Alnico-8H (14 wt% Ni) and Alnico-8H (19 wt% Ni) were additively fabricated from a blend of elemental powders with compositions (in wt.%) of 38Co-29Fe-14Ni-8Al-8Ti-3Cu and 33Co-29Fe-19Ni-8Al-8Ti-3Cu, respectively, using laser-directed energy deposition technique. Post additive fabrication both compositions were subjected to homogenization heat treatment at 1250 °C for 30 min and magnetic annealed at 650 °C under 2.5 T magnetic field for 60 mins (1 hr). X-ray diffraction was employed for studying the phase evolution. Scanning and transmission electron microscopes were utilized for characterization of Alnico alloys. The targeted compositions for Alnico-8H (14 wt% Ni) and Alnico-8H (19 wt% Ni) were nearly achieved in the L-DED processed samples. homogenization at 1250 °C, followed by magnetic annealing at 650 °C, resulted in an increase in grain size. The transmission electron microscopy revealed the presence of ferromagnetic α1 and paramagnetic α2 phases in the magnetic annealed microstructure. The increase in Nickel content from 14 to 19 wt% resulted in increase in coercivity (242 to 255 Oe), remanence (4437 to 8659 G), and maximum energy product (BHmax) (0.27 to 0.53 MGOe).
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