Superior Mechanical and Magnetic Performance of Highly Anisotropic Sendust-Flake Composites Freeze Cast in a Uniform Magnetic Field

Despite extensive research, the manufacture in the bulk of high-performance flake-based magnetic composites with a highly aligned, nacre-like structure remains challenging. Many challenges can be overcome by freeze casting in an externally applied, uniform magnetic field, which causes both the flakes and the composite walls of the cellular solid to align parallel to the B-field lines. When appropriately sized, the flakes experience a second alignment parallel to the freezing direction because of a shear flow that occurs due to both the volumetric expansion of the ice phase and mold contraction during the directional solidification. The resulting orthotropic structure of the freeze-cast magnetic composite is reflected in orthotropic mechanical and magnetic properties of the material. The magnetic composites manufactured by magnetic-field assisted freeze casting outperform by a factor of 2-4 in terms of stiffness, strength, and toughness materials that are processed in the absence of a magnetic field and do not exhibit a monodomain architecture. Because of the highly aligned microstructure, it is possible to compact the initially lamellar composite with 90% porosity to at least 80% strain. The results presented in this study illustrate the tremendous potential for magnetic freeze casting of magnetic composites for use in power conversion.

Automated summary

Manufacturing high-performance flake-based magnetic composites with a highly aligned, nacre-like structure remains challenging, but can be overcome through freeze casting in an externally applied magnetic field. The resulting orthotropic structure of the freeze-cast magnetic composite leads to superior mechanical and magnetic properties compared to materials processed without a magnetic field. The highly aligned microstructure allows for compacting the composite with high porosity to a significant strain level.