Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets

Cramer, Corson L.; Nandwana, Peeyush; Yan, Jiaqiang; Evans, Samuel F.; Elliott, Amy M.; Chinnasamy, Chins; Paranthaman, M. Parans

doi:10.1016/j.heliyon.2019.e02804

Title: Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets

Abstract

High silicon (Si) electrical steel has the potential for efficient use in applications such as electrical motors and generators with cost-effective in processing, but it is difficult to manufacture. Increasing the Si content beyond 3 wt.% improves magnetic and electrical properties, with 6.5 wt.% being achievable. The main goal of this research is to design, develop, and implement a scalable additive manufacturing process to fabricate Fe with 6.5 wt.% Si (Fe–6Si) steel with high magnetic permeability, high electrical resistivity, low coercivity, and low residual induction that other methods cannot achieve because of manufacturing limitations. Binder jet additive manufacturing was used to deposit near net shape components that were subsequently sintered via solid-state sintering to achieve near full densification. Here, it is shown that the use of solid-state sintering mitigates cracking since no rapid solidification occurs unlike fusion-based additive technologies. The Fe–6Si samples demonstrated an ultimate tensile strength of 434 MPa, electrical resistivity of 98 μΩ cm, and saturation magnetization of 1.83 T with low coercivity and high permeability. The results strongly supports to replace the only available 0.1 mm thick chemical vapor deposition (CVD) produced Si steel using the cost effective AM method with good mechanical and magnetic properties formore » motor applications.« less

Authors:: Cramer, Corson L.; Nandwana, Peeyush; Yan, Jiaqiang; Evans, Samuel F.; Elliott, Amy M.; Chinnasamy, Chins; Paranthaman, M. Parans

Publication Date:: 2019-11-19

Research Org.:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

OSTI Identifier:: 1574542

Alternate Identifier(s):: OSTI ID: 1607076

Grant/Contract Number:: AC05-00OR22725

Resource Type:: Published Article

Journal Name:: Heliyon

Additional Journal Information:: Journal Name: Heliyon Journal Volume: 5 Journal Issue: 11; Journal ID: ISSN 2405-8440

Publisher:: Elsevier

Country of Publication:: United Kingdom

Language:: English

Subject:: 36 MATERIALS SCIENCE; Electromagnetism; Soft magnetic alloy; Fe–6Si; Binder jet additive manufacturing; DC and AC magnetic properties; Stators

Citation Formats


                    Cramer, Corson L., Nandwana, Peeyush, Yan, Jiaqiang, Evans, Samuel F., Elliott, Amy M., Chinnasamy, Chins, and Paranthaman, M. Parans. Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets.  United Kingdom: N. p., 2019. 
Web.  doi:10.1016/j.heliyon.2019.e02804.

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                    Cramer, Corson L., Nandwana, Peeyush, Yan, Jiaqiang, Evans, Samuel F., Elliott, Amy M., Chinnasamy, Chins, & Paranthaman, M. Parans. Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets.  United Kingdom.  https://doi.org/10.1016/j.heliyon.2019.e02804

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                    Cramer, Corson L., Nandwana, Peeyush, Yan, Jiaqiang, Evans, Samuel F., Elliott, Amy M., Chinnasamy, Chins, and Paranthaman, M. Parans. Tue .  
"Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets".  United Kingdom.  https://doi.org/10.1016/j.heliyon.2019.e02804.

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@article{osti_1574542,

  title        = {Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets},

  author       = {Cramer, Corson L. and Nandwana, Peeyush and Yan, Jiaqiang and Evans, Samuel F. and Elliott, Amy M. and Chinnasamy, Chins and Paranthaman, M. Parans},

  abstractNote = {High silicon (Si) electrical steel has the potential for efficient use in applications such as electrical motors and generators with cost-effective in processing, but it is difficult to manufacture. Increasing the Si content beyond 3 wt.% improves magnetic and electrical properties, with 6.5 wt.% being achievable. The main goal of this research is to design, develop, and implement a scalable additive manufacturing process to fabricate Fe with 6.5 wt.% Si (Fe–6Si) steel with high magnetic permeability, high electrical resistivity, low coercivity, and low residual induction that other methods cannot achieve because of manufacturing limitations. Binder jet additive manufacturing was used to deposit near net shape components that were subsequently sintered via solid-state sintering to achieve near full densification. Here, it is shown that the use of solid-state sintering mitigates cracking since no rapid solidification occurs unlike fusion-based additive technologies. The Fe–6Si samples demonstrated an ultimate tensile strength of 434 MPa, electrical resistivity of 98 μΩ cm, and saturation magnetization of 1.83 T with low coercivity and high permeability. The results strongly supports to replace the only available 0.1 mm thick chemical vapor deposition (CVD) produced Si steel using the cost effective AM method with good mechanical and magnetic properties for motor applications.},

  doi          = {10.1016/j.heliyon.2019.e02804},

  journal      = {Heliyon},

  number       = 11,

  volume       = 5,

  place        = {United Kingdom},

  year         = {2019},

  month        = {11}

}

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Title: Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets

Abstract

Citation Formats

Relative effect(s) of texture and grain size on magnetic properties in a low silicon non-grain oriented electrical steel journal, August 2003

Magnetic properties evaluation of spray formed and rolled Fe–6.5wt.% Si–1.0wt.% Al alloy journal, March 2007

Review of Fe-6.5 wt%Si high silicon steel—A promising soft magnetic material for sub-kHz application journal, July 2019

Evolution of Optimum Grain Size for Low Loss Ferritic FeSi Steels journal, September 2017

Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets journal, October 2016

Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process journal, April 2016

Production of high silicon steel for electrical applications by thermomechanical processing journal, December 2003

Texture of Cold Rolled Strip of Fe-3Si Steel Produced by Thin Slab Casting and Rolling journal, March 2011

Basic Investigation of CVD Method for Manufacturing 6.5% Si Steel Sheet. journal, January 1996

High-silicon steel produced by hot dipping and diffusion annealing journal, January 2002

Texture and magnetic properties of rapidly quenched Fe-6.5wt%Si ribbon journal, July 1984

Coincidence Site Lattice (CSL) grain boundaries and Goss texture development in Fe-3% Si alloy journal, December 1996

Recent developments of non-oriented electrical steel sheets journal, September 1984

Influence of plastic strain on magnetic behaviour of non-oriented Fe–3Si and application to manufacturing test by punching journal, May 1995

Texture of hot rolled strip for Fe-3Si steel produced by thin slab casting and rolling journal, December 2010

The effect of heat treatments and Si contents on B2 ordering reaction in high-silicon steels journal, June 2001

Thermomechanical processing of high Si-steel (up to 6.3% Si) journal, July 2001

Effects of precipitated phase and order degree on bending properties of an Fe-6.5 wt%Si alloy with columnar grains journal, July 2011

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

On abnormal growth of Goss grains in grain-oriented silicon steel journal, March 2011

On the development of the goss texture in iron-3% silicon journal, December 1984

The Eftects of Superheating on Texture and Microstructure of Fe-4.5wt%Si Steel Strip by Twin-roll Strip Casting. journal, January 2001

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

Additive manufacturing of anisotropic hybrid NdFeB-SmFeN nylon composite bonded magnets journal, December 2018

Study of order-disorder effect on magnetic properties of rapidly quenched Fe-6.5 wt% Si alloys journal, February 1989

Additive manufacturing of near-net-shape bonded magnets: Prospects and challenges journal, July 2017

Influence of thermal debinding on the final properties of Fe–Si soft magnetic alloys for metal injection molding (MIM) journal, October 2016

Ordering–disordering phenomena and micro-hardness characteristics of B2 phase in Fe–(5–6.5%)Si alloys journal, October 2005

Frequency dependence of core loss in rapidly quenched Fe‐6.5 wt. %Si journal, November 1988

Relative effect(s) of texture and grain size on magnetic properties in a low silicon non-grain oriented electrical steel
journal, August 2003

Magnetic properties evaluation of spray formed and rolled Fe–6.5wt.% Si–1.0wt.% Al alloy
journal, March 2007

Review of Fe-6.5 wt%Si high silicon steel—A promising soft magnetic material for sub-kHz application
journal, July 2019

Evolution of Optimum Grain Size for Low Loss Ferritic FeSi Steels
journal, September 2017

Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets
journal, October 2016

Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process
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Production of high silicon steel for electrical applications by thermomechanical processing
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Texture of Cold Rolled Strip of Fe-3Si Steel Produced by Thin Slab Casting and Rolling
journal, March 2011

Basic Investigation of CVD Method for Manufacturing 6.5% Si Steel Sheet.
journal, January 1996

High-silicon steel produced by hot dipping and diffusion annealing
journal, January 2002

Texture and magnetic properties of rapidly quenched Fe-6.5wt%Si ribbon
journal, July 1984

Coincidence Site Lattice (CSL) grain boundaries and Goss texture development in Fe-3% Si alloy
journal, December 1996

Recent developments of non-oriented electrical steel sheets
journal, September 1984

Influence of plastic strain on magnetic behaviour of non-oriented Fe–3Si and application to manufacturing test by punching
journal, May 1995

Texture of hot rolled strip for Fe-3Si steel produced by thin slab casting and rolling
journal, December 2010

The effect of heat treatments and Si contents on B2 ordering reaction in high-silicon steels
journal, June 2001

Thermomechanical processing of high Si-steel (up to 6.3% Si)
journal, July 2001

Effects of precipitated phase and order degree on bending properties of an Fe-6.5 wt%Si alloy with columnar grains
journal, July 2011

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

On abnormal growth of Goss grains in grain-oriented silicon steel
journal, March 2011

On the development of the goss texture in iron-3% silicon
journal, December 1984

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journal, January 2001

Metallurgy of high-silicon steel parts produced using Selective Laser Melting
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Study of order-disorder effect on magnetic properties of rapidly quenched Fe-6.5 wt% Si alloys
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Ordering–disordering phenomena and micro-hardness characteristics of B2 phase in Fe–(5–6.5%)Si alloys
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