Emerging Opportunities in Manufacturing Bulk Soft-Magnetic Alloys for Energy Applications: A Review

Kustas, Andrew B.; Susan, Donald F.; Monson, Todd

doi:10.1007/s11837-021-05019-9

Title: Emerging Opportunities in Manufacturing Bulk Soft-Magnetic Alloys for Energy Applications: A Review

Journal Article · 13 January 2022 · JOM. Journal of the Minerals, Metals & Materials Society

DOI: https://doi.org/10.1007/s11837-021-05019-9 · OSTI ID:1840067

; Susan, Donald F.; Monson, Todd

Abstract Soft-magnetic alloys exhibit exceptional functional properties that are beneficial for a variety of electromagnetic applications. These alloys are conventionally manufactured into sheet or bar forms using well-established ingot metallurgy practices that involve hot- and cold-working steps. However, recent developments in process metallurgy have unlocked opportunities to directly produce bulk soft-magnetic alloys with improved, and often tailorable, structure–property relationships that are unachievable conventionally. The emergence of unconventional manufacturing routes for soft-magnetic alloys is largely motivated by the need to improve the energy efficiency of electromagnetic devices. In this review, literature that details emerging manufacturing approaches for soft-magnetic alloys is overviewed. This review covers (1) severe plastic deformation, (2) recent advances in melt spinning, (3) powder-based methods, and (4) additive manufacturing. These methods are discussed in comparison with conventional rolling and bar processing. Perspectives and recommended future research directions are also discussed.

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Research Organization:: Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)

Sponsoring Organization:: USDOE Laboratory Directed Research and Development (LDRD) Program; USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: NA0003525

OSTI ID:: 1840067

Report Number(s):: SAND2022-11277J; PII: 5019

Journal Information:: JOM. Journal of the Minerals, Metals & Materials Society, Journal Name: JOM. Journal of the Minerals, Metals & Materials Society Journal Issue: 4 Vol. 74; ISSN 1047-4838

Publisher:: Springer Science + Business MediaCopyright Statement

Country of Publication:: United States

Language:: English

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