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

Zurui Cao, Pengcheng Zhang, Bailing An, Dawei Li, Yao Yu, Jie Pan, Cheng Zhang () and Lin Liu ()
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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

Nature Communications, 2024, vol. 15, issue 1, 1-12

Abstract: 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.

Date: 2024
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DOI: 10.1038/s41467-024-54133-0

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