Additive manufacturing of NiZnCu-ferrite soft magnetic composites

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

doi:10.1557/s43578-021-00343-x

Additive manufacturing of NiZnCu-ferrite soft magnetic composites

Caleb E. Andrews, Megan P. Chatham, Samantha F. Dorman, Ian D. McCue, Joseph J. Sopcisak, Mitra L. Taheri^*

^*Corresponding author for this work

Materials Science and Engineering

Research output: Contribution to journal › Article › peer-review

3 Scopus citations

Abstract

Soft magnetic composites (SMCs) are a class of magnetic materials that have the potential to create lighter and more efficient electronic devices. SMCs provide high electrical resistivity while providing high magnetic permeability, consisting of a magnetically conductive core and an insulating coating traditionally made via powder metallurgy. Until recent advances, devices needing materials with these magnetic properties have been made by complex and geometrically limited laminations or press and sinter methods; both possessing issues. This paper establishes that a multi-material system incorporating NiZnCu-ferrite and high purity iron processed via additive manufacturing (AM) can serve as a manufacturing route for SMCs, with as-built samples showing high maximum relative permeability (~ 200,000). The results demonstrate the viability of laser powder bed fusion (L-PBF) AM to produce SMCs with higher permeability than press and sinter SMCs utilizing the same powder system and chemistry while also indicating new challenges that must be overcome to produce a fully dense SMC via additive manufacturing. Graphic abstract: [Figure not available: see fulltext.].

Original language	English (US)
Pages (from-to)	3579-3590
Number of pages	12
Journal	Journal of Materials Research
Volume	36
Issue number	18
DOIs	https://doi.org/10.1557/s43578-021-00343-x
State	Published - Sep 28 2021

Funding

The authors gratefully acknowledge in-kind support from and useful discussions with Katie Jo Sunday, Alex Wartenberg, and Christopher Schade at GKN Hoeganaes, Steven Adler at A3DM Technologies, and senior design students Nicole Benack and Tony Wang for their contributions to powder SMC development. Funding from the Independent Research and Development (IRAD) Program at the Johns Hopkins Applied Physics Laboratory is acknowledged (MLT and JS). Amanda Green and Dale Clemons at the Johns Hopkins Applied Physics Laboratory are acknowledged for their editorial support.

Keywords

Additive manufacturing
Laser powder bed fusion
Magnetic materials
Soft magnetic composites

ASJC Scopus subject areas

General Materials Science
Condensed Matter Physics
Mechanics of Materials
Mechanical Engineering

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title = "Additive manufacturing of NiZnCu-ferrite soft magnetic composites",

abstract = "Soft magnetic composites (SMCs) are a class of magnetic materials that have the potential to create lighter and more efficient electronic devices. SMCs provide high electrical resistivity while providing high magnetic permeability, consisting of a magnetically conductive core and an insulating coating traditionally made via powder metallurgy. Until recent advances, devices needing materials with these magnetic properties have been made by complex and geometrically limited laminations or press and sinter methods; both possessing issues. This paper establishes that a multi-material system incorporating NiZnCu-ferrite and high purity iron processed via additive manufacturing (AM) can serve as a manufacturing route for SMCs, with as-built samples showing high maximum relative permeability (~ 200,000). The results demonstrate the viability of laser powder bed fusion (L-PBF) AM to produce SMCs with higher permeability than press and sinter SMCs utilizing the same powder system and chemistry while also indicating new challenges that must be overcome to produce a fully dense SMC via additive manufacturing. Graphic abstract: [Figure not available: see fulltext.].",

keywords = "Additive manufacturing, Laser powder bed fusion, Magnetic materials, Soft magnetic composites",

author = "Andrews, {Caleb E.} and Chatham, {Megan P.} and Dorman, {Samantha F.} and McCue, {Ian D.} and Sopcisak, {Joseph J.} and Taheri, {Mitra L.}",

note = "Publisher Copyright: {\textcopyright} 2021, The Author(s), under exclusive licence to The Materials Research Society.",

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doi = "10.1557/s43578-021-00343-x",

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AU - Andrews, Caleb E.

AU - Chatham, Megan P.

AU - Dorman, Samantha F.

AU - McCue, Ian D.

AU - Sopcisak, Joseph J.

AU - Taheri, Mitra L.

PY - 2021/9/28

Y1 - 2021/9/28

N2 - Soft magnetic composites (SMCs) are a class of magnetic materials that have the potential to create lighter and more efficient electronic devices. SMCs provide high electrical resistivity while providing high magnetic permeability, consisting of a magnetically conductive core and an insulating coating traditionally made via powder metallurgy. Until recent advances, devices needing materials with these magnetic properties have been made by complex and geometrically limited laminations or press and sinter methods; both possessing issues. This paper establishes that a multi-material system incorporating NiZnCu-ferrite and high purity iron processed via additive manufacturing (AM) can serve as a manufacturing route for SMCs, with as-built samples showing high maximum relative permeability (~ 200,000). The results demonstrate the viability of laser powder bed fusion (L-PBF) AM to produce SMCs with higher permeability than press and sinter SMCs utilizing the same powder system and chemistry while also indicating new challenges that must be overcome to produce a fully dense SMC via additive manufacturing. Graphic abstract: [Figure not available: see fulltext.].

AB - Soft magnetic composites (SMCs) are a class of magnetic materials that have the potential to create lighter and more efficient electronic devices. SMCs provide high electrical resistivity while providing high magnetic permeability, consisting of a magnetically conductive core and an insulating coating traditionally made via powder metallurgy. Until recent advances, devices needing materials with these magnetic properties have been made by complex and geometrically limited laminations or press and sinter methods; both possessing issues. This paper establishes that a multi-material system incorporating NiZnCu-ferrite and high purity iron processed via additive manufacturing (AM) can serve as a manufacturing route for SMCs, with as-built samples showing high maximum relative permeability (~ 200,000). The results demonstrate the viability of laser powder bed fusion (L-PBF) AM to produce SMCs with higher permeability than press and sinter SMCs utilizing the same powder system and chemistry while also indicating new challenges that must be overcome to produce a fully dense SMC via additive manufacturing. Graphic abstract: [Figure not available: see fulltext.].

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Additive manufacturing of NiZnCu-ferrite soft magnetic composites

Abstract

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Keywords

ASJC Scopus subject areas

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