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<p>Alnico alloys are values for their high-temperature magnetic stability and corrosion resistance, yet traditional manufacturing methods limit their geometric flexibility and property optimization. This study explores the additive manufacturing of various Alnico alloys (Alloys 1, 2, 3, and 5) using laser metal deposition (LMD) technology. The goal is to produce alnico alloys that meet industry standards in magnetic performance and mechanical resilience, leveraging the precision and adaptability of LMD. To evaluate the resulting material quality, consistent LMD parameters were applied across all alloys, including 600 W laser power, 700 mm/min travel speed, and 20 g/min powder feed. The experimental approach focused on analyzing the microstructural, mechanical, and magnetic properties of each alloy, with testing protocols examining their response to heat treatment and solidification behavior. Notable vertical cracks were observed across all alloys due to thermal stress-induced brittleness and the formation of mushy zones formed during solidification. Two distinct solidification structures, columnar, and equiaxed grains, were identified. Magnetic and mechanical performance varied among the alloys. Alnico 5 and alnico 2 exhibited superior magnetic characteristics, achieving coercivity, remanence, and saturation magnetization values of 75 kA/m, 750 mT, and 1259 mT for alnico 5, and 68 kA/m, 500 mT, 1011 mT for Alnico 2. In comparison, Alnico 1 and Alnico 3 exhibited lower magnetic values, with Alnico 1 reaching 64 kA/m, 440 mT, and 944 mT, and Alnico 3 reaching 60 kA/m, 400 mT, and 900 mT. A transition from columnar to equiaxed dendrites at the substrate interface correlated with increased microhardness, with Alnico 5 achieving the highest values due to its cobalt content, measuring 608 HV before and 520 HV after heat treatment. These findings offer key insights into the viability and limitation of LMD processing for Alnico alloys and lay the groundwork for optimizing additive manufacturing strategies for high-performance magnetic materials.</p>

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Insights into Additively Manufactured Alnico Alloys Using Laser Metal Deposition Technology

  • 期刊论文

  • 发表日期：

    2025年8月4日

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  • Amirkeyvan Rahimi,
  • Yara Almubarak

摘要

Alnico alloys are values for their high-temperature magnetic stability and corrosion resistance, yet traditional manufacturing methods limit their geometric flexibility and property optimization. This study explores the additive manufacturing of various Alnico alloys (Alloys 1, 2, 3, and 5) using laser metal deposition (LMD) technology. The goal is to produce alnico alloys that meet industry standards in magnetic performance and mechanical resilience, leveraging the precision and adaptability of LMD. To evaluate the resulting material quality, consistent LMD parameters were applied across all alloys, including 600 W laser power, 700 mm/min travel speed, and 20 g/min powder feed. The experimental approach focused on analyzing the microstructural, mechanical, and magnetic properties of each alloy, with testing protocols examining their response to heat treatment and solidification behavior. Notable vertical cracks were observed across all alloys due to thermal stress-induced brittleness and the formation of mushy zones formed during solidification. Two distinct solidification structures, columnar, and equiaxed grains, were identified. Magnetic and mechanical performance varied among the alloys. Alnico 5 and alnico 2 exhibited superior magnetic characteristics, achieving coercivity, remanence, and saturation magnetization values of 75 kA/m, 750 mT, and 1259 mT for alnico 5, and 68 kA/m, 500 mT, 1011 mT for Alnico 2. In comparison, Alnico 1 and Alnico 3 exhibited lower magnetic values, with Alnico 1 reaching 64 kA/m, 440 mT, and 944 mT, and Alnico 3 reaching 60 kA/m, 400 mT, and 900 mT. A transition from columnar to equiaxed dendrites at the substrate interface correlated with increased microhardness, with Alnico 5 achieving the highest values due to its cobalt content, measuring 608 HV before and 520 HV after heat treatment. These findings offer key insights into the viability and limitation of LMD processing for Alnico alloys and lay the groundwork for optimizing additive manufacturing strategies for high-performance magnetic materials.