Additively manufactured high permeability Fe-Ni alloys and novel bi-metallic magnetic shields

Abstract

The sensitivity and sophistication of spacecraft for Earth Science and Planetary Science missions are increasing with each successive mission. Advances in instrumentation, robotics, remote sensing, avionics and controls are allowing un-crewed missions to be incredibly sophisticated. Effective electromagnetic shielding is critical for high fidelity functioning of the spacecraft and onboard instrumentation. Moreover, the geometrical complexity of the shielding arrangement and the constraints of size and shape, make additive manufacturing (AM) a critical, enabling technology for current and future missions. Two AM approaches - directed energy deposition (DED) and laser powder bed fusion (LPBF) - were used to produce Fe-80Ni-5Mo alloy rings and shields. The microstructure and magnetic properties of the materials produced through these processes are reported in this paper. A mechanism relating the microstructure to the soft magnetic performance of the material is proposed. The AM material produced in this work demonstrated the highest reported magnetic permeability and lowest reported coercivity of any additively manufactured soft magnetic material. Two different combinations of bi-metallic shields, Fe-80Ni-5Mo/FeCo-2V and Fe-80Ni-5Mo/Fe-49Ni, were fabricated using the DED process. The creation of these shields as monoliths in general, and for space-related applications in particular, is a novel aspect of this work. These multi-alloy, multi-layer shields showed a nearly 10 dB increase in shielding performance over Fe-80Ni-5Mo single alloy shielding, a significant improvement. For the DED builds, the coercivity decreases and permeability increases (better soft magnetic performance) with increasing build power. With increasing build power in the DED process, the grain size in the printed part increases. The corresponding reduction in the grain boundary area results in fewer obstacles to the movement of magnetic domain walls.