Soft magnetic property of (Fe60Co35Ni5)78 Si6B12Cu1Mo3 alloys by laser additive manufacturing

Laser additive manufacturing (LAM) is a novel method for processing compositionally graded alloys and becomes increasingly important in the context of next-generation manufacturing technology. In this work, (Fe60Co35Ni5)78Si6B12Cu1Mo3 soft magnetic alloys with different laser power were designed and processed by the LAM. The magnitudes of magnetic properties were analyzed, and the relationships among composition-microstructure-magnetic properties assessed. Results show that the (Fe60Co35Ni5)78Si6B12Cu1Mo3 alloys by LAM exhibits relative uniform microstructure and comparable magnetic property compared with those conventional processed alloys. The bcc dominated microstructures exhibit a substantially higher saturation magnetization (Ms). With the increase in power, the average grain size of the alloy increased slightly and the increasing volume fraction of the FeSi phase leaded to the enhancement of magnetization. The (Fe60Co35Ni5)78 Si6B12Cu1Mo3 alloys with laser power of 3000 W exhibits the highest Ms (199 emu/g). The appearance of Fe3B results in coarse dendrites and high coercivity (Hc) in the multiple re-heating cycles.