Role of scan strategies and heat treatment on grain structure evolution in Fe-Si soft magnetic alloys made by laser-powder bed fusion

Haines, M.; List, F.A.; Carver, Keith; Leonard, D. N.; Plotkowski, Alex; Fancher, CM; Dehoff, RR; Babu, S. Hari

doi:10.1016/j.addma.2021.102578

Cited by 11 publications

(4 citation statements)

References 53 publications

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“…The study highlights the potential of AM techniques to open new frontiers for the electromagnetic sector. Regarding the experimentation carried out for the same Fe–3%Si via L-PBF technology, different scanning strategies were used for producing thin-walled samples by Haines et al [ 90 ]. The main purpose was to examine how the scanning strategy would impact the microstructure of the alloy after undergoing an annealing heat treatment (argon atmosphere at 1000 °C for 5, 60, and 240 min and 1200 °C for 5 and 60 min using a 10 °C/min ramp rate and furnace cooling).…”

Section: Fe–simentioning

confidence: 99%

“… ( A ) Schematic illustration of the prismatic shape used for L-PBF processing; scan directions with reference to the top surface of the prism: ( B ) longitudinal; ( C ) transverse; and ( D ) rotated. Reprinted from Haines et al [ 90 ], with permission from Elsevier ® . …”

Section: Figurementioning

confidence: 99%

“… Schematic illustration of “point-skipping” during laser scanning. Reprinted from Haines et al [ 90 ], with permission from Elsevier ® . …”

Section: Figurementioning

confidence: 99%

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Recent Advances in Additive Manufacturing of Soft Magnetic Materials: A Review

Vargas

Stornelli

Folgarait³

et al. 2023

Materials

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Additive manufacturing (AM) is an attractive set of processes that are being employed lately to process specific materials used in the fabrication of electrical machine components. This is because AM allows for the preservation or enhancement of their magnetic properties, which may be degraded or limited when manufactured using other traditional processes. Soft magnetic materials (SMMs), such as Fe–Si, Fe–Ni, Fe–Co, and soft magnetic composites (SMCs), are suitable materials for electrical machine additive manufacturing components due to their magnetic, thermal, mechanical, and electrical properties. In addition to these, it has been observed in the literature that other alloys, such as soft ferrites, are difficult to process due to their low magnetization and brittleness. However, thanks to additive manufacturing, it is possible to leverage their high electrical resistivity to make them alternative candidates for applications in electrical machine components. It is important to highlight the significant progress in the field of materials science, which has enabled the development of novel materials such as high-entropy alloys (HEAs). These alloys, due to their complex chemical composition, can exhibit soft magnetic properties. The aim of the present work is to provide a critical review of the state-of-the-art SMMs manufactured through different AM technologies. This review covers the influence of these technologies on microstructural changes, mechanical strengths, post-processing, and magnetic parameters such as saturation magnetization (MS), coercivity (HC), remanence (Br), relative permeability (Mr), electrical resistivity (r), and thermal conductivity (k).

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Section: Fe–simentioning

confidence: 99%

Section: Figurementioning

confidence: 99%

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Recent Advances in Additive Manufacturing of Soft Magnetic Materials: A Review

Vargas

Stornelli

Folgarait³

et al. 2023

Materials

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“…A major goal in printing soft magnetic Fe-Si steels using additive manufacturing is to take advantage of the potential for complex geometric designs and site-specific grain control for a thin wall geometry that produced a strongly columnar grain structure [26].…”

Section: Introductionmentioning

confidence: 99%

Investigation of Soft Magnetic Material Fe-6.5Si Fracture Obtained by Additive Manufacturing

et al. 2022

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The freeform capability additive manufacturing (AM) technique and the magnetic efficiency of Fe-6.5Si steel have the potential for the development of electromechanical component designs with thin body sections. Moreover, the directional anisotropy of the material, which is formed during growth, improves the magnetic and electrical properties of Fe-6.5 wt%Si. We obtained the range of optimal technological modes of Laser Power Bed Fusion process (volume energy density (VED) of 100–140 J/mm3, scanning speed of 750–500 mm/s) to produce the samples from Fe-6.5 wt%Si powder, but even at the best of them cracks may appear. The optical microscopy and SEM with EDX analysis of the laser-fabricated structures are applied for investigation of this phenomena. We detected a carbon content at the boundaries of the cracks. This suggests that one of the reasons for the crack formation is the presence of Fe3C in the area of the ordered α'FeSi (B2) + Fe3Si(DO3) phases. Quantitative analysis based on crack initiation criteria (CIC) showed that the safe level of internal stresses in terms of the CIC criteria in the area of discontinuities is exceeded by almost 190%. Local precipitates of carbides in the area of cracks are explained by the heterogeneity and high dynamics of temperature fields, as well as the transfer of substances due to Marangoni convection, which, as a result, contributes to a significant segregation of elements and the formation of precipitate phases.

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