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Patterned magnetic pole configurations in bonded magnets.

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Summary

Researchers developed novel bonded magnets using laser powder bed fusion, enabling controlled magnetic heterogeneity by precisely dispersing multiple magnetic materials. This advancement allows for tailored magnetic properties in 3D-printed magnets.

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Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Magnetism

Background:

  • Established methods for additive manufacturing of bonded magnets include polymer extrusion, powder bed fusion, and stereolithography.
  • Selective laser sintering (SLS) is a key powder bed fusion technique for consolidating magnetic particles within polymer matrices.

Purpose of the Study:

  • To investigate the potential of laser powder bed fusion for creating bonded magnets with controlled magnetic heterogeneity.
  • To explore the effects of controlled powder dispersion and localized magnetic fields on particle alignment and magnetic properties.

Main Methods:

  • Utilized laser powder bed fusion (LPSF) to selectively sinter mixed polymer and magnetic powders (NdFeB/FeSi and NdFeB/FeCo).
  • Applied localized external magnetic fields during sintering to influence particle orientation.
  • Characterized the magnetic properties of the as-printed and post-magnetized samples.

Main Results:

  • Demonstrated that controlled dispersion of multiple powder materials and localized magnetic fields lead to bonded magnets with engineered magnetic heterogeneity.
  • As-printed samples showed weak polarization (1.5-2 mT), but post-magnetization significantly amplified flux values (up to 14 mT N / 6 mT S for NdFeB/FeCo).
  • Achieved significant differential polarities (80-100 mT North, 50-100 mT South) and confirmed easy-axis alignment through persistent remanent magnetization.

Conclusions:

  • The study successfully demonstrated the hypothesis that controlled powder dispersion and localized magnetic fields during SLS can produce bonded magnets with tailored magnetic heterogeneity.
  • This research opens avenues for fabricating advanced magnetic components with precisely placed different magnetic materials.
  • The developed technique enhances magnetic properties and offers control over magnetic anisotropy in additively manufactured magnets.