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Functional Grading Between Soft-Magnetic Fe-Co/Fe-Ni Alloys and the Effect on Magnetic and Microstructural
Jesse Min-Tze Adamczyk1, Erin J Barrick1, Charles J Pearce1
1Sandia National Laboratories, Albuquerque, New Mexico 87123, United States.
ACS Applied Engineering Materials
|May 13, 2024
Summary
Functionally graded soft magnetic alloys produced via additive manufacturing overcome processing challenges. This method combines high magnetic saturation of iron-cobalt alloys with the ductility of nickel-iron alloys for enhanced performance.
Area of Science:
- Materials Science
- Additive Manufacturing
- Magnetic Materials
Background:
- Conventional processing of soft magnetic alloys like iron-cobalt (Fe-Co) is limited by cracking and brittle fracture.
- Fe-Co alloys offer high magnetic saturation but poor ductility, while nickel-iron (Ni-Fe) alloys have good ductility but lower magnetic saturation.
Purpose of the Study:
- To investigate the production of functionally graded soft magnetic materials by combining Fe-Co and Ni-Fe alloys.
- To analyze the microstructure, crystal structure, and magnetic properties of these graded materials.
Main Methods:
- Blown powder directed energy deposition was used to create functionally graded coupons of Fe49Co49V2/Ni80Fe16Mo4.
- Microstructural, crystallographic, and magnetic property analyses were performed.
- Postbuild thermal treatments were applied.
Main Results:
- Functional grading refined the microstructure, enhancing mechanical hardness without nonmagnetic elements.
- Thermal treatments recrystallized the microstructure, increasing grain size and improving magnetic properties.
- Analysis revealed solubility limits and phase equilibria between BCC (Fe-Co) and FCC (Ni-Fe) structures.
Conclusions:
- Additive manufacturing enables the creation of functionally graded soft magnetic alloys with combined properties.
- This approach offers a pathway to improved energy conversion efficiency by integrating high saturation and high strength materials.
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