Laser powder bed fusion (L-PBF) 3D printing thin overhang walls of permalloy for a modified honeycomb magnetic-shield structure

Abstract

Modified honeycomb parts of Ni-15Fe-5Mo permalloy for magnetic shielding applications were designed and fabricated via laser powder bed fusion (L-PBF) 3D printing. We focused on the L-PBF process and performances of the thin-walled samples with different overhangs. After temperature-field numerical simulations and mechanism analyses on the L-BPF molten pools, the process optimizations were conducted to achieve a high bulk relative density. The thin walls with different wall thicknesses (0.3, 0.4, 0.5, 0.6, 0.7, and 0.8 mm) and overhanging angles (10°, 20°, 30°, 40°, 50°, 60°, 70°, 80°, and 90°) were printed without any supporting struts. The structures, mechanical properties, and formation mechanisms of the thin-walled overhangs were studied. We roughly gained some such trends or inferences about the tensile properties of the thin-walled overhangs. The microstructural anisotropies and surface “step effects” were the primary factors affecting the tensile properties. The numerical simulation and experiment of compression on the modified honeycomb parts with several sidewall inclination angles were performed. The modified honeycomb structures transferred stress and premature failure to other local structures far away from the compression face. The preferential plastic deformation of the modified honeycomb structures occurred at the inclined corners, exhibiting good plastic deformation buffering effect and thus avoiding instantaneous cracking. This work presented some reference significance for high-quality formation and performance evaluation of thin-walled overhanging structures via L-PBF.