3D-Printed Fe-Co Magnetostrictive Material for Anisotropic Energy Conversion
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Solution Overview
Problem
Conventional methods for producing magnetostrictive materials require molds, increasing manufacturing costs and time, and additive manufacturing techniques have not been utilized to produce these materials, limiting the development of anisotropy necessary for practical energy conversion applications.
Innovation Solution
A method involving directed energy deposition for additive manufacturing of magnetostrictive materials using Fe—Co alloy powder, allowing for mold-free production with three-dimensional magnetic anisotropy and enhanced output power density, and the integration of these materials with soft magnetic layers for energy conversion members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mold is used to form a magnetostrictive material, then the shape and size can be precisely controlled, but manufacturing cost and time increase due to mold fabrication requirements
Solution Approach 1:
The invention extracts and removes the mold from the manufacturing process entirely. By using additive manufacturing with powder materials and selective melting, the patent eliminates the need for traditional molds while maintaining precise shape control through digital modeling and controlled deposition processes.
Solution Approach 2:
The invention replaces the mechanical mold-based forming system with a thermal field-based additive manufacturing system. Instead of using physical molds to constrain and shape the material, the patent uses directed energy (laser or electron beam) to selectively melt and deposit material layer by layer, achieving shape control through energy distribution rather than mechanical constraints.
2Productivity
If conventional hot working and cold working methods are used, then magnetostrictive material can be produced, but the process requires multiple steps and cannot easily achieve three-dimensional magnetic anisotropy
Solution Approach 1:
The invention merges multiple manufacturing steps into a single additive manufacturing process. By combining material deposition, shaping, and microstructure control into one integrated process, the patent eliminates the need for separate hot working and cold working steps while achieving the desired material properties and magnetic anisotropy.
Solution Approach 2:
The invention transitions from two-dimensional planar processing to three-dimensional additive manufacturing. By building the magnetostrictive material layer by layer in three dimensions, the patent can control magnetic anisotropy in all three spatial directions, achieving 3D magnetic anisotropy that cannot be obtained through conventional planar processing methods.
3Ease of manufacture
If additive manufacturing is used to produce magnetostrictive material, then mold-free production is achieved, but the material must develop sufficient anisotropy for practical energy conversion applications
Solution Approach 1:
The invention applies local quality control by varying processing parameters (such as laser power, scanning speed, and layer thickness) in different regions of the build space. This allows the patent to create specific microstructures and magnetic properties in different zones of the material, achieving the required anisotropy while maintaining mold-free production.
Solution Approach 2:
The invention utilizes parameter changes during the additive manufacturing process to control material properties. By adjusting processing parameters such as energy density, scanning patterns, and layer thickness, the patent can influence the microstructure formation and magnetic anisotropy development, achieving practical energy conversion performance without molds.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of magnetostrictive materials with enhanced anisotropy and output power density without molds, facilitating the creation of energy conversion members that can generate induced currents through the inverse magnetostriction effect, suitable for applications like vibration-powered devices.
Implementation Method 1
melting raw material powder for a magnetostrictive material by a directed energy deposition method to perform additive manufacturing
Implementation Method 2
melting the raw material powder by a laser or electron beam using a metal 3D additive manufacturing machine
Implementation Method 3
melting the raw material powder by a laser or electron beam using a metal 3D additive manufacturing machine
Implementation Method 4
utilizing deformation caused by magnetostriction of the material or an inverse magnetostriction effect caused by the deformation
Data Source
AI summary
A method for producing a magnetostrictive material producible without using a mold, a magnetostrictive material, and a method for producing an energy conversion member; the first method includes melting raw material powder for the magnetostrictive material by a laser or electron beam using a metal 3D additive manufacturing machine to perform additive manufacturing. The raw material powder is composed of an Fe—Co alloy. A method for producing an energy conversion member includes laminating and joining one of a magnetostrictive layer formed by melting raw material powder for a magnetostrictive material by a directed energy deposition method to perform additive manufacturing and a soft magnetic material layer formed by melting raw material powder for a soft magnetic material by the directed energy deposition method to perform additive manufacturing on another.