Additive manufacturing of Fe–Cr–Co magnet structures with a functionally graded chemical composition

Abstract Recent advancements in the additive manufacturing (AM) of magnetic materials has opened the possibility of producing tailored functional gradients, which can offer significant potential in the creation of components with changing hard magnetic properties across different regions. In this study, an Fe–Cr–Co base alloy was produced by laser powder bed fusion (LPBF) and then modified with in-situ alloying. incorporating increasing concentrations of an alloying element that either enhances or diminishes the hard magnetic properties. We investigated the chemical composition and the morphology of the boundary layer between regions, as well as the corresponding magnetic properties in each region. Boundary layer thickness was found to be independent of the printing process, and post processing conditions and VSM measurements reveal distinct variations in the magnetic properties across the chemical gradient, highlighting the impact of alloying concentration on the hard magnetic performance. Finally, an anisotropic behaviour of the magnetic properties was observed in the base alloy which changes as a function of the aluminum content. These findings contribute valuable insights into the design and fabrication of functionally graduated materials via LPBF, with potential applications in advanced magnetic devices and components requiring materials with spatially tailored magnetic properties.