Elastocaloric cooling, which exploits the latent heat released and absorbed as stress-induced phase transformations are reversibly cycled in shape memory alloys, has recently emerged as a frontrunner in non-vapor-compression cooling technologies. The intrinsically high thermodynamic efficiency of elastocaloric materials is limited only by work hysteresis. Here, we report on creating high-performance low-hysteresis elastocaloric cooling materials via additive manufacturing of Titanium-Nickel (Ti-Ni) alloys. Contrary to established knowledge of the physical metallurgy of Ti-Ni alloys, intermetallic phases are found to be beneficial to elastocaloric performances when they are combined with the binary Ti-Ni compound in nanocomposite configurations. The resulting microstructure gives rise to quasi-linear stressstrain behaviors with extremely small hysteresis, leading to enhancement in the materials efficiency by a factor of five. Furthermore, despite being composed of more than 50% intermetallic phases, the reversible, repeatable elastocaloric performance of this material is shown to be stable over one million cycles. This result opens the door for direct implementation of additive manufacturing to elastocaloric cooling systems where versatile design strategy enables both topology optimization of heat exchangers as well as unique microstructural control of metallic refrigerants.One Sentence Summary: 3D printing produces highly efficient solid-state cooling nanocomposites with long fatigue life.

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Alternatives to rare earth permanent magnets, such as alnico, will reduce supply instability, increase sustainability, and could decrease the cost of permanent magnets, especially for high temperature applications, such as traction drive motors. Alnico magnets with moderate coercivity, high remanence, and relatively high energy product are conventionally processed by directional solidification and (significant) final machining, contributing to increased costs and additional material waste. Additive manufacturing (AM) is developing as a cost effective method to build net-shape three-dimensional parts with minimal final machining and properties comparable to wrought parts. This work describes initial studies of net-shape fabrication of alnico magnets by AM using a laser engineered net shaping (LENS) system. High pressure gas atomized (HPGA) pre-alloyed powders of two different modified alnico "8" compositions, with high purity and sphericity, were built into cylinders using the LENS process, followed by heat treatment. The magnetic properties showed improvement over their cast and sintered counterparts. The resulting alnico permanent magnets were characterized using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), electron backscatter diffraction (EBSD), and hysteresisgraph measurements. These results display the potential for net-shape processing of alnico permanent magnets for use in next generation traction drive motors and other applications requiring high temperatures and/or complex engineered part geometries.Alternatives to rare earth permanent magnets, such as alnico, will reduce supply instability, increase sustainability, and could decrease the cost of permanent magnets, especially for high temperature applications, such as traction drive motors. Alnico magnets with moderate coercivity, high remanence, and relatively high energy product are conventionally processed by directional solidification and (significant) final machining, contributing to increased costs and additional material waste. Additive manufacturing (AM) is developing as a cost effective method to build net-shape three-dimensional parts with minimal final machining and properties comparable to wrought parts. This work describes initial studies of net-shape fabrication of alnico magnets by AM using a laser engineered net shaping (LENS) system. High pressure gas atomized (HPGA) pre-alloyed powders of two different modified alnico "8" compositions, with high purity and sphericity, were built into cylinders using the LENS process, followed by heat treatment. The magnetic properties showed improvement over their cast and sintered counterparts. The resulting alnico permanent magnets were characterized using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), electron backscatter diffraction (EBSD), and hysteresisgraph measurements. These results display the potential for net-shape processing of alnico permanent magnets for use in next generation traction drive motors and other applications requiring hi...

The stress-induced martensitic phase transformation of shape memory alloys (SMAs) is the basis for elastocaloric cooling. Here we employ additive manufacturing to fabricate TiNi SMAs, and demonstrate compressive elastocaloric cooling in the TiNi rods with transformation latent heat as large as 20 J g −1 . Adiabatic compression on as-fabricated TiNi displays cooling DT as high as −7.5 °C with recoverable superelastic strain up to 5 %. Unlike conventional SMAs, additive manufactured TiNi SMAs exhibit linear superelasticity with narrow hysteresis in stress-strain curves under both adiabatic and isothermal conditions. Microstructurally, we find that there are Ti 2 Ni precipitates typically one micron in size with a large aspect ratio enclosing the TiNi matrix. A stress transfer mechanism between reversible phase transformation in the TiNi matrix and mechanical deformation in Ti 2 Ni precipitates is believed to be the origin of the unique superelasticity behavior. Abstract:The stress-induced martensitic phase transformation of shape memory alloys (SMAs) is the basis for elastocaloric cooling. Here we employ additive manufacturing to fabricate TiNi SMAs, and demonstrate compressive elastocaloric cooling in the TiNi rods with transformation latent heat as large as 20 J g −1 . Adiabatic compression on as-fabricated TiNi displays cooling ∆T as high as −7.5 °C with recoverable superelastic strain up to 5 %. Unlike conventional SMAs, additive manufactured TiNi SMAs exhibit linear superelasticity with narrow hysteresis in stress-strain curves under both adiabatic and isothermal conditions. Microstructurally, we find that there are Ti2Ni precipitates typically one micron in size with a large aspect ratio enclosing the TiNi matrix.A stress transfer mechanism between reversible phase transformation in the TiNi matrix and mechanical deformation in Ti2Ni precipitates is believed to be the origin of the unique superelasticity behavior.

A bulk combinatorial approach for synthesizing alloy libraries using laser engineered net shaping (LENS TM ; i.e., 3D printing) was utilized to rapidly assess material systems for magnetic applications. The LENS TM system feeds powders in different ratios into a melt pool created by a laser to synthesize samples with bulk (millimeters) dimensions. By analyzing these libraries with autosampler differential scanning calorimeter/thermal gravimetric analysis and vibrating sample magnetometry, we are able to rapidly characterize the thermodynamic and magnetic properties of the libraries. The Fe-Co binary alloy was used as a model system and the results were compared with data in the literature.

This work focuses on the rapid synthesis and characterization of quaternary Ce(CoFeCu)5 alloy libraries to assess their potential viability as permanent magnets. Arrays of bulk specimens with controlled compositions were synthesized via laser engineered net shaping (LENS) by feeding different ratios of alloy powders into a melt pool created by a laser. Based on the assessment of the magnetic properties of the LENS printed samples, arc-melted and cast ingots were prepared with varying Fe (5-20 at.%) and Co (60-45 at.%) compositions while maintaining constant Ce (16 at.%) and Cu (19 at.%) content. The evolution of the microstructure and phases with varying chemical compositions and their dependence on magnetic properties are analyzed in ascast and heat-treated samples. In both the LENS printed and cast samples, we find the best magnetic properties correspond to a predominantly single-phase Ce(CoFeCu)5 microstructure in which high coercivity (Hc > 10 kOe) can be achieved without any microstructural refinement.

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