Enhanced Functional Alloys with High Strength and Ductility

A technique for tailoring the mechanical properties of traditionally low-strength and low ductility alloys using laser beam powder bed fusion (LB-PBF) additive manufacturing

Additive manufacturing (AM) offers unprecedented design freedom that can lead to novel materials development. Intermetallic alloys have useful magnetic properties such as high permeability, low coercivity, and high saturation induction that are ideal for electromagnetic devices, particularly those in aerospace applications. However, when they are conventionally manufactured, these alloys are notoriously brittle and have poor mechanical properties that have impeded their commercialization in bulk form.

Researchers at Sandia National Laboratories and Lehigh University developed a technique to tailor the mechanical properties of traditionally low strength and low ductility alloys by introducing removable heat sink artifacts using laser beam powder bed fusion (LB-PBF) additive manufacturing. The technology enables the end-user to circumvent dependence on conventional manufacturing to achieve the desired material structure and function. This potentially impacts aerospace technologies and industries that would benefit from high strength and high ductility soft magnetic alloys, such as power generating units, internal generators for propulsion engines, and magnetic bearings.

Benefits

• Improved strength and ductility of brittle alloys
• Improved yield strength up to 300%
• Increased ductility up to an order of magnitude

Applications and Industries

• Aerospace
• Electromagnetic devices (i.e. transformers, motors, and switches)
• Internal generators for propulsion engines
• Magnetic bearings
• Power generating unit
• Relevant Additive Manufacturing Approach: Laser Powder Bed Fusion (LP-PBF)