In Situ Alloying of Fe-Cr-Co Permanent Magnet by Selective Laser Melting of Elemental Iron, Chromium and Cobalt Mixed Powders

Fe-25Cr-15Co (wt.%) permanent magnets were fabricated via selective laser melting (SLM) and in situ alloying from a blend of Fe, Cr and Co elemental powders. Under the optimal laser scanning process, the as-built Fe-25Cr-15Co alloy has a homogeneous composition distribution without defects such as holes or un-melted particles, and presents a single α phase with the bcc crystal structure. The density of as-built samples was 7.705 g/cm3 (the relative density is 99.32%). The preferred magnetic properties of the sample in the isotropic state were obtained as Hc = 22.84 kA/m, Br = 0.86 T and (BH)max = 7.98 kJ/m3. The hardness and yield strength of Fe-25Cr-15Co permanent magnets are above 331.5 HV and 800 MPa, respectively. The results of this study verified the feasibility of fabricating Fe-Cr-Co permanent magnets by SLM in situ alloying and can be extended to a wide range of applications that require complex shapes with variable magnetic circuit characteristics or gradient structures.