Electron beam-based additive manufacturing of Fe93.5Si6.5 (wt.%) soft magnetic material with controllable magnetic performance

Crack-free Fe-Si soft magnetic material with various microstructural features is additively manufactured by means of Electron beam Powder Bed Fusion (E-PBF). Owing to different microstructural features caused by using different processing parameters, E-PBF-processed Fe93.5Si6.5 (wt.%) shows adjustable magnetic performance (e.g., power losses and saturation magnetic flux density) and various electrical properties. The correlation between the processing parameters used during E-PBF and the corresponding microstructural features as well as the resulting magnetic and electrical properties is discussed.