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arXiv · 2302.02217

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

Yangyiwei Yang·Timileyin David Oyedeji·Xiandong Zhou·Karsten Albe·Bai-Xiang Xu
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Abstract

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.

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Yangyiwei Yang, Timileyin David Oyedeji, Xiandong Zhou, Karsten Albe, Bai-Xiang Xu. 2023-02-04. Tailoring magnetic hysteresis of Fe-Ni permalloy by additive manufacturing: Multiphysics-multiscale simulations of process-property relationships. https://doi.org/10.1038/s41524-023-01058-9

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