Biblio

We demonstrate how a unique nanomodulation within a continuous ferromagnetic film can induce magnetic dipoles at predefined, submicrometer scale locations, which can tune the global magnetic properties of the film due to dipole-dipole interactions. Arrays of tunable magnetic dipoles are generated with in-plane and out-of-plane directions, which can be rotated in-plane within the three-dimensional (3-D) modulated structure of a continuous film. In-plane magnetic dipole rotation enables a methodology to control overall magnetic properties of a ferromagnetic thin film. Formation of magnetic dipoles and their tunability were studied in detail by magnetic force microscopy, high-resolution magnetic measurements, and micromagnetic simulation of a nanomodulated Ni45Fe55 alloy film. A pattern larger than a single magnetic domain would normally form a vortex in the remanent state. However, here the unique 3-D nanostructure prevents vortex formation due to the competition between in-plane and out-of-plane dipole-dipole interaction giving rise to a metastable state. Experimentally, at zero remanence, the magnetization goes through a transformation from a metastable to a stable state, where the dipole-dipole interaction depends on their geometrical arrangement. Thus, the magnetic properties of the continuous film can be varied by the proposed pattern geometry. A detail analytical study of the dipolar energy for the system agrees well with the experimental and simulated results.

Alternatives to rare earth permanent magnets, such as alnico, will reduce supply instability, increase sustainability, and could decrease the cost of permanent magnets, especially for high-temperature applications, such as traction drive motors. Alnico magnets with moderate coercivity, high remanence, and relatively high-energy product are conventionally processed by directional solidification and (significant) final machining, contributing to increased costs and additional material waste. Additive manufacturing (AM) is developing as a cost effective method to build net-shape 3-D parts with minimal final machining and properties comparable to wrought parts. This paper describes initial studies of net-shape fabrication of alnico magnets by AM using a laser engineered net shaping (LENS) system. High-pressure gas atomized pre-alloyed powders of two different modified alnico “8” compositions, with high purity and sphericity, were built into cylinders using the LENS process, and followed by heat treatment. The magnetic properties showed improvement over their cast and sintered counterparts. The resulting alnico permanent magnets were characterized using scanning electron microscopy, energy dispersive spectroscopy, electron backscatter diffraction, and hysteresisgraph measurements. These results display the potential for net-shape processing of alnico permanent magnets for use in next generation traction-drive motors and other applications requiring high temperatures and/or complex engineered part geometries.