The current work presents the results of an investigation focused on the influence of process parameters on the melt-track stability and its consequence to the sample density printed out of NdFeB powder. Commercially available powder of Nd7.5Pr0.7Fe75.4Co2.5B8.8Zr2.6Ti2.5 alloy was investigated at the angle of application in selective laser melting of permanent magnets. Using single track printing the stability of the melt pool was investigated under changing process parameters. The influence of changing laser power, scanning speed, and powder layer thickness on density, porosity structure, microstructure, phase composition, and magnetic properties were investigated. The results showed that energy density coupled with powder layer thickness plays a crucial role in melt-track stability. It was possible to manufacture magnets of both high relative density and high magnetic properties. Magnetization tests showed a significant correlation between the shape of the demagnetization curve and the layer height. While small layer heights are beneficial for sufficient magnetic properties, the remaining main parameters tend to affect the magnetic properties less. A quasi-linear correlation between the layer height and the magnetic properties remanence (J_r), coercivity (H_cJ) and maximum energy product ((BH)_max) was found.

The quality and characteristics of a powder in powder bed fusion processes play a vital role in the quality of additively manufactured components. Its characteristics may influence the process in various ways. This paper presents an investigation highlighting the influence of powder deterioration on the stability of a molten pool in a laser beam powder bed fusion (LB-PBF, selective laser melting) process and its consequences to the physical properties of the alloy, porosity of 3D-printed components and their mechanical properties. The intention in this was to understand powder reuse as a factor playing a role in the formation of porosity in 3D-printed components. Ti6Al4V (15 μm–45 μm) was used as a base material in the form of a fresh powder and a degraded one (reused 12 times). Alloy degradation is described by possible changes in the shape of particles, particle size distribution, chemical composition, surface tension, density and viscosity of the melt. An approach of 3D printing singular lines was applied in order to study the behavior of a molten pool at varying powder bed depths. Single-track cross-sections (STCSs) were described with shape parameters and compared. Furthermore, the influence of the molten pool stability on the final density and mechanical properties of a material was discussed. Electromagnetic levitation (EML) was used to measure surface tension and the density of the melt using pieces of printed samples. It was found that the powder degradation influences the mechanical properties of a printed material by destabilizing the pool of molten metal during printing operation by facilitating the axial flow on the melt along the melt track axis. Additionally, the observed axial flow was found to facilitate a localized lack of fusion between concurrent layers. It was also found that the surface tension and density of the melt are only impacted marginally or not at all by increased oxygen content, yet a difference in the temperature dependence of the surface tension was observed.

Additive manufacturing has become increasingly important in the production of magnetic materials in recent years due to the great demands for miniaturization and complex-shaped magnet parts. In this study, the laser beam-powder bed fusion process (LPBF) has been used to develop an in-situ alloying process for the additive manufacturing of a permanent magnet material of the Fe–Cr–Co system. This novel method allows for the production of complex alloys with a chemical composition suited to each specific case of application, achieved by using elemental powders or simpler commercial alloy powders as base materials. The core focus of this study has been on the development and characterization of the printing process using a Fe-30.5Cr-15Co-1.5Mo alloy. The in-situ alloying process has been developed by performing melt pool tests on the two main component powders Fe and Cr and by conducting parameter studies using two different powder mixtures with different sphericity of their components. The influence of different printing parameters and post-printing treatments on the chemical homogeneity and magnetic properties has been studied for selected samples. In addition, magnetic measurements at different temperatures have been performed to investigate the temperature stability of the magnetic properties of the 3D printed material. Impact Statement As by today, the current amount of research done on the additive manufacturing of magnetic materials is rather low. Most of research is focused on rare- earth containing magnetic materials. In this work therefore, we are taking another direction in which we will show that LPBF combined with in- situ alloying is an ideal method for the production of a great variety of different rare- earth free magnetic materials. The positive results of our work can both have an influence on the the scientific community, as further research in the field on different promising rare- earth free magnetic materials is to be expected. Furthermore, a positiv economic impact may occur since the production of rare- earth free magnetic materials is dependent on different raw material sources which are both more cost- effectiv and less critical in terms of their supply chain. This effect is also accompanied by a positive environmental impact, since the mining of rare- earth metals usually comes with considerable environmental pollution.

Exploring the chemical micro- and nanostructure of metal alloys is essential to understand their physical properties, such as magnetism or hardness. Additively manufactured (AM) materials, e.g. via laser powder bed fusion (LPBF) followed by various heat treatments, can raise further questions concerning the printed material. For the in-situ alloyed, spinodal Fe₅₄Cr₃₁Co₁₅ system, the macroscopic magnetic behaviour is greatly influenced by subsequent homogenisation and heat treatment steps. Here we show that the decomposition takes place on the nanometre scale, resulting in ferromagnetic FeCo-rich particles embedded in a Cr-rich matrix. By studying phenomena like chemical homogeneity, grain structure, and texture of the in-situ alloyed material at different scales, we reveal correlations between the heat treatment and the resulting nanostructure and its ferromagnetic properties. We found that the isothermal heating conditions determine the degree of phase segregation and that a homogenization step can be omitted for additively manufactured, in-situ alloyed FeCrCo alloys. The approach thereby offers insight and a path for also tailoring specific manufacturing parameters to provide the right quality printed materials with desired functionalities. For example, magnetic FeCrCo alloys are often used in electric motors or magnetic sensors, and the flexibility of the presented approach can lead to optimal use of the material.