Additive manufacturing of NiZnCu-ferrite soft magnetic composites

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 coati...

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Bibliographic Details
Published inJournal of materials research Vol. 36; no. 18; pp. 3579 - 3590
Main Authors Andrews, Caleb E., Chatham, Megan P., Dorman, Samantha F., McCue, Ian D., Sopcisak, Joseph J., Taheri, Mitra L.
Format Journal Article
LanguageEnglish
Published Cham Springer International Publishing 28.09.2021
Springer Nature B.V
Subjects
Additive manufacturing
Applied and Technical Physics
Biomaterials
Chemistry and Materials Science
Composite materials
Electronic devices
Ferrites
Inorganic Chemistry
Magnetic materials
Magnetic permeability
Magnetic properties
Manufacturing
Materials Engineering
Materials research
Materials Science
Nanotechnology
Permeability
Powder beds
Powder metallurgy
Laser powder bed fusion
Magnetic materials
Soft magnetic composites
Additive manufacturing
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Summary: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
ISSN:0884-2914
2044-5326
DOI:10.1557/s43578-021-00343-x