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<p>This study investigates the use of cold spray additive manufacturing (CSAM) to fabricate Permalloy ferromagnetic components using two ferromagnetic iron-nickel FeNi50 alloy powders with particle sizes of D50 = 13&#xa0;µm and 35&#xa0;µm. By varying spraying distance and gas temperature, the research evaluates how process parameters influence deposition efficiency, microstructure, and functional properties. The highest deposition efficiency (62%) was achieved using the coarser powder at 640&#xa0;°C and 35&#xa0;mm distance. Microstructural analysis showed compact, low-porosity deposits, with the fine powder reaching porosity below 1%. All samples retained the FCC γ-phase structure of the feedstock without forming new phases. Microhardness was highest near the substrate, with the fine powder reaching 247 ± 5 HV. Magnetic characterization revealed superior performance from coarse powders, with higher saturation magnetization (1.06&#xa0;T), lower coercivity (2239 A/m), and higher permeability (653), while fine powders led to increased magnetic losses due to ultrafine grains and internal defects. Overall, CSAM demonstrates strong potential for producing soft magnetic Permalloy components with tunable properties, particularly when using coarser powders.</p>

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Cold Spray Additive Manufacturing as a Sustainable Route for FeNi-Based Ferromagnetic Alloy Production

  • 期刊论文

  • 发表日期：

    2025年10月24日

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  • Hassan Hammouda,
  • Sabeur Msolli,
  • Nouredine Fenineche,
  • Hanlin Liao,
  • Sihao Deng

摘要

This study investigates the use of cold spray additive manufacturing (CSAM) to fabricate Permalloy ferromagnetic components using two ferromagnetic iron-nickel FeNi50 alloy powders with particle sizes of D50 = 13 µm and 35 µm. By varying spraying distance and gas temperature, the research evaluates how process parameters influence deposition efficiency, microstructure, and functional properties. The highest deposition efficiency (62%) was achieved using the coarser powder at 640 °C and 35 mm distance. Microstructural analysis showed compact, low-porosity deposits, with the fine powder reaching porosity below 1%. All samples retained the FCC γ-phase structure of the feedstock without forming new phases. Microhardness was highest near the substrate, with the fine powder reaching 247 ± 5 HV. Magnetic characterization revealed superior performance from coarse powders, with higher saturation magnetization (1.06 T), lower coercivity (2239 A/m), and higher permeability (653), while fine powders led to increased magnetic losses due to ultrafine grains and internal defects. Overall, CSAM demonstrates strong potential for producing soft magnetic Permalloy components with tunable properties, particularly when using coarser powders.