Controlling the extent of atomic ordering in intermetallic alloys through additive manufacturing

Abstract

Control of the atomic structure, as measured by the extent of the embrittling B2 chemically ordered phase, is demonstrated in intermetallic alloys through additive manufacturing (AM) and characterized using high fidelity neutron diffraction. As a layer-by-layer rapid solidification process, AM was employed to suppress the extent of chemically ordered B2 phases in a soft ferromagnetic Fe-Co alloy, as a model material system of interest to electromagnetic applications. The extent of atomic ordering was found to be insensitive to the spatial location within specimens and suggests that the thermal conditions within only a few AM layers were most influential in controlling the microstructure, in agreement with the predictions from a thermal model for welding. Analysis of process parameter effects on ordering found that suppression of B2 phase was the result of an increased average cooling rate during processing. AM processing parameters, namely interlayer interval time and build velocity, were used to systematically control the relative fraction of ordered B2 phase in specimens from 0.49 to 0.72. Hardness of AM specimens was more than 150% higher than conventionally processed bulk material. Implications for tailoring microstructures of intermetallic alloys are discussed.