Additive manufacturing of NiZnCu-ferrite soft magnetic composites

Andrews, Caleb E.; Chatham, Megan P.; Dorman, Samantha F.; McCue, Ian; Sopcisak, Joseph; Taheri, Mitra L.

doi:10.1557/s43578-021-00343-x

Cited by 3 publications

(2 citation statements)

References 45 publications

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“…This can be observed in the studies conducted by Liu et al [ 134 , 135 ], who developed a UV-curable Ni–Zn paste and fabricated components using a direct-extrusion 3D printer, exhibiting, in some situations, magnetic properties (relative permeability ranging from 63 to 103 and resonance frequency exceeding 30 MHz) similar to those of commercial Ni–Zn ferrite cores. Andrews et al [ 136 ] developed the toroid with Ni–Zn–Cu/Fe–oxide ceramic powder using L-PBF and achieved high permeability values in the fabricated samples. Additionally, the study determined that the proper selection of parameters (process and powder fabrication), as well as heat treatment and weight percentage of ferrite loading, are crucial for reducing porosity and improving magnetic properties.…”

Section: Soft Ferritesmentioning

confidence: 99%

Recent Advances in Additive Manufacturing of Soft Magnetic Materials: A Review

Vargas

Stornelli

Folgarait³

et al. 2023

Materials

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Additive manufacturing (AM) is an attractive set of processes that are being employed lately to process specific materials used in the fabrication of electrical machine components. This is because AM allows for the preservation or enhancement of their magnetic properties, which may be degraded or limited when manufactured using other traditional processes. Soft magnetic materials (SMMs), such as Fe–Si, Fe–Ni, Fe–Co, and soft magnetic composites (SMCs), are suitable materials for electrical machine additive manufacturing components due to their magnetic, thermal, mechanical, and electrical properties. In addition to these, it has been observed in the literature that other alloys, such as soft ferrites, are difficult to process due to their low magnetization and brittleness. However, thanks to additive manufacturing, it is possible to leverage their high electrical resistivity to make them alternative candidates for applications in electrical machine components. It is important to highlight the significant progress in the field of materials science, which has enabled the development of novel materials such as high-entropy alloys (HEAs). These alloys, due to their complex chemical composition, can exhibit soft magnetic properties. The aim of the present work is to provide a critical review of the state-of-the-art SMMs manufactured through different AM technologies. This review covers the influence of these technologies on microstructural changes, mechanical strengths, post-processing, and magnetic parameters such as saturation magnetization (MS), coercivity (HC), remanence (Br), relative permeability (Mr), electrical resistivity (r), and thermal conductivity (k).

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Section: Soft Ferritesmentioning

confidence: 99%

Recent Advances in Additive Manufacturing of Soft Magnetic Materials: A Review

Vargas

Stornelli

Folgarait³

et al. 2023

Materials

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show abstract

“…[28,29] Finally, AM of soft magnetic composites and ferrites has also been explored using printing techniques which typically involve printing a green body geometry and sintering to achieve final density. [30][31][32] These classes of materials also have high electrical resistivity and are used in high-frequency electronic applications.…”

mentioning

confidence: 99%

Magnetic Behavior of a Laser Deposited Fe–Ni–Mo Alloy

et al. 2023

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Magnetic shielding in spacecraft is a mission‐critical issue that must be addressed in a timely and effective manner. The high permeability of Fe–Ni–Mo alloys, makes them excellent candidates for magnetic shielding. This article explores a new and innovative approach, enabled by additive manufacturing (AM), to design, build, and test geometrically complex magnetic shields. A Fe–79.7Ni–4.1Mo alloy is additively manufactured using blown powder laser‐directed energy deposition (DED). AM build conditions are explored in the production of magnetic test rings and magnetic shield prototypes. Magnetic hysteresis test data are obtained, allowing for the determination of magnetic permeability, saturation, and coercivity. Detailed microstructural characterization is carried out. Three different prototype shield designs are printed and magnetic shield attenuation data is obtained. The magnetic field attenuation (shield effectiveness) obtained for the AM components is comparable to wrought equivalents. The values reported here for the magnetic permeability are the highest, and that for the magnetic coercivity the lowest, for any blown powder DED‐printed material currently known. The magnetic behavior is discussed with regard to grain size and orientation, as well as grain boundary effects, with all of these attributes contributing to the ultimate performance.

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