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Title: Net shape processing of alnico magnets by additive manufacturing

Alternatives to rare earth permanent magnets, such as alnico, will reduce supply instability, increase sustainability, and could decrease the cost of permanent magnets, especially for high temperature applications, such as traction drive motors. Alnico magnets with moderate coercivity, high remanence, and relatively high energy product are conventionally processed by directional solidification and (significant) final machining, contributing to increased costs and additional material waste. Additive manufacturing (AM) is developing as a cost effective method to build net-shape three-dimensional parts with minimal final machining and properties comparable to wrought parts. This work describes initial studies of net-shape fabrication of alnico magnets by AM using a laser engineered net shaping (LENS) system. High pressure gas atomized (HPGA) pre-alloyed powders of two different modified alnico “8” compositions, with high purity and sphericity, were built into cylinders using the LENS process, followed by heat treatment. The magnetic properties showed improvement over their cast and sintered counterparts. The resulting alnico permanent magnets were characterized using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), electron backscatter diffraction (EBSD), and hysteresisgraph measurements. Furthermore, these results display the potential for net-shape processing of alnico permanent magnets for use in next generation traction drive motors and other applications requiring highmore » temperatures and/or complex engineered part geometries.« less
ORCiD logo [1] ;  [2] ;  [1] ;  [1] ;  [1] ;  [2]
  1. Ames Lab., Ames, IA (United States)
  2. Ames Lab. and Iowa State Univ., Ames, IA (United States)
Publication Date:
Report Number(s):
IS-J-9292; IS-J-9438
Journal ID: ISSN 0018-9464
Grant/Contract Number:
Accepted Manuscript
Journal Name:
IEEE Transactions on Magnetics
Additional Journal Information:
Journal Volume: 53; Journal Issue: 11; Journal ID: ISSN 0018-9464
Institute of Electrical and Electronics Engineers. Magnetics Group
Research Org:
Ames Lab., Ames, IA (United States); Ames Laboratory (AMES), Ames, IA (United States)
Sponsoring Org:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Vehicle Technologies Office (EE-3V)
Country of Publication:
United States
36 MATERIALS SCIENCE; additive manufacturing; alnico; permanent magnets
OSTI Identifier:
Alternate Identifier(s):
OSTI ID: 1406560