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Register a new userFabrication of highly dense isotropic Nd-Fe-B bonded magnets via extrusion-based additive manufacturing
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Isotropic bonded magnets with a high loading fraction of 70 vol.% Nd-Fe-B are fabricated via an extrusion-based additive manufacturing, or 3D printing system that enables rapid production of large parts for the first time. The density of the printed magnet is 5.15 g/cm3. The room temperature magnetic properties are: intrinsic coercivity Hci = 8.9 kOe (708.2 kA/m), remanence Br = 5.8 kG (0.58 Tesla), and energy product (BH)max = 7.3 MGOe (58.1 kJ/m3). The as-printed magnets are then coated with two types of polymers, both of which improve the thermal stability at 127 {deg}C as revealed by flux aging loss measurements. Tensile tests performed at 25 {deg}C and 100 {deg}C show that the ultimate tensile stress (UTS) increases with increasing loading fraction of the magnet powder, and decreases with increasing temperature. AC magnetic susceptibility and resistivity measurements show that the 3D printed Nd-Fe-B bonded magnets exhibit extremely low eddy current loss and high resistivity. Finally, we show that through back electromotive force measurements that motors installed with 3D printed Nd-Fe-B magnets exhibit similar performance as compared to those installed with sintered ferrites.
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By means of temperature and wavelength-dependent small-angle neutron scattering (SANS) experiments on sintered isotropic and textured Nd-Fe-B magnets we provide evidence for the existence of an anisometric structure in the microstructure of the textured magnets. This conclusion is reached by observing a characteristic cross-shaped angular anisotropy in the total unpolarized SANS cross section at temperatures well above the Curie temperature. Comparison of the experimental SANS data to a microstructural model based on the superquadrics form factor allows us to estimate the shape and lower bounds for the size of the structure. Subtraction of the scattering cross section in the paramagnetic regime from data taken at room temperature provides the magnetic SANS cross section. Surprisingly, the anisotropy of the magnetic scattering is very similar to the nuclear SANS signal, suggesting that the nuclear structure is decorated by the magnetic moments via spin-orbit coupling. Based on the computation of the two-dimensional correlation function we estimate lower bounds for the longitudinal and transversal magnetic correlation lengths.
The future of space exploration missions will rely on technologies increasing their endurance and self-sufficiency, including for manufacturing objects on-demand. We propose a process for handling and additively manufacturing powders that functions independently of the gravitational environment and with no restriction on feedstock powder flowability. Based on a specific sequence of boundary loads applied to the granular packing, powder is transported to the printing zone, homogenized and put under compression to increase the density of the final part. The powder deposition process is validated by simulations that show the homogeneity and density of deposition to be insensitive to gravity and cohesion forces within the DEM model. We further provide an experimental proof of concept of the process by successfully 3D printing parts on-ground and in weightlessness, on parabolic flight. Powders exhibiting high and low flowability are used as model feedstock material to demonstrate the versatility of the process, opening the way for additive manufacturing of recycled material.
Numerical simulations are used in this work to investigate aspects of microstructure and microsegregation during rapid solidification of a Ni-based superalloy in a laser powder bed fusion additive manufacturing process. Thermal modeling by finite element analysis simulates the laser melt pool, with surface temperatures in agreement with in situ thermographic measurements on Inconel 625. Geometric and thermal features of the simulated melt pools are extracted and used in subsequent mesoscale simulations. Solidification in the melt pool is simulated on two length scales. For the multicomponent alloy Inconel 625, microsegregation between dendrite arms is calculated using the Scheil-Gulliver solidification model and DICTRA software. Phase-field simulations, using Ni-Nb as a binary analogue to Inconel 625, produced microstructures with primary cellular/dendritic arm spacings in agreement with measured spacings in experimentally observed microstructures and a lesser extent of microsegregation than predicted by DICTRA simulations. The composition profiles are used to compare thermodynamic driving forces for nucleation against experimentally observed precipitates identified by electron and X-ray diffraction analyses. Our analysis lists the precipitates that may form from FCC phase of enriched interdendritic compositions and compares these against experimentally observed phases from 1 h heat treatments at two temperatures: stress relief at 1143 K (870{deg}C) or homogenization at 1423 K (1150{deg}C).
A thick electrode with high areal capacity has been developed as a strategy for high-energy-density lithium-ion batteries, but thick electrodes have difficulties in manufacturing and limitations in ion transport. Here, we reported a new manufacturing approach for ultra-thick electrode with aligned structure, called structure electrode additive manufacturing or SEAM, which aligns active materials to the through-thicknesses direction of electrodes using shear flow and a designed printing path. The ultra-thick electrodes with high loading of active materials, low tortuous structure, and good structure stability resulting from a simple and scalable SEAM lead to rapid ion transport and fast electrolyte infusion, delivering a higher areal capacity than slurry-casted thick electrodes. SEAM shows strengths in design flexibility and scalability, which allows the production of practical high energy/power density structure electrodes.
The hydrogenation of Nd2Fe14B under a high pressure of hydrogen has been investigated for the first time. At the heat-treatment temperature of 600 degree C, the almost complete decomposition of Nd2Fe14B into NdH2+x and alpha-Fe is observed, although a rather long heat-treatment time is necessary to achieve the sufficient hydrogenation. The desorption of hydrogen from NdH2+x does not occur in the furnace-cooling process.
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