Laser Powder Bed Fusion of Fe-10 at% Ni and Fe-10 at% Si Soft-Magnetic Materials from Powder Blends

Soft-magnetic materials can benefit significantly from additive manufacturing using Laser Powder Bed Fusion of metals with laser beam, as this technology allows the production of parts with complex geometries. In this study, two iron-based alloys were investigated: Fe-10%Ni (at%) and Fe-10%Si (at%), which are known for their promising soft-magnetic properties. A parameter study was first conducted to optimize the process settings with the goal of maximizing the relative density, which strongly influences magnetic performance. Using AI-based optimization software (xT-Saam by Exponential Technologies Ltd., Riga, Latvia), geometrically simple specimens with a relative density of ≥99.95% were successfully produced. Utilizing the developed parameter sets, toroids were manufactured and heat-treated to improve their magnetic properties. The best obtained ferromagnetic properties were HC = 1621 A/m (coercivity) and µR = 305 (permeability) for Fe-10%Ni, and HC = 300 A/m and µR = 1114 for Fe-10%Si.