal gradients and applied magnetic fields govern grain morphology and phase segregation. The magnetic field induces anisotropic grain alignment, increases part density, and promotes ferromagnetic phase orientation, enabling as-built samples to achieve energy products comparable to heat-treated counterparts. By eliminating post-processing and reducing energy demands, MF-DED offers a scalable, efficient route for fabricating high-performance, AlNiCo magnets. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Magnetic Materials, Sustainability |