Finished surface morphology, microstructure and magnetic properties of selective laser melted Fe-50wt% Ni permalloy

doi:10.1007/s40195-022-01386-7

Abstract

Abstract:

This work focuses on the structure and magnetic properties of Fe-50wt% Ni permalloy manufactured from the pre-alloyed powder by selective laser melting (SLM). The selective laser melted (SLMed) alloys were characterized by a 3D profilometer, optical microscope, scanning electron microscope, X-ray diffraction, etc. The effects of the volume energy density of laser (LVED) on structure, and magnetic properties with coercivity (H_c), remanence (B_r), and power losses (P_50-1), were evaluated and discussed systematically. The results show that the relative porosity rate and the surface roughness of the SLMed specimens decreased with the increase in LVED. Only the γ-(FeNi) phase was detected in the X-ray diffraction patterns of the SLMed permalloys fabricated from the different LVEDs. Statistical analysis of optical microscopy images indicated that the grain coarsened at higher LVED. Furthermore, the microstructure of the SLMed parts was a typical columnar structure with an oriented growth of building direction. The highest microhardness reached 198 HV_0.1. Besides, the magnetic properties including B_r, H_c, and P_50-1 of SLMed samples decreased when the LVED ranged from 33.3 to 60.0 J/mm³ firstly and then increased while LVED further up to 93.3 J/mm³, which is related to the decrease in porosity and the increase in grain size, while the higher residual stress and microcracks presented in the samples manufactured using very high LVED. The observed evolution of magnetic properties and LVED provides a good compromise in terms of reduced porosity and crack formation for the fabrication of SLMed Fe-50wt% Ni permalloy. The theoretical mechanism in this study can offer guidance to further investigate SLMed soft magnetic alloys.

Key words: Selective laser melting, Fe-50wt%Ni permalloy, Finished surface morphology, Microstructural evolution, Magnetic properties

Shuohong Gao, Xingchen Yan, Cheng Chang, Xinliang Xie, Qingkun Chu, Zhaoyang Deng, Bingwen Lu, Min Liu, Hanlin Liao, Nouredine Fenineche. Finished surface morphology, microstructure and magnetic properties of selective laser melted Fe-50wt% Ni permalloy[J]. Acta Metallurgica Sinica (English Letters), 2022, 35(9): 1439-1452.

Figures/Tables 16

Fig. 1 Powder characterization and scanning strategy: a macroscopic morphology of the original feedstock, b EDS analysis result, c particle size distribution, d SLMed scanning strategy used to fabricate the samples

Fig. 2 3D models and dimensions of SLMed samples: a cubic specimen, b ring sample

Table 1 Details of manufacturing parameters

Sample number	Laser power (W)	Laser spot (μm)	Scanning speed (mm/s)	Hatch distance (mm)	Layer thickness (mm)	Energy density (J/mm³)
1	100	100	1000	0.1	0.03	33.3
2	140	100	1000	0.1	0.03	46.7
3	180	100	1000	0.1	0.03	60.0
4	280	100	1000	0.1	0.03	93.3

Fig. 3 SEM images of the SLMed samples fabricated using different LVEDs: a 33.3 J/mm3, b 46.7 J/mm3, c 60.0 J/mm3, d 93.3 J/mm3

Fig. 4 SEM images at an enlarged view of the SLMed samples: a fabricated using an LVED with 33.3 J/mm3, b fabricated using an LVED with 46.7 J/mm3

Fig. 5 Schematic diagrams of unjoined spacing and spattering phenomenon during the SLM process: a unjoined spacing, b spattering phenomenon [36]

Fig. 6 Three-dimensional surface topographies and top surface roughness of the SLMed specimens fabricated via different LVEDs: a 33.3 J/mm3, b 46.7 J/mm3, c 60.0 J/mm3, d 93.3 J/mm3

Fig. 7 Optical microscopy images of cross-sectional planes and scanning planes of the SLMed samples fabricated using different LVEDs: cross-sectional planes a 33.3 J/mm3, b 46.7 J/mm3, c 60.0 J/mm3, d 93.3 J/mm3, scanning planes e 33.3 J/mm3, f 46.7 J/mm3, g 60.0 J/mm3, h 93.3 J/mm3

Fig. 8 XRD phase analysis of the SLMed samples fabricated in different LVEDs

Fig. 9 Optical microscopy images (after etching) of scanning planes in the SLMed specimens fabricated using different LVEDs: a 33.3 J/mm3, b 46.7 J/mm3, c 60.0 J/mm3, d 93.3 J/mm3

Fig. 10 Optical microscopy images (after etching) of cross-sectional planes in the SLMed specimens fabricated using different LVEDs: a 33.3 J/mm3, b 46.7 J/mm3, c 60.0 J/mm3, d 93.3 J/mm3

Fig. 11 SEM images (after etching) of cross-sectional planes in the SLMed specimens fabricated using different LVEDs: a 33.3 J/mm3, b 46.7 J/mm3, c 60.0 J/mm3, d 93.3 J/mm3

Fig. 12 SEM photographs (after etching) of cross-sectional planes collected in the representative regions of SLMed sample-3 fabricated using an LVED = 60.0 J/mm3

Fig. 13 Microhardness of cross-sectional planes and scanning planes in the SLMed specimens fabricated using different LVEDs

Fig. 14 Evolution of the magnetic properties with LVEDs: a coercivity, b remenance, c power losses

Fig. 15 Schematic effect of defects on the movement of domain walls during magnetization and demagnetization

References 50

[1]	A. Bandyopadhyay, S. Bose, Additive Manufacturing, CRC Press, Boca Raton, 2019
[2]	X. Yan, C. Huang, C. Chen, R. Bolot, L. Dembinski, R. Huang, W. Ma, H. Liao, M. Liu, Surf. Coat. Technol. 371, 161 (2019) DOI URL
[3]	S. Gao, X. Yan, C. Chang, Eric Aubry, M. Liu, H. Liao, N. Fenineche, J. Mater. Eng. Perform. 30, 5020 (2021) DOI URL
[4]	J. Gunasekaran, P. Sevvel, I.J. Solomon Mater. Today: Proc. 37, 252 (2021)
[5]	X. Yan, S. Yin, C. Chen, R. Jenkins, R. Lupoi, R. Bolot, W. Ma, M. Kuang, H. Liao, J. Lu, Mater. Res. Lett. 7, 327 (2019) DOI URL
[6]	X. Yan, C. Chen, C. Chang, D. Dong, R. Zhao, R. Jenkins, J. Wang, Z. Ren, M. Liu, H. Liao, Mater. Sci. Eng. A 781, 139227 (2020)
[7]	Y. Lu, S. Guo, Y. Yang, Y. Liu, Y. Zhou, S. Wu, C. Zhao, J. Lin, J. Alloys Compd. 730, 552 (2018) DOI URL
[8]	X. Yan, S. Gao, C. Chang, J. Huang, K. Khanlari, D. Dong, W. Ma, N. Fenineche, H. Liao, M. Liu, J. Mater. Process. Technol. 288, 116878 (2021)
[9]	M. Higashi, T. Ozaki, Mater. Des. 191, 108588 (2020)
[10]	L. Zhou, J. Chen, C. Li, J. He, W. Li, T. Yuan, R. Li, Mater. Sci. Eng. A 785, 139352 (2020)
[11]	A. Iveković, N. Omidvari, B. Vrancken, K. Lietaert, L. Thijs, K. Vanmeensel, J. Vleugels, J.P. Kruth, Int. J. Refract. Met. Hard Mater 72, 27 (2018) DOI URL
[12]	X. Yan, Q. Li, S. Yin, Z. Chen, R. Jenkins, C. Chen, J. Wang, W. Ma, R. Bolot, R. Lupoi, J. Alloys Compd. 782, 209 (2019) DOI URL
[13]	H. Shokrollahi, K. Janghorban, J. Mater. Process. Technol. 189, 1 (2007) DOI URL
[14]	J.M. Silveyra, E. Ferrara, D.L. Huber, T.C. Monson, Science 362, 195 (2018) DOI URL
[15]	C.W. Chen, Magnetism and Metallurgy of Soft Magnetic Materials, Courier Corporation, 2013
[16]	S.D. Sudhoff, Power Magnetic Devices: A Multi-Objective Design Approach, John Wiley & Sons, 2014
[17]	L. Yang, K. Hsu, B. Baughman, D. Godfrey, F. Medina, M. Menon, S. Wiener, Additive Manufacturing Of Metals: The Technology, Materials, Design and Production, Springer, 2017
[18]	B. Zhang, N.E. Fenineche, H. Liao, C. Coddet, J. Magn. Magn. Mater. 336, 49 (2013) DOI URL
[19]	B. Zhang, N.E. Fenineche, H. Liao, C. Coddet, J. Mater. Sci. Technol. 29, 757 (2013) DOI URL
[20]	M. Garibaldi, I. Ashcroft, N. Hillier, S. Harmon, R. Hague, Mater. Charact. 143, 144 (2018) DOI URL
[21]	M. Garibaldi, I. Ashcroft, M. Simonelli, R. Hague, Acta Mater. 110, 207 (2016) DOI URL
[22]	J. Lemke, M. Simonelli, M. Garibaldi, I. Ashcroft, R. Hague, M. Vedani, R. Wildman, C. Tuck, J. Alloys Compd. 722, 293 (2017) DOI URL
[23]	J. Zou, Y. Gaber, G. Voulazeris, S. Li, L. Vazquez, L.F. Liu, M.Y. Yao, Y.J. Wang, M. Holynski, K. Bongs, Acta Mater. 158, 230 (2018) DOI URL
[24]	A. Mazeeva, M. Staritsyn, V. Bobyr, S. Manninen, P. Kuznetsov, V. Klimov, J. Alloys Compd. 814, 152315 (2020)
[25]	A. Plotkowski, J. Pries, F. List, P. Nandwana, B. Stump, K. Carver, R. Dehoff, Addit. Manuf. 29, 100781 (2019)
[26]	S. Alleg, R. Drablia, N. Fenineche, J. Supercond. Nov. Magn. 31, 3565 (2018) DOI URL
[27]	S. Gao, X. Yan, C. Chang, E. Aubry, P. He, M. Liu, H. Liao, N. Fenineche, Mater. Lett. 290, 129469 (2021)
[28]	T. Riipinen, S. Metsä-Kortelainen, T. Lindroos, J. Keränen, A. Manninen, J. Pippuri-Mäkeläinen, Rapid Prototyping J. 25, 699 (2019) DOI
[29]	A.E.M.A. Mohamed, J. Zou, R.S. Sheridan, K. Bongs, M.M. Attallah, Addit. Manuf. 32, 101079 (2020)
[30]	S. Bai, N. Perevoshchikova, Y. Sha, X. Wu, Appl. Sci. 9, 583 (2019) DOI URL
[31]	G. Yu, D. Gu, D. Dai, M. Xia, C. Ma, K. Chang, Appl. Phys. A 122, 1 (2016) DOI URL
[32]	S. Liu, J. Liu, J. Chen, X. Liu, Int. J. Therm. Sci. 146, 106075 (2019)
[33]	C. Ma, D. Bothe, Int. J. Multiphase Flow 37, 1045 (2011) DOI URL
[34]	D. Ye, K. Zhu, J.Y.H. Fuh, Y. Zhang, H.G. Soon, Opt. Laser Technol. 111, 395 (2019) DOI URL
[35]	Y. Bai, Z. Shi, Y.J. Lee, H. Wang, J. Mater. Process. Technol. 280, 116597 (2020)
[36]	S. Pal, G. Lojen, R. Hudak, V. Rajtukova, T. Brajlih, V. Kokol, I. Drstvenšek, Addit. Manuf. 33, 101147 (2020)
[37]	D. Wang, S. Wu, F. Fu, S. Mai, Y. Yang, Y. Liu, C. Song, Mater. Des. 117, 121 (2017) DOI URL
[38]	D. Dai, D. Gu, Int. J. Mach. Tools Manuf. 88, 95 (2015) DOI URL
[39]	M. Xia, D. Gu, G. Yu, D. Dai, H. Chen, Q. Shi, Int. J. Mach. Tools Manuf. 116, 96 (2017) DOI URL
[40]	J.I. Langford, A. Wilson, J. Appl. Crystallogr. 11, 102 (1978) DOI URL
[41]	M. Bayat, S. Mohanty, J.H. Hattel, Int. J. Heat Mass Transf. 139, 95 (2019) DOI URL
[42]	W. Yuan, H. Chen, T. Cheng, Q. Wei, Mater. Des. 189, 108542 (2020)
[43]	W.J. Sames, F. List, S. Pannala, R.R. Dehoff, S.S. Babu, Int. Mater. Rev. 61, 315 (2016) DOI URL
[44]	Y. Bai, C. Zhao, D. Wang, H. Wang, J. Mater. Process. Technol. 299, 117328 (2022)
[45]	Y. Liu, Y. Yang, D. Wang, Int. J. Adv. Manuf. Technol. 87, 647 (2016) DOI URL
[46]	L. Tonelli, A. Fortunato, L. Ceschini, J. Manuf. Processes 52, 106 (2020) DOI URL
[47]	X. Cui, S. Zhang, C. Zhang, J. Chen, J. Zhang, S. Dong, Mater. Sci. Eng. A 140957 (2021)
[48]	E. Bruck, Handbook of Magnetic Materials, Elsevier, 2017.
[49]	R. Conteri, T. Borkar, S. Nag, D. Jaeger, X. Chen, R. Ramanujan, R. Banerjee, J. Manuf. Processes 29, 175 (2017) DOI URL
[50]	T. Yamazaki, Y. Furuya, W. Nakao, J. Magn. Magn. Mater. 475, 240 (2019) DOI URL