3D printed ferromagnetic composites for microwave applications

Arbaoui, Younès; Agaciak, Philippe; Chevalier, Alexis; Laur, Vincent; Maalouf, Azar; Ville, Julien; Roquefort, Philippe; Aubry, Thierry; Quéffélec, Patrick

doi:10.1007/s10853-016-0737-3

Cited by 27 publications

(20 citation statements)

References 16 publications

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“…Several Fe-based magnetic materials produced by additive manufacturing have been studied owing to their wide range of potential applicability in the energy area [38][39][40][41][42][43][44]. Additive manufacturing of amorphous Fe-based magnetic materials is focused on within this review paper.…”

Section: Additive Manufacturing Of Amorphous Fe-based Magnetic Alloysmentioning

confidence: 99%

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Ozden

Morley

2021

Magnetochemistry

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Fe-based amorphous materials offer new opportunities for magnetic sensors, actuators, and magnetostrictive transducers due to their high saturation magnetostriction (λs = 20–40 ppm) and low coercive field compared with polycrystalline Fe-based alloys, which have high magnetostriction but large coercive fields and Co-based amorphous alloys with small magnetostriction (λs = −3 to −5 ppm). Additive layer manufacturing (ALM) offers a new fabrication technique for more complex net-shaping designs. This paper reviews the two different ALM techniques that have been used to fabricate Fe-based amorphous magnetic materials, including the structural and magnetic properties. Selective laser melting (SLM)—a powder-bed fusion technique—and laser-engineered net shaping (LENS)—a directed energy deposition method—have both been utilised to fabricate amorphous alloys, owing to their high availability and low cost within the literature. Two different scanning strategies have been introduced by using the SLM technique. The first strategy is a double-scanning strategy, which gives rise to maximum relative density of 96% and corresponding magnetic saturation of 1.22 T. It also improved the glassy phase content by an order of magnitude of 47%, as well as improving magnetic properties (decreasing coercivity to 1591.5 A/m and increasing magnetic permeability to around 100 at 100 Hz). The second is a novel scanning strategy, which involves two-step melting: preliminary laser melting and short pulse amorphisation. This increased the amorphous phase fraction to a value of up to 89.6%, and relative density up to 94.1%, and lowered coercivity to 238 A/m. On the other hand, the LENS technique has not been utilised as much as SLM in the production of amorphous alloys owing to its lower geometric accuracy (0.25 mm) and lower surface quality, despite its benefits such as providing superior mechanical properties, controlled composition and microstructure. As a result, it has been commonly used for large parts with low complexity and for repairing them, limiting the production of amorphous alloys because of the size limitation. This paper provides a comprehensive review of these techniques for Fe-based amorphous magnetic materials.

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Section: Additive Manufacturing Of Amorphous Fe-based Magnetic Alloysmentioning

confidence: 99%

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Ozden

Morley

2021

Magnetochemistry

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“…In recent years, the focus has shifted towards the development of 3D-printable functional composites [ 25 , 26 ] with the vision of assisting (or in some cases, replacing) traditional manufacturing technologies. Numerous investigations of composite materials for FDM have been undertaken, involving filler materials such as glass [ 27 ], ceramics [ 28 , 29 , 30 , 31 ], and metals [ 32 , 33 ]; characterized for their thermomechanical [ 34 , 35 , 36 , 37 , 38 , 39 ], electric [ 40 , 41 , 42 ], dielectric [ 43 , 44 ], and ferromagnetic [ 45 ] properties. Other studies have looked at the magnetic properties of polymer matrix composites, including those with Ni [ 46 ], ferrite [ 47 , 48 ], and Nd-Fe-B [ 49 ] as functional materials.…”

Section: Introductionmentioning

confidence: 99%

A 3D-Printable Polymer-Metal Soft-Magnetic Functional Composite—Development and Characterization

et al. 2018

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In this work, a 3D printed polymer–metal soft-magnetic composite was developed and characterized for its material, structural, and functional properties. The material comprises acrylonitrile butadiene styrene (ABS) as the polymer matrix, with up to 40 vol. % stainless steel micropowder as the filler. The composites were rheologically analyzed and 3D printed into tensile and flexural test specimens using a commercial desktop 3D printer. Mechanical characterization revealed a linearly decreasing trend of the ultimate tensile strength (UTS) and a sharp decrease in Young’s modulus with increasing filler content. Four-point bending analysis showed a decrease of up to 70% in the flexural strength of the composite and up to a two-factor increase in the secant modulus of elasticity. Magnetic hysteresis characterization revealed retentivities of up to 15.6 mT and coercive forces of up to 4.31 kA/m at an applied magnetic field of 485 kA/m. The composite shows promise as a material for the additive manufacturing of passive magnetic sensors and/or actuators.

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“…The use of composite materials for FDM has increased significantly in the past two decades [26,27,28]. Numerous studies have looked at the material characteristics of the parts produced by FDM [29,30,31], as well as the preparation and characterization of composite materials for FDM, including polymer-carbon [32,33], polymer-metal [34,35,36,37,38,39,40] and polymer-ceramic [41,42,43,44] composites. It is clear that ARP has come into its own and is rapidly evolving into a family of reliable manufacturing processes for the production of unique and specialized parts, both for prototyping and for low-volume production [45,46].…”

Section: Introductionmentioning

confidence: 99%

Fused Deposition Modeling of ABS-Barium Titanate Composites: A Simple Route towards Tailored Dielectric Devices

et al. 2018

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A process for the development, characterization and correlation of composite materials for 3D printing is presented, alongside the processing of a polymer-ceramic functional composite using fused deposition modeling (FDM). The composite was developed using acrylonitrile butadiene styrene (ABS) as the matrix material filled with barium titanate (BT) micro-powder up to 35 vol % (74.2 wt %). The ABS-BT composites exhibited a shear thinning behavior with increasing ceramic content. The composite was 3D printed into structural and functional test samples using FDM by adapting and optimizing the print parameters. Structural characterization revealed increasingly brittle behavior at higher filler ratios, with the ultimate tensile strength falling from 25.5 MPa for pure ABS to 13.7 MPa for the ABS-35 vol % BT composite. Four-point flexural tests showed a similar decrease in flexural strength with increasing ceramic content. Functional characterization revealed an increase in the relative permittivity at 200 kHz from 3.08 for pure ABS to 11.5 for the composite with 35 vol % BT. These results were correlated with the Maxwell-Garnett and Jayasundere-Smith effective medium models. The process described in this work can be used for other 3D printing processes and provides a framework for the rapid prototyping of functional composites into functional parts with reliable properties. The ABS-BT composite shows promise as a functional dielectric material, with potential applications as capacitors and light-weight passive antennas.

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3D printed ferromagnetic composites for microwave applications

Abstract: International audienc

Cited by 27 publications

References 16 publications

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

A 3D-Printable Polymer-Metal Soft-Magnetic Functional Composite—Development and Characterization

Fused Deposition Modeling of ABS-Barium Titanate Composites: A Simple Route towards Tailored Dielectric Devices

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