Additive manufacturing of anisotropic hybrid NdFeB-SmFeN nylon composite bonded magnets

Gandha, Kinjal; Li, Ling; Nlebedim, Ikenna C.; Post, Brian; Kunc, Vlastimil; Sales, B. C.; Bell, James F.; Paranthaman, M. Parans

doi:10.1016/j.jmmm.2018.07.021

Cited by 83 publications

(60 citation statements)

References 23 publications

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“…In other research, big area additive manufacturing of isotropic NdFeB powder in PA binder enabled the manufacturing of magnets with enhanced remanence and coercive field compared to traditional injection-molded magnets [16]. Polymer bonded permanent magnets with anisotropic properties were developed by applying an external magnetic field with intensities varying from 5 kOe to 50 kOe using an electromagnet as a part of the post printing process [17]. Methodologies to orient ferromagnetic particles at user defined angles and the influence of external magnetic field strength on degree of particle alignment at lower filler loadings for AM process have been reported in the technical literature [18].…”

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confidence: 99%

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites

Nagarajan

Kamkar

Schoen

et al. 2020

JMMP

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Polymer bonded permanent magnets find significant applications in a multitude of electrical and electronic devices. In this study, magnetic particle-loaded epoxy resin formulations were developed for in-situ polymerization and material jetting based additive manufacturing processes. Fundamental material and process issues like particle settling at room temperature and elevated temperature curing, rheology control and geometric stability of the magnetic polymer during the thermal curing process are addressed. Control of particle settling, modifications in rheological behavior and geometric stability were accomplished using an additive that enabled the modification of the formulation behavior at different process conditions. The magnetic particle size and additive loading were found to influence the rheological properties significantly. The synergistic effect of the additive enabled the developing of composites with engineered magnetic filler loading. Morphological characterization using scanning electron microscopy revealed a homogenous particle distribution in composites. It was observed that the influence of temperature was profound on the coercive field and remanent magnetization of the magnetic composites. The characterization of magnetic polymers and composites using rheometry, scanning electron microscopy, X-ray diffraction and superconducting quantum interference device (SQUID) magnetometry analysis enabled the correlating of the behavior observed in different stages of the manufacturing processes. Furthermore, this fundamental research facilitates a pathway to construct robust materials and processes to develop magnetic composites with engineered properties.

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confidence: 99%

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites

Nagarajan

Kamkar

Schoen

et al. 2020

JMMP

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“…Direct ink writing (DIW) and fused filament fabrication (FFF) have been used to fabricate fast responding actuators, inks containing high loads of magnetic fillers and 2D planar structures that exploit folding and unfolding processes . Additionally, 3D printed permanent magnets were developed …”

Section: Introductionmentioning

confidence: 99%

3D Printing of Magnetoresponsive Polymeric Materials with Tunable Mechanical and Magnetic Properties by Digital Light Processing

Lantean

Barrera

Pirri

et al. 2019

Adv Materials Technologies

102

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nanocomposites [12][13][14][15] -have been investigated for a broad variety of applications, from micro-and soft-robotics [10,[16][17][18] to biomedicine. [19][20][21][22][23][24] Among the different strategies, an accessible pathway to fabricate stimuli-responsive (4D) printed objects consists in magnetizing a soft-polymer by loading the polymeric matrix with magnetic fillers, such as particles of magnetite (Fe 3 O 4 ) or neodymium-iron-boron (NdFeB). [25][26][27][28][29][30][31] Direct ink writing (DIW) and fused filament fabrication (FFF) have been used to fabricate fast responding actuators, [32][33][34][35][36][37][38][39][40] inks containing high loads of magnetic fillers [41] and 2D planar structures that exploit folding and unfolding processes. [42] Additionally, 3D printed permanent magnets were developed. [43][44][45][46][47][48] However, both DIW and FFF present some drawbacks: first in terms of resolution; second in terms of the dispersion of the fillers, that may lead to nonhomogeneous magnetic response; and third in terms of temperature of processing, which could be not compatible with the fillers. [48,49] For the last one, the temperature can be decreased using some additives, however this approach may affect the mechanical performances of devices. [41] An alternative to DIW and FFF is digital light processing (DLP). This vat polymerization 3D printing technology involves the use of photosensitive (liquid) resins which are able to cure (i.e., to solidify) upon irradiation with a suitable light source. In DLP, a digital light projector (digital micromirror device) illuminates a photocurable resin with a 2D pixel pattern allowing the curing of single slices of the 3D object. [50][51][52] The aforementioned drawbacks associated to DIW and FFF can be overcome by the use of DLP. Indeed: (i) the printing resolution in DLP belongs to the pixel dimensions and it is generally higher than DIW and FFF, [53,54] (ii) in DLP the dispersion of the fillers is easier to control since liquid formulations are used; and (iii) the fabrication process generally occurs at room temperature. Nevertheless, two precautions must be taken into account: first, the increase of the content of nanoparticles may affect the photopolymerization process since they compete with the photoinitiator in absorbing the incident radiation; and second, the dispersion of the fillers must be stable for the whole printing procedure in order to print an object whose response is homogeneous to an external input. For the latter, macroscopic sedimentation, segregation, and spatial inhomogeneity must be avoided.Digital light processing is used for printing magnetoresponsive polymeric materials with tunable mechanical and magnetic properties. Mechanical properties are tailored, from stiff to soft, by combining urethane-acrylate resins with butyl acrylate as the reactive diluent. The magnetic response of the printed samples is tuned by changing the Fe 3 O 4 nanoparticle loading up to 6 wt%. Following this strategy, magnetoresponsive active components ar...

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“…[42][43][44][45][46][47][48] It has been used to produce magneto-responsive structures [49][50][51][52] and Nd-Fe-B-based magnets. [43,47] Herein, Fe flakes, prepared by high energy ball milling, have been partially transformed to more than 50% by volume Fe 16 N 2 phase following nitridation at low temperatures. Fe 16 N 2 -based permanent magnets have then been successfully fabricated using 3D printing, and the magnetic properties of the finished samples are compared with those of the original powders.…”

Section: Introductionmentioning

confidence: 99%

“…Additive manufacturing is becoming an ultimate tool to produce composites [ 41 ] and especially permanent magnets. [ 42–48 ] It has been used to produce magneto‐responsive structures [ 49–52 ] and Nd–Fe–B‐based magnets. [ 43,47 ]…”

Section: Introductionmentioning

confidence: 99%

Fabrication and Characterization of Fe₁₆N₂Micro‐Flake Powders and Their Extrusion‐Based 3D Printing into Permanent Magnet Form

et al. 2020

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Fe16N2 is a compound with giant saturation magnetization approaching or exceeding that of rare‐earth‐based permanent magnets. The abundance of its elements and low‐cost synthesis of this compound has made it highly attractive to replace rare‐earth‐based permanent magnets that are becoming ever more expensive to utilize in applications. Herein, its synthesis from Fe flakes by surfactant‐assisted high energy ball milling is demonstrated. The synthesized Fe flakes are then reduced under forming gas (Ar/H2), followed by nitridation at low temperatures under ammonia (NH3) gas. The formation of Fe16N2 phase exceeding 50% by volumetric fraction is observed and confirmed by X‐ray diffraction and Mössbauer analysis. Following the Fe16N2 flake synthesis, extrusion‐based 3D printing is used to check the feasibility of incorporation of the flakes into functional polymer matrix composites. For this purpose, an ink of intermixed synthesized powder with photoresist SU8 is used. Using the prescribed method, a prototype Fe16N2 permanent magnet composite is successfully produced using an additive manufacturing approach. Such efficient production of Fe16N2 powders via routes already applicable to magnet production and the consolidation of the powders with 3D printing are expected to open up new possibilities for next‐generation permanent magnet applications.

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Additive manufacturing of anisotropic hybrid NdFeB-SmFeN nylon composite bonded magnets

Cited by 83 publications

References 23 publications

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites

3D Printing of Magnetoresponsive Polymeric Materials with Tunable Mechanical and Magnetic Properties by Digital Light Processing

Fabrication and Characterization of Fe₁₆N₂Micro‐Flake Powders and Their Extrusion‐Based 3D Printing into Permanent Magnet Form

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Additive manufacturing of anisotropic hybrid NdFeB-SmFeN nylon composite bonded magnets

Cited by 83 publications

References 23 publications

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites

3D Printing of Magnetoresponsive Polymeric Materials with Tunable Mechanical and Magnetic Properties by Digital Light Processing

Fabrication and Characterization of Fe16N2Micro‐Flake Powders and Their Extrusion‐Based 3D Printing into Permanent Magnet Form

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Fabrication and Characterization of Fe₁₆N₂Micro‐Flake Powders and Their Extrusion‐Based 3D Printing into Permanent Magnet Form