Laser melting 3D printing prepared high-performance iron-based amorphous soft magnetic devices and their physical mechanisms

LIN Kexin; YANG Weiming; LI Wenyu; MA Yan; MA Li; ZHANG Xiang; LIU Haishun

doi:10.7498/aps.74.20250559

Abstract

Fe-based amorphous alloys have exceptional properties such as low coercivity and core loss. In recent years, the development of amorphous alloys by using selective laser melting (SLM) technology has become the focus of attention. However, the glass-forming ability (GFA) and mechanical properties pose challenges for fabricating Fe-based amorphous alloys with complex geometries. This work aims to establish fundamental processing-(micro) structure-property links in Fe-based amorphous alloys processed by selective laser melting (SLM). With that purpose, a low-energy-input melt pool is achieved and the overlap quality between adjacent melt tracks and successive deposition layers is enhanced, through optimization of printing parameters. The Fe-based amorphous alloy is obtained with a high relative density of 94.3% and low coercivity of 0.5 Oe. Furthermore, the saturation magnetization of the printed alloy increases to 0.89 T compared with that of the powder feedstock. This work overcomes the mutual constraint between the GFA and part quality in fabricating of complex-structure Fe-based amorphous alloys, and is of great significance for promoting the application of Fe-based amorphous alloys.

Keywords:

Authors and contacts

1.
School of Mechanics & Civil Engineering, China University of Mining and Technology, Xuzhou 221116, China
2.
School of Materials Science and Physics, China University of Mining and Technology, Xuzhou 221116, China

Corresponding author: YANG Weiming, wmyang@cumt.edu.cn

Funds: Project supported by the National Natural Science Foundation of China (Grant No. 52171165).

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References

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[41]	Rodríguez-Sánchez M, Sadanand S, Ghavimi A, Busch R, Tiberto P, Ferrara E, Barrera G, Thorsson L, Wachter H J, Gallino I, Pérez-Prado M T 2024 Mater. 35 102111

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图 1 (a)粉末的粒径分布图; (b) XRD图; (c) DSC图

Figure 1. (a) Particle size distribution diagram of powder; (b) XRD diagram; (c) DSC diagram.

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图 2 不同打印参数下样品的SEM形貌

Figure 2. SEM morphology of samples under different printing.

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图 3 (a)不同P和v下样品致密度情况; (b)不同h和t下样品致密度情况

Figure 3. (a) Density distribution of samples under different P and v conditions; (b) density distribution of samples under different h and t conditions.

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图 4 (a)不同P和v下样品的非晶含量; (b)样品(P = 160 W, v = 2600 mm/s, h = 95 μm, t = 30 μm) 的XRD图; (c) DSC图

Figure 4. (a) Amorphous content of samples under different P and v conditions; (b) XRD diagram of samples (P = 160 W, v = 2600 mm/s, h = 95 μm, t = 30 μm); (c) DSC diagram.

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图 5 (a)—(d)样品(P = 160 W, v = 2600 mm/s, h = 95 μm, t = 30 μm)的扫描电镜图; (e)—(k)透射电子显微镜图

Figure 5. (a)–(d) Scanning electron microscopy images of the sample (P = 160 W, v = 2600 mm/s, h = 95 μm, t = 30 μm); (e)–(k) transmission electron microscopy images.

DownLoad: Full-Size Img PowerPoint

图 6 (a)不同h和t下样品的非晶含量; (b)不同h和t下样品的XRD图; (c) DSC图; (d) 电机结构; (e)电机结构的XRD图; (f) DSC图

Figure 6. (a) Amorphous content of samples under different h and t conditions; (b) XRD diagram of samples under different h and t conditions; (c) DSC diagram; (d) motor structure; (e) XRD diagram of motor structure; (f) DSC diagram.

DownLoad: Full-Size Img PowerPoint

图 7 (a)室温下粉末及打印样品的磁滞回线; (b)低磁场下磁滞回线的放大图

Figure 7. (a) Hysteresis loops of the powder and printed samples at room temperature; (b) magnified view of the hysteresis loops under low magnetic field.

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表 1 本研究中获得的相对密度、非晶分数和磁性能, 并与文献报道的对比

Table 1. Comparison of the relative density, amorphous fraction, and magnetic properties achieved in this study with those reported in the literature for similar alloys.

BMG Composition	Density /%	Amorphous fraction/%	M_s/ T	H_c/ Oe	Reference
Fe_68.3C_6.9Si_2.5B_6.7P_8.7Cr_2.3Mo_2.5Al_2.1	99.7	—	1.08	0.35	[40]
Fe₇₁Si₁₀B₁₁C₆Cr₂	94	90	1.3	4.98	[37]
Fe_73.7B₁₁Si₁₁Cr_2.3C₂	96	47	1.22	20.1	[26,32]
Fe₇₃Si₁₁B₁₁C₃Cr₂	98	70	1.29	6.4	[16]
Fe_73.7B₁₁Si₁₁Cr_2.3C₂	74	46	1.19	35.06	[41]
Powder (Fe₇₀W₉Mo₃Cr₅Ni₃Si₄B₄CMn)	—	100	0.84	2	This work
Bulk (160 W/2600 mm/s /95 μm/15 μm)	79.1	98.1	0.89	0.7	This work
Bulk (160 W/2600 mm/s /65 μm /15 μm)	94.3	100	0.88	0.5	This work

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[1]	Wang Y J, Lucia O, Zhang Z, Guan Y S, Xu D G 2020 IET Power Electron. 13 1711 Google Scholar
[2]	Battal F, Balci S, Sefa I 2020 Meas. J. Int. Meas. Confed. 171 108848 Google Scholar
[3]	Mahesh M, Kumar K V, Abebe M, Udayakumar L, Mathankumar M 2021 Mater. Today Proc. 46 3888 Google Scholar
[4]	姚可夫, 施凌翔, 陈双琴, 邵洋, 陈娜, 贾蓟丽 2018 物理学报 67 016101 Google Scholar Yao K F, Shi L X, Chen S Q, Shao Y, Chen N, Jia J L 2018 Acta Phys. Sin. 67 016101 Google Scholar
[5]	Li H X, Lu Z C, Wang S L, Wu Y, Lu Z P 2019 Prog. Mater. Sci. 103 235 Google Scholar
[6]	Inoue A, Shinohara Y, Gook J S 1995 Mater. Trans. 36 1427 Google Scholar
[7]	Ponnambalam V, Poon S J, Shiflet G J 2004 J. Mater. Res. 19 1320 Google Scholar
[8]	Amiya K, Inoue A 2006 Mater. Trans. 47 1615 Google Scholar
[9]	张雅楠, 王有骏, 孔令体, 李金富 2012 物理学报 61 454 Google Scholar Zhang Y N, Wang Y J, Kong L T, Li J F 2012 Acta Phys. Sin. 61 454 Google Scholar
[10]	Suryanarayana C, Inoue A 2013 Int. Mater. Rev. 58 131 Google Scholar
[11]	孙吉, 沈鹏飞, 尚其忠, 张鹏雁, 刘莉, 李明瑞, 侯龙, 李维火 2023 物理学报 72 026101 Google Scholar Sun J, Shen P F, Shang Q Z, Zhang P Y, Liu L, Li M R, Hong L, Li W H 2023 Acta Phys. Sin. 72 026101 Google Scholar
[12]	Sohrabi S, Fu J N, Li L Y, Zhang Y, Li X, Sun F, Ma J, Wang W H 2024 Prog. Mater. Sci. 144 101283 Google Scholar
[13]	DebRoy T, Wei H L, Zuback J S, Mukherjee T, Elmer J W, Milewski J O, Beese A M, Wilson-Heid A D, De A, Zhang W 2018 Prog. Mater. Sci. 92 112 Google Scholar
[14]	Pauly S, Löber L, Petters R, Stoica M, Scudino S, Kühn U, Eckert J 2013 Mater. Today 16 37 Google Scholar
[15]	Mahbooba Z, Thorsson L, Unosson M, Skoglund P, West H, Horn T, Rock C, Vogli E, Harrysson O 2018 Appl. Mater. Today 11 264 Google Scholar
[16]	Thorsson L, Unosson M, Pérez-Prado M T, Jin X, Tiberto P, Barrera G, Adam B, Neuber N, Ghavimi A, Frey M, Busch R 2022 Mat. Design 215 110483 Google Scholar
[17]	Lu Y Z, Huang Y J, Wu J, Lu X, Qin Z X, Daisenberger D, Chiu Y L 2018 Intermetallics 103 67 Google Scholar
[18]	Ouyang D, Xing W, Li N, Li Y C, Liu L 2018 Addit. Manuf. 23 246
[19]	Marattukalam J J, Pacheco V, Karlsson D, Riekehr L, Lindwall J, Forsberg F, Jansson U, Sahlberg M, Hjörvarsson B 2020 Addit. Manuf. 33 101124
[20]	Qiu C, Panwisawas C, Ward M, Basoalto H C, Brooks J W, Attallah M M 2015 Acta Mater. 96 72 Google Scholar
[21]	Xing W, Ouyang D, Li N, Liu L 2018 Intermetallics 103 101 Google Scholar
[22]	Ren Z, Zhang D Z, Fu G, Jiang J, Zhao M 2021 Mat. Design 207 109857 Google Scholar
[23]	Ge Y Q, Qiao J F, Chang Z X, Hou M, Xu H J, Yang A A, Song Y, Bi W H, Ma N S 2024 Mater. Today Commun. 39 108597 Google Scholar
[24]	Nguyen Q B, Luu D N, Nai S M, Zhu Z, Chen Z, Wei J 2018 Arch. Civ. Mech. Eng. 18 948 Google Scholar
[25]	Yang G L, Lin X, Liu F C, Hu Q, Ma L, Li J F, Huang W D 2012 Intermetallics 22 110 Google Scholar
[26]	Nam Y G, Koo B, Chang M S, Yang S, Yu J, Park Y H, Jeong J W 2020 Mater. Lett. 261 127068 Google Scholar
[27]	石岩, 魏登松 2023 中国激光 50 131 Google Scholar Shi Y, Wei D S 2023 Chin. J. Lasers 50 131 Google Scholar
[28]	Han Q, Gu H, Setchi R 2019 Powder Technol. 352 91 Google Scholar
[29]	Luo N, Scheitler C, Ciftci N, Galgon F, Fu Z, Uhlenwinkel V, Schmidt M, Körner C 2020 Mater. Charact. 162 110206 Google Scholar
[30]	Yadroitsev I, Yadroitsava I, Bertrand P, Smurov I 2012 Rapid Prototyp. J. 18 201 Google Scholar
[31]	Yuan W, Chen H, Cheng T, Wei Q 2020 Mat. Design 189 108542 Google Scholar
[32]	Zhang Y, Liu H S, Mo J Y, Wang M Z, Chen Z, He Y Z, Yang W M, Tang C G 2019 Phys. Chem. Chem. Phys. 21 12406 Google Scholar
[33]	Özden M G, Morley N A 2023 J. Alloys Compd. 960 170644 Google Scholar
[34]	Sun H, Flores K M 2013 Intermetallics 43 53 Google Scholar
[35]	Li S Y, Fu G, Li H L, Ren Z H, Li S B, Xiao H Q, Peng Q G 2023 J. Alloys Compd. 967 171778 Google Scholar
[36]	Murayama S, Inaba H, Hoshi K, Obi Y 1993 IEEE Trans. Magn. 29 2682 Google Scholar
[37]	Żrodowski Ł, Wysocki B, Wróblewski R, Krawczyńska A, Adamczyk-Cieślak B, Zdunek J, Błyskun P, Ferenc J, Leonowicz M, Święszkowski W 2019 J. Alloys Compd. 771 769 Google Scholar
[38]	邬小萍, 刘淑凤, 马通达, 王书明, 王梦圆 2024 金属功能材料 31 99 Google Scholar Wu X P, Liu S F, Ma T D, Wang S M, Wang M Y 2024 AM& D. 31 99 Google Scholar
[39]	郭子政, 胡旭波 2013 物理学报 62 057501 Google Scholar Guo Z Z, Hu X B 2013 Acta Phys. Sin. 62 057501 Google Scholar
[40]	Jung H Y, Choi S J, Prashanth K G, Stoica M, Scudino S, Yi S, Kühn U, Kim D H, Kim K B, Eckert J 2015 Mat. Design 86 703 Google Scholar
[41]	Rodríguez-Sánchez M, Sadanand S, Ghavimi A, Busch R, Tiberto P, Ferrara E, Barrera G, Thorsson L, Wachter H J, Gallino I, Pérez-Prado M T 2024 Mater. 35 102111

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