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Laser Powder Bed Fusion of Fe-10 at% Ni and Fe-10 at% Si Soft-Magnetic Materials from Powder Blends.

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Title: Laser Powder Bed Fusion of Fe-10 at% Ni and Fe-10 at% Si Soft-Magnetic Materials from Powder Blends.
Authors: Bernsmann, Jan-Simeon Ludger1 (AUTHOR) jan.bernsmann@dap.rwth-aachen.de, Stahl, Paul1 (AUTHOR), Matzel, Luca Christian1 (AUTHOR), Schleifenbaum, Johannes Henrich1 (AUTHOR)
Source: Materials (1996-1944). Oct2025, Vol. 18 Issue 19, p4471. 30p.
Subjects: Soft magnetic materials, Iron-nickel alloys, Selective laser sintering, Ferromagnetism, Selective laser melting, Iron-silicon alloys, Mathematical optimization, Structural optimization
Abstract: Soft-magnetic materials can benefit significantly from additive manufacturing using Laser Powder Bed Fusion of metals with laser beam, as this technology allows the production of parts with complex geometries. In this study, two iron-based alloys were investigated: Fe-10%Ni (at%) and Fe-10%Si (at%), which are known for their promising soft-magnetic properties. A parameter study was first conducted to optimize the process settings with the goal of maximizing the relative density, which strongly influences magnetic performance. Using AI-based optimization software (xT-Saam by Exponential Technologies Ltd., Riga, Latvia), geometrically simple specimens with a relative density of ≥99.95% were successfully produced. Utilizing the developed parameter sets, toroids were manufactured and heat-treated to improve their magnetic properties. The best obtained ferromagnetic properties were HC = 1621 A/m (coercivity) and µR = 305 (permeability) for Fe-10%Ni, and HC = 300 A/m and µR = 1114 for Fe-10%Si. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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An: 188676839
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  Label: Title
  Group: Ti
  Data: Laser Powder Bed Fusion of Fe-10 at% Ni and Fe-10 at% Si Soft-Magnetic Materials from Powder Blends.
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Oct2025, Vol. 18 Issue 19, p4471. 30p.
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  Data: <searchLink fieldCode="DE" term="%22Soft+magnetic+materials%22">Soft magnetic materials</searchLink><br /><searchLink fieldCode="DE" term="%22Iron-nickel+alloys%22">Iron-nickel alloys</searchLink><br /><searchLink fieldCode="DE" term="%22Selective+laser+sintering%22">Selective laser sintering</searchLink><br /><searchLink fieldCode="DE" term="%22Ferromagnetism%22">Ferromagnetism</searchLink><br /><searchLink fieldCode="DE" term="%22Selective+laser+melting%22">Selective laser melting</searchLink><br /><searchLink fieldCode="DE" term="%22Iron-silicon+alloys%22">Iron-silicon alloys</searchLink><br /><searchLink fieldCode="DE" term="%22Mathematical+optimization%22">Mathematical optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Structural+optimization%22">Structural optimization</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Soft-magnetic materials can benefit significantly from additive manufacturing using Laser Powder Bed Fusion of metals with laser beam, as this technology allows the production of parts with complex geometries. In this study, two iron-based alloys were investigated: Fe-10%Ni (at%) and Fe-10%Si (at%), which are known for their promising soft-magnetic properties. A parameter study was first conducted to optimize the process settings with the goal of maximizing the relative density, which strongly influences magnetic performance. Using AI-based optimization software (xT-Saam by Exponential Technologies Ltd., Riga, Latvia), geometrically simple specimens with a relative density of ≥99.95% were successfully produced. Utilizing the developed parameter sets, toroids were manufactured and heat-treated to improve their magnetic properties. The best obtained ferromagnetic properties were HC = 1621 A/m (coercivity) and µR = 305 (permeability) for Fe-10%Ni, and HC = 300 A/m and µR = 1114 for Fe-10%Si. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma18194471
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      – Code: eng
        Text: English
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        PageCount: 30
        StartPage: 4471
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      – SubjectFull: Soft magnetic materials
        Type: general
      – SubjectFull: Iron-nickel alloys
        Type: general
      – SubjectFull: Selective laser sintering
        Type: general
      – SubjectFull: Ferromagnetism
        Type: general
      – SubjectFull: Selective laser melting
        Type: general
      – SubjectFull: Iron-silicon alloys
        Type: general
      – SubjectFull: Mathematical optimization
        Type: general
      – SubjectFull: Structural optimization
        Type: general
    Titles:
      – TitleFull: Laser Powder Bed Fusion of Fe-10 at% Ni and Fe-10 at% Si Soft-Magnetic Materials from Powder Blends.
        Type: main
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          Name:
            NameFull: Bernsmann, Jan-Simeon Ludger
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            NameFull: Stahl, Paul
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            NameFull: Matzel, Luca Christian
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            NameFull: Schleifenbaum, Johannes Henrich
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            – D: 01
              M: 10
              Text: Oct2025
              Type: published
              Y: 2025
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              Value: 18
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              Value: 19
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            – TitleFull: Materials (1996-1944)
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