Stress related magnetic imaging of iron-based metallic glass produced with laser beam powder bed fusion

Abstract

Additive manufacturing makes the production of bulk metallic glasses possible in thicknesses exceeding the critical casting thickness. However, a crucial challenge is the build-up of thermally induced stress, often resulting in printed parts suffering from cracking. In this study, the process parameters are optimised for printing soft-magnetic metallic glass samples of an Fe-based alloy (Fe73.8P10.6Mo4.2B2.3Si2.3C6.7), using laser beam powder bed fusion. In addition, the structural and magnetic properties of as-received and heat-treated powder are investigated and compared to those of the printed samples. Kerr microscopy is used for imaging the magnetic domains on single track cross-sections produced on top of a polished printed sample. This reveals the shape of the melt pool of a single laser track, as well as the magnetic domains around it and in other regions of the printed sample. The shape and size of the magnetic domains reflect the residual stress in the sample through the effect of magneto-elastic coupling. This magnetic contrast could be used to get further insights into how to control the development of stress during the printing process.