Journal
ACTA MATERIALIA
Volume 180, Issue -, Pages 149-157Publisher
PERGAMON-ELSEVIER SCIENCE LTD
DOI: 10.1916/j.actamat.2019.08.044
Keywords
Intermetallic alloys; Soft magnetic alloys; Additive manufacturing; Multiscale microstructures; Ductile fracture
Funding
- National Science Foundation [1842163]
- SNL Laboratory Directed Research and Development program
- U.S. Department of Energy's National Nuclear Security Administration [DE-NA-0003525]
- Direct For Education and Human Resources
- Division Of Graduate Education [1842163] Funding Source: National Science Foundation
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Intermetallic alloys possess exceptional soft magnetic properties, including high permeability, low coercivity, and high saturation induction, but exhibit poor mechanical properties that make them impractical to bulk process and use at ideal compositions. We used laser-based Additive Manufacturing to process traditionally brittle Fe-Co and Fe-Si alloys in bulk form without macroscopic defects and at near-ideal compositions for electromagnetic applications. The binary Fe-50Co, as a model material, demonstrated simultaneous high strength (600-700 MPa) and high ductility (35%) in tension, corresponding to a similar to 300% increase in strength and an order-of-magnitude improvement in ductility relative to conventionally processed material. Atomic-scale toughening and strengthening mechanisms, based on engineered multiscale microstructures, are proposed to explain the unusual combination of mechanical properties. This work presents an instance in which metal Additive Manufacturing processes are enabling, rather than limiting, the development of higher-performance alloys. (C) 2019 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.
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