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Magnetostrictive Terfenol-D alloys printed via material extrusion
Joy Morin1,2, Atik Ishrak Al Nahian3, Xinchang Zhang2
1Micron School of Materials Science and Engineering, Boise State University, Boise, ID 83725, USA.
Nanoscale
|May 11, 2026
Summary
Additive manufacturing using material extrusion (MEX) offers a novel approach for fabricating Terfenol-D magnetostrictive acoustic transducers. This method overcomes brittleness and integration challenges, enabling streamlined production of advanced acoustic devices.
Area of Science:
- Materials Science
- Mechanical Engineering
- Acoustics
Background:
- Terfenol-D exhibits unique magneto-mechanical coupling for acoustic applications.
- Manufacturing challenges, including brittleness and integration, limit Terfenol-D adoption.
- Current integration methods (clamping, welding, bonding) are labor-intensive and unreliable in harsh environments.
Purpose of the Study:
- To develop and evaluate an additive manufacturing strategy for Terfenol-D.
- To overcome limitations of conventional machining and integration methods.
- To enable streamlined fabrication and integration of Terfenol-D magnetostrictive devices.
Main Methods:
- Synthesized Terfenol-D nanoparticles (approx. 155 nm) via high-energy ball milling.
- Printed colloidal ink onto stainless steel using material extrusion (MEX).
- Sintered printed structures via conventional thermal treatment and electric field-assisted sintering.
Main Results:
- Electric field-assisted sintering achieved strong diffusion bonding, unlike thermal sintering which caused delamination.
- MEX process yielded highly dense Terfenol-D thin films on stainless steel.
- X-ray diffraction confirmed alloy composition preservation with minimal contamination.
Conclusions:
- Material extrusion (MEX) is a viable additive manufacturing route for Terfenol-D.
- Electric field-assisted sintering enhances bonding and integration of Terfenol-D.
- This approach streamlines fabrication and integration of magnetostrictive acoustic devices.
