Additive manufacturing of magnetic materials

Chaudhary, Varun; Mantri, S.A.; Ramanujan, R.V.; Banerjee, R.

doi:10.1016/j.pmatsci.2020.100688

Cited by 180 publications

(68 citation statements)

References 270 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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“…Magnetic materials are essential in a wide and growing variety of industrial, commercial, and residential applications, including rotating electrical machines, electric vehicles, wind turbines, transformers, power converters, electronic article surveillance systems, magnetically coupled devices, sensors, and high-frequency electromagnetic devices ( Chaudhary et al., 2020 ; McHenry et al., 1999 ) , . To illustrate the importance of magnetic materials, we note that the energy utilization of electrical machines is a significant fraction of the total energy consumption in the world ( Weiss et al., 2020 ).…”

Section: Introductionmentioning

confidence: 99%

Highly complex magnetic behavior resulting from hierarchical phase separation in AlCo(Cr)FeNi high-entropy alloys

et al. 2022

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“…145 To date, AM has been explored with numerous soft-magnetic materials and was recently reviewed. [146][147][148][149][150] Thus, only a brief synopsis of the most recent AM studies on soft-magnetic alloys is provided in this review. Since the critical reviews published by Refs.146-150, a few additional studies on AM processing of soft-magnetic alloys have been published.…”

Section: Additive Manufacturingmentioning

confidence: 99%

Emerging Opportunities in Manufacturing Bulk Soft-Magnetic Alloys for Energy Applications: A Review

Kustas

Susan

Monson

2022

JOM

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Soft-magnetic alloys exhibit exceptional functional properties that are beneficial for a variety of electromagnetic applications. These alloys are conventionally manufactured into sheet or bar forms using well-established insgot metallurgy practices that involve hot- and cold-working steps. However, recent developments in process metallurgy have unlocked opportunities to directly produce bulk soft-magnetic alloys with improved, and often tailorable, structure–property relationships that are unachievable conventionally. The emergence of unconventional manufacturing routes for soft-magnetic alloys is largely motivated by the need to improve the energy efficiency of electromagnetic devices. In this review, literature that details emerging manufacturing approaches for soft-magnetic alloys is overviewed. This review covers (1) severe plastic deformation, (2) recent advances in melt spinning, (3) powder-based methods, and (4) additive manufacturing. These methods are discussed in comparison with conventional rolling and bar processing. Perspectives and recommended future research directions are also discussed.

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Additive manufacturing of magnetic materials

Cited by 180 publications

References 270 publications

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Highly complex magnetic behavior resulting from hierarchical phase separation in AlCo(Cr)FeNi high-entropy alloys

Emerging Opportunities in Manufacturing Bulk Soft-Magnetic Alloys for Energy Applications: A Review

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