SIM-AM 2025

Phase-field modelling of microstructure evolution and properties of magnetic materials by powder bed fusion

  • Suo, Yifan (TU Darmstadt)
  • Yang, Yangyiwei (TU Darmstadt)
  • Xu, Baixiang (TU Darmstadt)

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Tailoring magnetic hysteresis by additive manufacturing (AM) has drawn growing interest for its application prospects due to the significant structural, chemical, and even thermo-mechanical factors during the AM processes[1]. For permanent magnets, due to the strong magneto-crystalline anisotropy, the structural factors such as polycrystalline texture, grain size and shape, the existence of the grain boundary/interior phases, and segregation of the chemical species form the significant effects on the magnetic hysteresis of the AM-produced parts. For soft magnets, on the other hand, magnetic hysteresis of AM-processed parts presents the dependence on the residual stress due to relatively evident magneto-mechanical coupling[2]. It should be noticed that these factors are across a broad range of chronological-spatial scales. Adopting simulation-oriented methods to achieve magnetic hysteresis tailoring, the critical challenge is to define the proper thermodynamic and kinetic framework, explicitly counting and bridging those influencing factors among distinctive scales. We consider the multiscale multiphysics simulation platform, e.g., the process parameter influence on texture and residual stress in the printed material. The model material system will be the binary permanent magnets SmCo5. A phenomenological model [3] was used to simulate the LPBF process, with comprehensive consideration of various processing parameters and their effects. The model was rigorously calibrated against experimental results. Building upon the validated LPBF framework, an extended simulation approach was introduced for Dual-LPBF. This method allows for precise control of the inter-laser time interval, thereby tailoring the thermal history to achieve a more homogeneous temperature distribution during processing. The study further investigates the influence of both LPBF and DLPBF on grain growth behaviour, that elucidates the evolution of microstructural features and residual stress. Future investigations will address the effects of varying scanning strategies on chemical segregation and grain texture.