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Laser powder bed fusion of a newly designed Fe-based bulk metallic glass with enhanced soft magnetic properties
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DOI：10.1016/j.actamat.2026.122636.png)
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Abstract
En 中文
Additive manufacturing of Fe-based bulk metallic glasses (BMGs) is hindered by their limited glass-forming ability (GFA) and by devitrification during repeated thermal cycling in laser powder bed fusion (LPBF), which degrades soft magnetic performance. Here, we investigate the LPBF processability of a newly designed Fe–Si–B–Nb–Ni alloy exhibiting enhanced GFA (critical casting thickness ≈1 mm) without the addition of P, Co, or rare-earth elements. A systematic study combining varied energy densities, time delays, and double-scanning strategies is conducted to establish processing–structure–property relationships. Multiscale characterization (X-ray diffraction, differential scanning calorimetry, electron backscatter diffraction, transmission electron microscopy, atom probe tomography, and X-ray computed tomography) reveals that the improved GFA suppresses micron-scale crystallization across a broad processing window, yielding amorphous fractions above 87% and fully XRD-amorphous states under optimized remelting conditions. Atom probe tomography confirms chemical randomness irrespective of scan strategy, whereas calorimetry and nanoindentation mapping demonstrate that double scanning reduces structural heterogeneity through enhanced relaxation of the amorphous phase. This relaxation increases resistance to devitrification during subsequent thermal cycles. The resulting as-built specimens exhibit coercivities as low as 44 A m⁻¹, i.e. over an order of magnitude lower than previously reported for P-, Co-, and rare-earth-free Fe-based MGs processed by LPBF, while maintaining stable specific saturation magnetization. At high amorphous fractions, coercivity becomes weakly correlated with residual crystallinity and more sensitive to porosity and structural heterogeneity. These results demonstrate that synergistic alloy and scan-strategy design can control structural relaxation and crystallization pathways in LPBF-processed MGs, providing a mechanistic foundation for manufacturing high-performance soft magnetic components.
Keywords:
Laser powder bed fusion (LPBF)
Fe-based bulk metallic glass (BMG)
Glass-forming ability (GFA)
Soft magnetic materials
Devitrification control
Structural relaxation
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9.3
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2.0W
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12.9W
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