Abstract
Permanent magnets based on FePrCuB were realized on a laboratory scale through additive manufacturing (laser powder bed fusion, L-PBF) and book mold casting (reference). A well-adjusted two-stage heat treatment of the as-cast/as-printed FePrCuB alloys produces hard magnetic properties without the need for subsequent powder metallurgical processing. This resulted in a coercivity of 0.67 T, remanence of 0.67 T and maximum energy density of 69.8 kJ/m3 for the printed parts. While the annealed book-mold-cast FePrCuB alloys are easy-plane permanent magnets (BMC magnet), the printed magnets are characterized by a distinct, predominantly directional microstructure that originated from the AM process and was further refined during heat treatment. Due to the higher degree of texturing, the L-PBF magnet has a 26% higher remanence compared to the identically annealed BMC magnet of the same composition.
Highlights
Additive manufacturing based on laser powder bed fusion L-PBF promises a variety of new opportunities for functional materials: customized material properties, new component and topology structures, and individual components of complex geometry and functional integration
In this paper we demonstrate that significantly larger bodies of FePrCuB can be realized by additive manufacturing
To investigate whether there are texture effects, further hysteresis measurements were performed with the magnetic field applied along the y direction (L-PBF: perpendicular laser scanning direction, BCM: parallel to mold wall but perpendicular to x) and along reference BMC magnet (26% increase)
Summary
Additive manufacturing based on laser powder bed fusion L-PBF promises a variety of new opportunities for functional materials: customized material properties, new component and topology structures, and individual components of complex geometry and functional integration. As important key materials for electrification, new degrees of freedom in the development and design of products may be expected. L-PBF has potential for texture/grain orientation control and tailored microstructures. L-PBF technology is challenging, especially for today’s strongest permanent magnets based on rare earth (RE) metals such as Fe-Nd-B. The three main challenges are: First, RE-based material is highly sensitive to oxidation. There is a lack of powders with spherical morphology and suitable chemical compositions
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