Tailoring magnetic hysteresis of Fe-Ni permalloy by additive manufacturing: Multiphysics-multiscale simulations of process-property relationships

Designing the microstructure of Fe-Ni permalloy by additive manufacturing (AM) opens new avenues to tailor the materials' magnetic properties. Yet, AM-produced parts suffer from spatially inhomogeneous thermal-mechanical and magnetic responses, which are less investigated in terms of process simulation and modeling schemes. Here we present a powder-resolved multiphysics-multiscale simulation scheme for describing magnetic hysteresis in materials produced via AM. The underlying physical processes are explicitly considered, including the coupled thermal-structural evolution, chemical order-disorder transitions, and associated thermo-elasto-plastic behaviors. The residual stress is identified as the key thread in connecting the physical processes and in-process 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 permalloy 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 AM-process parameters

Variational quantitative phase-field modeling of non-isothermal sintering process

Phase-field modeling has become a powerful tool in describing the complex pore-structure evolution and the intricate multiphysics in nonisothermal sintering processes. However, the quantitative validity of conventional variational phase-field models involving diffusive processes is a challenge. Artificial interface effects, like the trapping effects, may originate at the interface when the kinetic properties of two opposing phases are different. On the other hand, models with prescribed antitrapping terms do not necessarily guarantee the thermodynamics variational nature of the model. This issue has been solved for liquid-solid interfaces via the development of the variational quantitative solidification phase-field model. However, there is no related work addressing the interfaces in nonisothermal sintering, where the free surfaces between the solid phase and surrounding pore regions exhibit strong asymmetry of mass and thermal properties. Also, additional challenges arise due to the conserved order parameter describing the free surfaces. In this work, we present a variational and quantitative phase-field model for nonisothermal sintering processes. The model is derived via an extended nondiagonal phase-field model. The model evolution equations have naturally cross-coupling terms between the conserved kinetics (i.e., mass and thermal transfer) and the nonconserved one (grain growth). These terms are shown via asymptotic analysis to be instrumental in ensuring the elimination of interface artifacts, while also examined to not modify the thermodynamic equilibrium condition (characterized by a dihedral angle). Moreover, we demonstrate that the trapping effects and the existence of surface diffusion in conservation laws are direction-dependent. An anisotropic interpolation scheme of the kinetic mobilities that differentiates between the normal and tangential directions along the interface is discussed. Numerically, we demonstrate the importance of the cross-couplings and the anisotropic interpolation by presenting thermal-microstructural evolutions

Nanoparticle Tracing during Laser Powder Bed Fusion of Oxide Dispersion Strengthened Steels

The control of nanoparticle agglomeration during the fabrication of oxide dispersion strengthened steels is a key factor in maximizing their mechanical and high temperature reinforcement properties. However, the characterization of the nanoparticle evolution during processing represents a challenge due to the lack of experimental methodologies that allow in situ evaluation during laser powder bed fusion (LPBF) of nanoparticle-additivated steel powders. To address this problem, a simulation scheme is proposed to trace the drift and the interactions of the nanoparticles in the melt pool by joint heat-melt-microstructure–coupled phase-field simulation with nanoparticle kinematics. Van derWaals attraction and electrostatic repulsion with screened-Coulomb potential are explicitly employed to model the interactions with assumptions made based on reported experimental evidence. Numerical simulations have been conducted for LPBF of oxide nanoparticle-additivated PM2000 powder considering various factors, including the nanoparticle composition and size distribution. The obtained results provide a statistical and graphical demonstration of the temporal and spatial variations of the traced nanoparticles, showing ~55% of the nanoparticles within the generated grains, and a smaller fraction of ~30% in the pores, ~13% on the surface, and ~2% on the grain boundaries. To prove the methodology and compare it with experimental observations, the simulations are performed for LPBF of a 0.005 wt % yttrium oxide nanoparticle-additivated PM2000 powder and the final degree of nanoparticle agglomeration and distribution are analyzed with respect to a series of geometric and material parameters

Influence of silver nanoparticle additivation on Nd-Fe-B permanent magnets produced by Laser Powder Bed Fusion

Powder bed fusion of metals using a laser beam (PBF-LB/M) is an established additive manufacturing (AM) method that can be used to fabricate geometrically complex Nd Fe-B magnets. However, the magnetic properties of Nd-Fe-B magnets manufactured by PBF-LB/M are typically inferior to conventionally produced magnets. To overcome this drawback, we modified the surface of the permanent magnet feedstock powder with 1 wt.% surfactant-free Ag nanoparticles (NPs) supporting the formation of relevant phases required for permanent magnetic performance to achieve a suitable micro- and nanostructure after AM. Our study is accompanied by finite element simulations, revealing the impact and dependency of process parameters during PBF-LB/M: a wide temperature field with a high-gradient profile in the front and on the bottom of an overheated region, implying a vast local heating/cooling rate and in-process high thermal stress. We found experimentally that the as-built part density can be affected by both the laser power and scan speed, causing a reduction in density as both parameters increase. The functionality and microstructural properties are also investigated via VSM, HR-SEM, EDX, EBSD, and exemplarily with HR-TEM-EDX and APT. Our study found that modifying MQP-S with Ag NPs increases the coercivity by approximately 20%, which we correlate to a decreased grain size. Additionally, we identified three distinct phases in the modified and unmodified samples, where Ag is primarily found in the intergranular and Nd-rich phases of the as-built parts. Overall, the study\u27s findings contribute to the understanding of the factors that affect the quality and magnetic properties of Nd-Fe-B magnets fabricated through PBF-LB/M and provide valuable insights for further research in this area