Influence of scan pattern and geometry on the microstructure and soft-magnetic performance of additively manufactured Fe-Si

Plotkowski, Alex; Pries, Jason; List III, Fred; Nandwana, Peeyush; Stump, Benjamin; Carver, Keith; Dehoff, Ryan

doi:10.1016/j.addma.2019.100781

Title: Influence of scan pattern and geometry on the microstructure and soft-magnetic performance of additively manufactured Fe-Si

Journal Article · Wed Jul 03 00:00:00 EDT 2019 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2019.100781· OSTI ID:1559675

^[1];

^[2];

^[1];

^[1]; Stump, Benjamin ^[1];

^[1];

^[1]

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Materials Science & Technology Division, and Manufacturing Demonstration Facility
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Electrical & Electronic Systems Division

The influence of geometry and scan pattern on the microstructure evolution and magnetic performance of additively manufactured Fe-3Si components was investigated. To reduce eddy current losses, novel geometries were designed and built and the microstructure and properties of these samples were characterized. The laser scan pattern was shown to strongly influence both the as-built grain structure and strength of the crystallographic texture, resulting in measurable changes in the as-built magnetic performance. In thin wall samples, heat treatment resulted in an increase in the maximum relative magnetic permeability and decrease in power losses in most samples, consistent with grain growth. However, decreases in the spacing between thin walls to increase the stacking factor of the cross-section was shown to result in unwanted electrical shorting between walls and an increase in eddy current losses. Compared to simple parallel plate construction and a mesh structure, a novel cross-section design based on the Hilbert space filling curve was found to produce the lowest power losses. The mechanisms behind these results were explored using a combination of heat conduction and electromagnetic simulations, providing a route for future component and process optimization.

View Accepted Manuscript (DOE)

View Accepted Manuscript (Publisher)

Cite

Export

Save

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE); USDOE Office of Electricity (OE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1559675

Alternate ID(s):: OSTI ID: 1877294

Journal Information:: Additive Manufacturing, Vol. 29, Issue C; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

Citation Metrics:

Cited by: 37 works

Citation information provided by
Web of Science

References (30)

Bulk Combinatorial Synthesis and High Throughput Characterization for Rapid Assessment of Magnetic Materials: Application of Laser Engineered Net Shaping (LENS™) Geng, J.; Nlebedim, I. C.; Besser, M. F. JOM, Vol. 68, Issue 7 https://doi.org/10.1007/s11837-016-1918-x	journal	April 2016
Tuning the phase stability and magnetic properties of laser additively processed Fe-30at%Ni soft magnetic alloys Mikler, C. V.; Chaudhary, V.; Soni, V. Materials Letters, Vol. 199 https://doi.org/10.1016/j.matlet.2017.04.054	journal	July 2017
Laser Additive Manufacturing of Magnetic Materials Mikler, C. V.; Chaudhary, V.; Borkar, T. JOM, Vol. 69, Issue 3 https://doi.org/10.1007/s11837-017-2257-2	journal	January 2017
Laser additive processing of Ni-Fe-V and Ni-Fe-Mo Permalloys: Microstructure and magnetic properties Mikler, C. V.; Chaudhary, V.; Borkar, T. Materials Letters, Vol. 192 https://doi.org/10.1016/j.matlet.2017.01.059	journal	April 2017
Microstructure and Magnetic Properties of Fe–Ni Alloy Fabricated by Selective Laser Melting Fe/Ni Mixed Powders Zhang, Baicheng; Fenineche, Nour-Eddine; Liao, Hanlin Journal of Materials Science & Technology, Vol. 29, Issue 8 https://doi.org/10.1016/j.jmst.2013.05.001	journal	August 2013
Iron and silicon-iron alloys Littmann, M. IEEE Transactions on Magnetics, Vol. 7, Issue 1 https://doi.org/10.1109/TMAG.1971.1066998	journal	March 1971
Magnetic properties and workability of 6.5% Si steel sheet Haiji, H.; Okada, K.; Hiratani, T. Journal of Magnetism and Magnetic Materials, Vol. 160 https://doi.org/10.1016/0304-8853(96)00128-X	journal	July 1996
Recent researches on high silicon-iron alloys Narita, K.; Teshima, N.; Mori, Y. IEEE Transactions on Magnetics, Vol. 17, Issue 6 https://doi.org/10.1109/TMAG.1981.1061740	journal	November 1981
Influence of alloy elements on the plasticity of high-silicon iron Glezer, A. M.; Maleeva, I. V.; Zakharov, A. I. Metal Science and Heat Treatment, Vol. 27, Issue 12 https://doi.org/10.1007/BF00700099	journal	December 1985
Effect of nickel and manganese addition on ductility and magnetic properties of 6.5% silicon-iron alloy Narita, K.; Enokizono, M. IEEE Transactions on Magnetics, Vol. 14, Issue 4 https://doi.org/10.1109/TMAG.1978.1059756	journal	July 1978
Commercial scale production of Fe‐6.5 wt. % Si sheet and its magnetic properties Takada, Y.; Abe, M.; Masuda, S. Journal of Applied Physics, Vol. 64, Issue 10 https://doi.org/10.1063/1.342373	journal	November 1988
Magnetic properties of commercially produced Fe-6.5wt% Si sheet Abe, M.; Takada, Y.; Murakami, T. Journal of Materials Engineering, Vol. 11, Issue 1 https://doi.org/10.1007/BF02833761	journal	March 1989
Improvement of magnetic properties of an Fe–6.5wt.% Si alloy by directional solidification Fu, Huadong; Zhang, Zhihao; Jiang, Yanbin Materials Letters, Vol. 65, Issue 9 https://doi.org/10.1016/j.matlet.2011.02.020	journal	May 2011
Texture Development in High-Silicon Iron Sheet Produced by Simple Shear Deformation Kustas, Andrew B.; Sagapuram, Dinakar; Trumble, Kevin P. Metallurgical and Materials Transactions A, Vol. 47, Issue 6 https://doi.org/10.1007/s11661-016-3437-3	journal	March 2016
Texture control during laser deposition of nickel-based superalloy Dinda, G. P.; Dasgupta, A. K.; Mazumder, J. Scripta Materialia, Vol. 67, Issue 5 https://doi.org/10.1016/j.scriptamat.2012.06.014	journal	September 2012
Site specific control of crystallographic grain orientation through electron beam additive manufacturing Dehoff, R. R.; Kirka, M. M.; Sames, W. J. Materials Science and Technology, Vol. 31, Issue 8 https://doi.org/10.1179/1743284714Y.0000000734	journal	November 2014
Localized melt-scan strategy for site specific control of grain size and primary dendrite arm spacing in electron beam additive manufacturing Raghavan, Narendran; Simunovic, Srdjan; Dehoff, Ryan Acta Materialia, Vol. 140 https://doi.org/10.1016/j.actamat.2017.08.038	journal	November 2017
Highly Anisotropic Steel Processed by Selective Laser Melting Niendorf, Thomas; Leuders, Stefan; Riemer, Andre Metallurgical and Materials Transactions B, Vol. 44, Issue 4 https://doi.org/10.1007/s11663-013-9875-z	journal	May 2013
Relationship between laser energy input, microstructures and magnetic properties of selective laser melted Fe-6.9%wt Si soft magnets Garibaldi, M.; Ashcroft, I.; Hillier, N. Materials Characterization, Vol. 143 https://doi.org/10.1016/j.matchar.2018.01.016	journal	September 2018
Calorimetric study and microstructure analysis of the order-disorder phase transformation in silicon steel built by SLM Lemke, J. N.; Simonelli, M.; Garibaldi, M. Journal of Alloys and Compounds, Vol. 722 https://doi.org/10.1016/j.jallcom.2017.06.085	journal	October 2017
Effect of annealing on the microstructure and magnetic properties of soft magnetic Fe-Si produced via laser additive manufacturing Garibaldi, M.; Ashcroft, I.; Lemke, J. N. Scripta Materialia, Vol. 142 https://doi.org/10.1016/j.scriptamat.2017.08.042	journal	January 2018
Metallurgy of high-silicon steel parts produced using Selective Laser Melting Garibaldi, Michele; Ashcroft, Ian; Simonelli, Marco Acta Materialia, Vol. 110 https://doi.org/10.1016/j.actamat.2016.03.037	journal	May 2016
Geometry-Induced Spatial Variation of Microstructure Evolution During Selective Electron Beam Melting of Rene-N5 Frederick, Curtis Lee; Plotkowski, Alexander; Kirka, Michael M. Metallurgical and Materials Transactions A, Vol. 49, Issue 10 https://doi.org/10.1007/s11661-018-4793-y	journal	August 2018
Analysis of solidification microstructures in Fe-Ni-Cr single-crystal welds Rappaz, M.; David, S. A.; Vitek, J. M. Metallurgical Transactions A, Vol. 21, Issue 6 https://doi.org/10.1007/BF02672593	journal	June 1990
In-process closed-loop control for stabilising the melt pool temperature in selective laser melting Renken, Volker; von Freyberg, Axel; Schünemann, Kevin Progress in Additive Manufacturing, Vol. 4, Issue 4 https://doi.org/10.1007/s40964-019-00083-9	journal	May 2019
Additive manufacturing of metallic components – Process, structure and properties DebRoy, T.; Wei, H. L.; Zuback, J. S. Progress in Materials Science, Vol. 92 https://doi.org/10.1016/j.pmatsci.2017.10.001	journal	March 2018
The metallurgy and processing science of metal additive manufacturing Sames, W. J.; List, F. A.; Pannala, S. International Materials Reviews, Vol. 61, Issue 5 https://doi.org/10.1080/09506608.2015.1116649	journal	March 2016
Calculation of solidification-related thermophysical properties for steels Miettinen, Jyrki Metallurgical and Materials Transactions B, Vol. 28, Issue 2 https://doi.org/10.1007/s11663-997-0095-2	journal	April 1997
Efficient additive manufacturing production of oxide- and nitride-dispersion-strengthened materials through atmospheric reactions in liquid metal deposition Springer, H.; Baron, C.; Szczepaniak, A. Materials & Design, Vol. 111 https://doi.org/10.1016/j.matdes.2016.08.084	journal	December 2016
Grain structure evolution in Inconel 718 during selective electron beam melting Helmer, H.; Bauereiß, A.; Singer, R. F. Materials Science and Engineering: A, Vol. 668 https://doi.org/10.1016/j.msea.2016.05.046	journal	June 2016

Cited By (1)

Additive Manufacturing and Topology Optimization of Magnetic Materials for Electrical Machines—A Review Pham, Thang; Kwon, Patrick; Foster, Shanelle Energies, Vol. 14, Issue 2 https://doi.org/10.3390/en14020283	journal	January 2021