Tailoring magnetic hysteresis of additive manufactured Fe-Ni permalloy via multiphysics-multiscale simulations of process-property relationships

Designing the microstructure of Fe-Ni permalloy produced by additive manufacturing (AM) opens new avenues to tailor its magnetic properties. Yet, AM-produced parts suffer from spatially inhomogeneous thermal-mechanical and magnetic responses, which are less investigated in terms of process modeling and simulations. We present a powder-resolved multiphysics-multiscale simulation scheme for describing magnetic hysteresis in AM-produced material, explicitly considering the coupled thermal-structural evolution with associated thermo-elasto-plastic behaviors and chemical order-disorder transitions. The residual stress is identified as the key thread in connecting the physical processes and phenomena across scales. By employing this scheme, we investigate the dependence of the fusion zone size, the residual stress and plastic strain, and the magnetic hysteresis of AM-produced Fe21.5Ni78.5 on beam power and scan speed. Simulation results also suggest a phenomenological relation between magnetic coercivity and average residual stress, which can guide the magnetic hysteresis design of soft magnetic materials by choosing appropriate processing parameters.

Automated summary

Designing the microstructure of Fe-Ni permalloy produced by additive manufacturing (AM) allows for customizing its magnetic properties. However, AM-produced parts exhibit spatially inhomogeneous thermal-mechanical and magnetic responses, which have been less studied in terms of process modeling and simulations. In this study, we propose a powder-resolved multiphysics-multiscale simulation scheme that explicitly considers the coupled thermal-structural evolution with associated thermo-elasto-plastic behaviors and chemical order-disorder transitions. By employing this scheme, we investigate the dependence of fusion zone size, residual stress and plastic strain, and magnetic hysteresis on beam power and scan speed for AM-produced Fe21.5Ni78.5. Results also demonstrate a phenomenological relation between magnetic coercivity and average residual stress, providing guidance for the design of magnetic hysteresis in soft magnetic materials through appropriate processing parameters.