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In situ phase engineering during additive manufacturing enables high-performance soft-magnetic medium-entropy alloys

Author

Listed:
  • Zurui Cao

    (Huazhong University of Science and Technology)

  • Pengcheng Zhang

    (Huazhong University of Science and Technology)

  • Bailing An

    (Huazhong University of Science and Technology)

  • Dawei Li

    (Huazhong University of Science and Technology)

  • Yao Yu

    (Huazhong University of Science and Technology)

  • Jie Pan

    (Huazhong University of Science and Technology)

  • Cheng Zhang

    (Huazhong University of Science and Technology)

  • Lin Liu

    (Huazhong University of Science and Technology)

Abstract

Additive manufacturing (AM) shows promise as a method for producing soft-magnetic multicomponent alloys for use in electric motors and sustainable electromobility applications. However, the simultaneous achievement of a high saturation magnetic flux density (Bs) and a low coercivity (Hc) in AM soft-magnetic materials remains challenging. Herein, we present an approach that integrates an elemental powder mixture of Fe45Co30Ni25 with Fe2O3 nano-oxides, which is then subjected to laser powder bed fusion (LPBF) followed by high-temperature annealing to achieve an FCC-structured Fe45Co30Ni25 MEA/FeO composite. The FeO nanoparticles, a byproduct of the reaction between Fe powders and Fe2O3 nano-oxides, serve as nucleation sites for the formation of a single FCC phase in the MEA matrix. The resulting LPBF MEA/FeO composite has a Bs of 2.05 T and an exceedingly low Hc of 115 A m−1, compared to those of the BCC/FCC dual phase MEA and other state-of-the-art additively manufactured soft-magnetic alloys. In situ Lorentz transmission electron microscope (TEM) revealed that the low Hc of the FCC-structured MEA/FeO composite originates from the reduced pinning effect of grain boundaries in the FCC phase on domain wall movement compared with those in the FCC/BCC dual phase.

Suggested Citation

  • Zurui Cao & Pengcheng Zhang & Bailing An & Dawei Li & Yao Yu & Jie Pan & Cheng Zhang & Lin Liu, 2024. "In situ phase engineering during additive manufacturing enables high-performance soft-magnetic medium-entropy alloys," Nature Communications, Nature, vol. 15(1), pages 1-12, December.
    • Handle: RePEc:nat:natcom:v:15:y:2024:i:1:d:10.1038_s41467-024-54133-0
    DOI: 10.1038/s41467-024-54133-0
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    1. Jingqi Zhang & Yingang Liu & Gang Sha & Shenbao Jin & Ziyong Hou & Mohamad Bayat & Nan Yang & Qiyang Tan & Yu Yin & Shiyang Liu & Jesper Henri Hattel & Matthew Dargusch & Xiaoxu Huang & Ming-Xing Zhan, 2022. "Designing against phase and property heterogeneities in additively manufactured titanium alloys," Nature Communications, Nature, vol. 13(1), pages 1-10, December.
    2. Liuliu Han & Fernando Maccari & Isnaldi R. Souza Filho & Nicolas J. Peter & Ye Wei & Baptiste Gault & Oliver Gutfleisch & Zhiming Li & Dierk Raabe, 2022. "A mechanically strong and ductile soft magnet with extremely low coercivity," Nature, Nature, vol. 608(7922), pages 310-316, August.
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