Achieving high strength and ductility in traditionally brittle soft magnetic intermetallics via additive manufacturing

Babuska, Tomas F.; Wilson, Mark A.; Johnson, Kyle L.; Whetten, Shaun R.; Curry, John F.; Rodelas, Jeffrey M.; Atkinson, Cooper; Lu, Ping; Chandross, Michael; Krick, Brandon A.; Michael, Joseph R.; Argibay, Nicolas; Susan, Donald F.; Kustas, Andrew B.

doi:10.1016/j.actamat.2019.08.044

Title: Achieving high strength and ductility in traditionally brittle soft magnetic intermetallics via additive manufacturing

Abstract

Intermetallic alloys possess exceptional soft magnetic properties, including high permeability, low coercivity, and high saturation induction, but exhibit poor mechanical properties that make them impractical to bulk process and use at ideal compositions. We used laser-based Additive Manufacturing to process traditionally brittle Fe–Co and Fe–Si alloys in bulk form without macroscopic defects and at near-ideal compositions for electromagnetic applications. The binary Fe–50Co, as a model material, demonstrated simultaneous high strength (600–700 MPa) and high ductility (35%) in tension, corresponding to a ~300% increase in strength and an order-of-magnitude improvement in ductility relative to conventionally processed material. Atomic-scale toughening and strengthening mechanisms, based on engineered multiscale microstructures, are proposed to explain the unusual combination of mechanical properties. Here, this work presents an instance in which metal Additive Manufacturing processes are enabling, rather than limiting, the development of higher-performance alloys.

Authors:

Babuska, Tomas F. ^[1]; Wilson, Mark A. ^[2]; Johnson, Kyle L. ^[2]; Whetten, Shaun R. ^[2]; Curry, John F. ^[2]; Rodelas, Jeffrey M. ^[2]; Atkinson, Cooper ^[3]; Lu, Ping ^[2]; Chandross, Michael ^[2]; Krick, Brandon A. ^[3]; Michael, Joseph R. ^[2]; Argibay, Nicolas ^[2]; Susan, Donald F. ^[2]; Kustas, Andrew B. ^[2]

Sandia National Lab. (SNL-NM), Albuquerque, NM (United States); Lehigh Univ., Bethlehem, PA (United States)
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Lehigh Univ., Bethlehem, PA (United States)

Publication Date:: Wed Aug 28 00:00:00 EDT 2019

Research Org.:: Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Sponsoring Org.:: USDOE National Nuclear Security Administration (NNSA)

OSTI Identifier:: 1570253

Alternate Identifier(s):: OSTI ID: 1694070

Report Number(s):: SAND-2019-10411J
Journal ID: ISSN 1359-6454; 679062; TRN: US2001069

Grant/Contract Number:: AC04-94AL85000; NA-0003525

Resource Type:: Accepted Manuscript

Journal Name:: Acta Materialia

Additional Journal Information:: Journal Volume: 180; Journal Issue: C; Journal ID: ISSN 1359-6454

Publisher:: Elsevier

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; Intermetallic alloys; Soft magnetic alloys; Additive manufacturing; Multiscale microstructures; Ductile fracture

Citation Formats


                    Babuska, Tomas F., Wilson, Mark A., Johnson, Kyle L., Whetten, Shaun R., Curry, John F., Rodelas, Jeffrey M., Atkinson, Cooper, Lu, Ping, Chandross, Michael, Krick, Brandon A., Michael, Joseph R., Argibay, Nicolas, Susan, Donald F., and Kustas, Andrew B. Achieving high strength and ductility in traditionally brittle soft magnetic intermetallics via additive manufacturing.  United States: N. p., 2019. 
Web.  doi:10.1016/j.actamat.2019.08.044.

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                    Babuska, Tomas F., Wilson, Mark A., Johnson, Kyle L., Whetten, Shaun R., Curry, John F., Rodelas, Jeffrey M., Atkinson, Cooper, Lu, Ping, Chandross, Michael, Krick, Brandon A., Michael, Joseph R., Argibay, Nicolas, Susan, Donald F., & Kustas, Andrew B. Achieving high strength and ductility in traditionally brittle soft magnetic intermetallics via additive manufacturing.  United States.  https://doi.org/10.1016/j.actamat.2019.08.044

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                    Babuska, Tomas F., Wilson, Mark A., Johnson, Kyle L., Whetten, Shaun R., Curry, John F., Rodelas, Jeffrey M., Atkinson, Cooper, Lu, Ping, Chandross, Michael, Krick, Brandon A., Michael, Joseph R., Argibay, Nicolas, Susan, Donald F., and Kustas, Andrew B. Wed .  
"Achieving high strength and ductility in traditionally brittle soft magnetic intermetallics via additive manufacturing".  United States.  https://doi.org/10.1016/j.actamat.2019.08.044.  https://www.osti.gov/servlets/purl/1570253.

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@article{osti_1570253,

  title        = {Achieving high strength and ductility in traditionally brittle soft magnetic intermetallics via additive manufacturing},

  author       = {Babuska, Tomas F. and Wilson, Mark A. and Johnson, Kyle L. and Whetten, Shaun R. and Curry, John F. and Rodelas, Jeffrey M. and Atkinson, Cooper and Lu, Ping and Chandross, Michael and Krick, Brandon A. and Michael, Joseph R. and Argibay, Nicolas and Susan, Donald F. and Kustas, Andrew B.},

  abstractNote = {Intermetallic alloys possess exceptional soft magnetic properties, including high permeability, low coercivity, and high saturation induction, but exhibit poor mechanical properties that make them impractical to bulk process and use at ideal compositions. We used laser-based Additive Manufacturing to process traditionally brittle Fe–Co and Fe–Si alloys in bulk form without macroscopic defects and at near-ideal compositions for electromagnetic applications. The binary Fe–50Co, as a model material, demonstrated simultaneous high strength (600–700 MPa) and high ductility (35%) in tension, corresponding to a ~300% increase in strength and an order-of-magnitude improvement in ductility relative to conventionally processed material. Atomic-scale toughening and strengthening mechanisms, based on engineered multiscale microstructures, are proposed to explain the unusual combination of mechanical properties. Here, this work presents an instance in which metal Additive Manufacturing processes are enabling, rather than limiting, the development of higher-performance alloys.},

  doi          = {10.1016/j.actamat.2019.08.044},

  journal      = {Acta Materialia},

  number       = C,

  volume       = 180,

  place        = {United States},

  year         = {Wed Aug 28 00:00:00 EDT 2019},

  month        = {Wed Aug 28 00:00:00 EDT 2019}

}

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Title: Achieving high strength and ductility in traditionally brittle soft magnetic intermetallics via additive manufacturing

Abstract

Citation Formats

Near equiatomic FeCo alloys: Constitution, mechanical and magnetic properties journal, September 2005

A review of the mechanical properties of B2 compounds journal, February 1995

Plastic deformation in Fe-Si alloys journal, April 1974

The Disorder → Order Transformation in Iron–Cobalt-Based Alloys journal, January 1973

Ordering transformations in Fe-50Co based alloys journal, January 1981

Effect of additive elements on cold workability in FeCo alloys journal, June 1983

Effects of rare earth elements doping on ordered structures and ductility improvement of Fe–6.5wt%Si alloy journal, December 2016

Effects of order–disorder reactions on rapidly quenched Fe–6.5%Si alloy journal, February 2014

Structure and magnetic properties study of iron-based thermally sprayed alloys journal, April 2004

Magnetic properties and ordering in C-coated FexCo1−x alloy nanocrystals journal, June 1998

Deformation twinning feature and its effects on significant enhancement of tensile ductility in columnar-grained Fe–6.5wt.%Si alloy at intermediate temperatures journal, April 2012

Magnetic properties of RF diode sputtered Co/sub x/Fe/sub 100-x/ alloy thin films journal, January 1996

Correlation of coercivity and microstructure of thin CoFe films journal, August 2000

Fabrication and magnetic properties of Fe–6.5% Si alloys by magnetron sputtering method journal, July 2010

Magnetic properties of amorphous Fe‐Si thin films journal, September 1976

Magnetic properties of high silicon iron sheet fabricated by direct powder rolling journal, October 2004

Commercial scale production of Fe‐6.5 wt. % Si sheet and its magnetic properties journal, November 1988

Mechanism of mechanical alloying phase formation and related magnetic and mechanical properties in the FeSi system journal, August 1993

Formation and magnetic properties of nanocrystalline mechanically alloyed Fe‐Co and Fe‐Ni journal, May 1993

Studies of magnetic properties of permalloy (Fe–30%Ni) prepared by SLM technology journal, February 2012

Laser metal deposition and selective laser melting of Fe–28 at.% Al journal, July 2014

Properties of soft magnetic Fe-Co-V alloy produced by laser powder bed fusion journal, May 2019

Metallurgy of high-silicon steel parts produced using Selective Laser Melting journal, May 2016

Effect of annealing on the microstructure and magnetic properties of soft magnetic Fe-Si produced via laser additive manufacturing journal, January 2018

Laser Additive Manufacturing of Magnetic Materials journal, January 2017

Tuning the phase stability and magnetic properties of laser additively processed Fe-30at%Ni soft magnetic alloys journal, July 2017

Laser additive processing of Ni-Fe-V and Ni-Fe-Mo Permalloys: Microstructure and magnetic properties journal, April 2017

Bulk Combinatorial Synthesis and High Throughput Characterization for Rapid Assessment of Magnetic Materials: Application of Laser Engineered Net Shaping (LENS™) journal, April 2016

Fe-Al thin walls manufactured by Laser Engineered Net Shaping journal, March 2017

Misfit-energy-increasing dislocations in vapor-deposited CoFe/NiFe multilayers journal, April 2004

Fast Parallel Algorithms for Short-Range Molecular Dynamics journal, March 1995

Visualization and analysis of atomistic simulation data with OVITO–the Open Visualization Tool journal, December 2009

Enhancing workability in sheet production of high silicon content electrical steel through large shear deformation journal, July 2018

Texture Development in High-Silicon Iron Sheet Produced by Simple Shear Deformation journal, March 2016

The plastic deformation of ordered FeCo and Fe3 Al alloys journal, May 1964

Relationship between flow stress and atomic order in the FeCo alloy journal, November 1964

Geometric flow control of shear bands by suppression of viscous sliding journal, August 2016

Deformation twinning in an Fe-6.5wt.% Si alloy with columnar grains during intermediate temperature compression journal, March 2012

Tensile properties of strip casting 6.5wt% Si steel at elevated temperatures journal, July 2015

Hot drawn Fe–6.5wt.%Si wires with good ductility journal, August 2014

Simulation and experimental comparison of the thermo-mechanical history and 3D microstructure evolution of 304L stainless steel tubes manufactured using LENS journal, December 2017

An Experimental Investigation into Additive Manufacturing-Induced Residual Stresses in 316L Stainless Steel journal, September 2014

The metallurgy and processing science of metal additive manufacturing journal, March 2016

Predicting Texture Evolution in Ta and Ta-10W Alloys Using Polycrystal Plasticity journal, August 2015

The effect of grain size and Fe:Co ratio on the room temperature yielding of FeCo journal, June 1994

Mechanical properties of soft magnetic FeCo alloys journal, June 2002

The conflicts between strength and toughness journal, October 2011

Additive manufacturing of metals journal, September 2016

Metal Additive Manufacturing: A Review journal, April 2014

Calorimetric study and microstructure analysis of the order-disorder phase transformation in silicon steel built by SLM journal, October 2017

Solidification velocity of undercooled Fe–Co alloys journal, January 2017

Additively manufactured hierarchical stainless steels with high strength and ductility journal, October 2017

Microstructure stabilization in a rapidly solidified journal, September 1992

Equal channel angular extrusion for bulk processing of Fe–Co–2V soft magnetic alloys, part I: Processing and mechanical properties journal, May 2018

Temperature dependent mechanical properties of ultra-fine grained FeCo–2V journal, August 2003

Competition between densification and microstructure of functionalmaterials by Selective Laser Melting journal, February 2020

Near equiatomic FeCo alloys: Constitution, mechanical and magnetic properties
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A review of the mechanical properties of B2 compounds
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Plastic deformation in Fe-Si alloys
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The Disorder → Order Transformation in Iron–Cobalt-Based Alloys
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Ordering transformations in Fe-50Co based alloys
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Effect of additive elements on cold workability in FeCo alloys
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Effects of rare earth elements doping on ordered structures and ductility improvement of Fe–6.5wt%Si alloy
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Effects of order–disorder reactions on rapidly quenched Fe–6.5%Si alloy
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Structure and magnetic properties study of iron-based thermally sprayed alloys
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Magnetic properties and ordering in C-coated FexCo1−x alloy nanocrystals
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Deformation twinning feature and its effects on significant enhancement of tensile ductility in columnar-grained Fe–6.5wt.%Si alloy at intermediate temperatures
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Magnetic properties of RF diode sputtered Co/sub x/Fe/sub 100-x/ alloy thin films
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Correlation of coercivity and microstructure of thin CoFe films
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Fabrication and magnetic properties of Fe–6.5% Si alloys by magnetron sputtering method
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Magnetic properties of amorphous Fe‐Si thin films
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Magnetic properties of high silicon iron sheet fabricated by direct powder rolling
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Commercial scale production of Fe‐6.5 wt. % Si sheet and its magnetic properties
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Mechanism of mechanical alloying phase formation and related magnetic and mechanical properties in the FeSi system
journal, August 1993

Formation and magnetic properties of nanocrystalline mechanically alloyed Fe‐Co and Fe‐Ni
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Studies of magnetic properties of permalloy (Fe–30%Ni) prepared by SLM technology
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Laser metal deposition and selective laser melting of Fe–28 at.% Al
journal, July 2014

Properties of soft magnetic Fe-Co-V alloy produced by laser powder bed fusion
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Metallurgy of high-silicon steel parts produced using Selective Laser Melting
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Effect of annealing on the microstructure and magnetic properties of soft magnetic Fe-Si produced via laser additive manufacturing
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Laser Additive Manufacturing of Magnetic Materials
journal, January 2017

Tuning the phase stability and magnetic properties of laser additively processed Fe-30at%Ni soft magnetic alloys
journal, July 2017

Laser additive processing of Ni-Fe-V and Ni-Fe-Mo Permalloys: Microstructure and magnetic properties
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Bulk Combinatorial Synthesis and High Throughput Characterization for Rapid Assessment of Magnetic Materials: Application of Laser Engineered Net Shaping (LENS™)
journal, April 2016

Fe-Al thin walls manufactured by Laser Engineered Net Shaping
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Misfit-energy-increasing dislocations in vapor-deposited CoFe/NiFe multilayers
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Fast Parallel Algorithms for Short-Range Molecular Dynamics
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Visualization and analysis of atomistic simulation data with OVITO–the Open Visualization Tool
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Enhancing workability in sheet production of high silicon content electrical steel through large shear deformation
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Texture Development in High-Silicon Iron Sheet Produced by Simple Shear Deformation
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The plastic deformation of ordered FeCo and Fe3 Al alloys
journal, May 1964

Relationship between flow stress and atomic order in the FeCo alloy
journal, November 1964

Geometric flow control of shear bands by suppression of viscous sliding
journal, August 2016

Deformation twinning in an Fe-6.5wt.% Si alloy with columnar grains during intermediate temperature compression
journal, March 2012

Tensile properties of strip casting 6.5wt% Si steel at elevated temperatures
journal, July 2015

Hot drawn Fe–6.5wt.%Si wires with good ductility
journal, August 2014

Simulation and experimental comparison of the thermo-mechanical history and 3D microstructure evolution of 304L stainless steel tubes manufactured using LENS
journal, December 2017

An Experimental Investigation into Additive Manufacturing-Induced Residual Stresses in 316L Stainless Steel
journal, September 2014

The metallurgy and processing science of metal additive manufacturing
journal, March 2016

Predicting Texture Evolution in Ta and Ta-10W Alloys Using Polycrystal Plasticity
journal, August 2015

The effect of grain size and Fe:Co ratio on the room temperature yielding of FeCo
journal, June 1994

Mechanical properties of soft magnetic FeCo alloys
journal, June 2002

The conflicts between strength and toughness
journal, October 2011

Additive manufacturing of metals
journal, September 2016

Metal Additive Manufacturing: A Review
journal, April 2014

Calorimetric study and microstructure analysis of the order-disorder phase transformation in silicon steel built by SLM
journal, October 2017

Solidification velocity of undercooled Fe–Co alloys
journal, January 2017

Additively manufactured hierarchical stainless steels with high strength and ductility
journal, October 2017

Microstructure stabilization in a rapidly solidified
journal, September 1992

Equal channel angular extrusion for bulk processing of Fe–Co–2V soft magnetic alloys, part I: Processing and mechanical properties
journal, May 2018

Temperature dependent mechanical properties of ultra-fine grained FeCo–2V
journal, August 2003

Competition between densification and microstructure of functionalmaterials by Selective Laser Melting
journal, February 2020