SOFT MAGNETIC COMPOSITE MATERIALS AND METHODS AND POWDERS FOR PRODUCING THE SAME

Abstract

A powder including a plurality of particulates, each particulate including a soft magnetic metallic core coated with a continuous dielectric coating having a thickness selected from a range of 100 nanometers to 100 micrometers. The particulates have a mean particle size selected from a range of 100 nanometers to 250 micrometers. Methods for forming the powder are disclosed. A soft magnetic composite component includes a soft magnetic material in a dielectric matrix, wherein (i) the soft magnetic material comprises a plurality of particulates comprising metallic cores, (ii) each metallic core is coated by a continuous dielectric coating covering >90% of a surface area of the metallic core, (iii) the metallic cores are electrically isolated from each other, and (iv) the dielectric coatings of adjacent metallic cores are consolidated together. Methods for formation of the soft magnetic component by additive manufacturing and hot isostatic pressing are disclosed.

Claims

1. A method for fabricating a soft magnetic composite component by additive manufacturing, the method comprising: providing to an additive manufacturing system a powder comprising a plurality of particulates, each particulate comprising a soft magnetic metallic core coated with a continuous dielectric coating comprising a dielectric material; and fabricating the soft magnetic composite component by forming consolidated material from the powder by additive manufacturing, wherein a porosity of the magnetic composite component is less than 5% by volume, and the soft magnetic metallic cores in the magnetic composite component are electrically and magnetically isolated from each other by a continuous three-dimensional network of the dielectric material.

2. The method of claim 1, wherein the metallic core comprises a soft magnetic pure metal or alloy comprising at least one of Fe, Co, Ni, Fe—Co, Fe—Co—V, Fe—Ni, Fe—Si, FeCoSiB, FeSiAl, amorphous magnetic materials, metal-metalloid systems (metallic glasses), or alloys or combinations thereof.

3. The method of claim 1, wherein the metallic core comprises a coercivity selected from a range of 0.01 Oe to 50 Oe.

4. The method of claim 1, wherein the continuous three-dimensional network of the dielectric material comprises physical interfaces disposed between proximate particulates.

5. The method of claim 1, wherein the continuous dielectric coating comprises a first surface layer comprising a dielectric material comprising at least one of a hydride, an oxide, a nitride, a boride, a carbide, carbon, a sulfide, a fluoride, a polymer, phosphorus, or combinations thereof.

6.-17. (canceled)

18. The method of claim 1, wherein a thickness of the continuous dielectric coating is less than 1 micrometer.

19.-20. (canceled)

21. The method of claim 1, wherein additive manufacturing comprises at least one of Binder Jetting, Directed Energy Deposition, Mask-Image-Projection-Based Stereolithography, Material Extrusion, Material Jetting, Powder Bed Fusion, Sheet Lamination, nanoparticle additive manufacturing, or derivations or combinations thereof.

22. The method of claim 1, further comprising densifying the magnetic composite component

23.-24. (canceled)

25. The method of claim 1, wherein the magnetic composite component has a tensile breaking strength greater than 150 MPa.

26.-27.

28. The method of claim 1, wherein the particulates comprise a unimodal particle size distribution with a mean particle size selected from a range of 100 nanometers to 250 micrometers or a multi-modal particle size distribution.

29.-32. (canceled)

33. The method of claim 1, wherein the powder further comprises a plurality of uncoated soft magnetic particulates, and a smaller mean particle size of the powder is a mean particle size of the uncoated soft magnetic particulates and a larger mean particle size of the powder is a mean particle size of the coated particulates, the plurality of uncoated soft magnetic particulates and the coated particulates comprising a same alloy.

34. The method of claim 1, wherein the continuous dielectric coating comprises a plurality of heterogeneous surface layers.

35.-86. (canceled)

87. A soft magnetic composite component comprising: a soft magnetic material in a dielectric matrix, wherein (i) the soft magnetic material comprises a plurality of particulates comprising metallic cores, (ii) each metallic core is coated by a continuous dielectric coating covering >90% of a surface area of the metallic core, (iii) the metallic cores are electrically isolated from each other (iv) the dielectric coatings of adjacent metallic cores are consolidated together, and (v) a surface of the component comprises striations having a height selected from a range of 100 nanometers to 250 micrometers.

88. The soft magnetic composite component of claim 87, wherein a permeability of the component is selected from a range of 100-25,000.

89. The soft magnetic composite component of claim 87, wherein a saturation flux density of the component is selected from a range of 1.0 T-2.4 T.

90. The soft magnetic composite component of claim 87, wherein a ratio of dielectric material to metal in the component is selected from a range of 1:1-1:2,500.

91. The soft magnetic composite component of claim 87, wherein a density of the component is selected from a range of 90-100%.

92.-94. (canceled)

95. A method for fabricating a soft magnetic composite component by hot isostatic pressing (HIP), the method comprising: providing to a HIP container a powder comprising a plurality of particulates, each particulate comprising a soft magnetic metallic core coated with a continuous dielectric coating comprising a dielectric material; and fabricating the soft magnetic composite component by forming consolidated material from the powder by hot isostatic pressing, wherein a packing density of the magnetic composite component is greater than 95%, and the soft magnetic metallic cores in the magnetic composite component are electrically and magnetically isolated from each other by a continuous three-dimensional network of the dielectric material.

96. The method of claim 1, wherein a shape of each particulate is at least one of flat or oblong.

97. The method of claim 1, wherein a ratio of dielectric material to metal in the component is selected from a range of 1:1-1:2,500.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0106] FIG. 1 is a graph illustrating electrical properties of soft magnetic composite components fabricated by the methods in accordance with embodiments of the invention.

[0107] FIG. 2 is a schematic diagram illustrating a core-shell particulate structure of a dielectric shell formed on a soft magnetic core, including an interdiffusion layer formed after sintering, in accordance with an embodiment of the invention.

[0108] FIG. 3 is a schematic diagram illustrating the formation of soft magnetic metallic cores coated by a continuous dielectric coating, wherein the dielectric coating is formed by consolidating a coating of dielectric nanoparticles, in accordance with an embodiment of the invention.

[0109] FIG. 4 is a graph illustrating a difference in saturation magnetization of a Fe-35Co soft magnetic alloy in particulate form and the saturation magnetization of the same Fe-35Co alloy coated with amorphous aluminum oxide using atomic layer deposition, in accordance with an embodiment of the invention.

[0110] FIGS. 5a-5e are electron dispersive spectroscopy (EDS) images of Fe-35Co soft magnetic alloy formed from particles coated with amorphous aluminum oxide, in accordance with embodiments of the invention.

[0111] FIGS. 6a-6l are electron dispersive spectroscopy (EDS) images of Fe-35Co soft magnetic alloy formed from particles coated with amorphous aluminum oxide, in accordance with embodiments of the invention.

[0112] FIGS. 7a and 7b are photographs of examples of soft magnetic composite components fabricated by binder jet additive manufacturing, in accordance with embodiments of the invention.

[0113] FIGS. 8a and 8b are scanning electron microscope (SEM) micrographs of a component formed of Fe—Co soft magnetic alloy coated with different thicknesses of amorphous aluminum oxide, in accordance with an embodiment of the invention.

[0114] FIG. 9 is a photograph of a sealed hot isostatic pressing (HIP) can/tube, suitable for use with embodiments of the invention.

[0115] FIG. 10 is a graph of an exemplary pressure—temperature HIP profile suitable for use with embodiments of the invention.

[0116] FIGS. 11a and 11b are a schematic figure and a photograph, respectively, illustrating a binder jet processed complex shaped soft magnetic composite part placed in a HIP can filled with a refractory media, in accordance with an embodiment of the invention.

[0117] FIG. 12 is a flow chart illustrating a hot isostatic pressing (HIP) process, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

[0118] As used herein, a soft magnetic composite means materials that include soft magnetic powder particles surrounded by an electrically insulating layer. Some of the unique properties of these materials include: three-dimensional isotropic soft magnetic behavior, low eddy current loss, low core loss at medium and high frequencies above 200 Hz, flexible component design, and a prospect for lower weight and coil winding costs.

[0119] Disclosed herein are powders suitable for manufacturing of soft magnetic composite components, including by additive manufacturing; both the composition of the particulates and methods of manufacture thereof are addressed. Also disclosed are additive manufacturing methods for forming soft magnetic composites with reduced eddy currents.

[0120] As used herein, “additive manufacturing system” means any machine and auxiliary equipment configured to produce components by additive manufacturing.

[0121] As used herein, “soft magnetic composite” means a material manufactured by consolidating ferromagnetic powder particles, each surrounded by an electrically insulating layer and typically having an intrinsic coercivity 50 Oe, e.g., less than 12.5 Oe.

[0122] As used herein, “core” mean a single particle or an agglomeration of several particles.

[0123] Particulate Structures and Compositions

[0124] Embodiments of invention include powders suitable for forming soft magnetic composites by, e.g., additive manufacturing.

[0125] Referring to FIG. 2, an exemplary powder includes a plurality of particulates 100, with each particulate including a soft magnetic metallic core 110 coated with a continuous dielectric coating 120 having a thickness less 100 micrometers, e.g., less than 50 micrometers, less than 1 micrometer, or less than 200 nm, with a minimum thickness of 100 nm. The dielectric coating is preferably thick/resistive enough to electrically isolate cores and thin enough to subsequently constitute a relatively low volume fraction of consolidated soft magnetic composite material, thereby increasing magnetic saturation induction of the composite. An amorphous and/or crystalline intermediate layer 130, i.e., a magnetic-dielectric diffused layer, may be disposed between the metallic core 110 and dielectric coating 120.

[0126] The powder may have a flowability suitable for additive manufacturing, as discussed below.

[0127] The particulates may have a mean particle size selected from a range of 100 nanometers to 250 micrometers, e.g., 1 μm to 200 μm or 10 μm to 150 μm. The particulates may include a unimodal particle size distribution. If the particle diameter is greater than the domain size, magnetic domain wall movement will likely occur during magnetization reversal, resulting in generation of a high hysteresis loss. Particle size distributions with mean particle sizes below 100 micrometers are typically suitable for binder jet or selective laser sintering (SLS) additive manufacturing. Particle size distributions with mean particle sizes between 45-150 micrometers are typically suitable for direct energy deposition additive manufacturing. Unimodal particle size distributions typically offer the advantage of less processing effort and cost, and higher yield, in comparison to multimodal particle size distributions.

[0128] The combination of metallic core and a dielectric coating (also referred to herein as “shell”) enables the formation of soft magnetic composites with high resistivities, in which the metallic cores are surrounded by dielectric material, thereby improving core loss, permeability, and device efficiency.

[0129] In particular, the soft magnetic metallic core may include or consist essentially of a soft magnetic pure metal or alloy thereof, such as Fe, Co, Ni, Fe—Co, Fe—Ni, Fe—Si, FeCoSiB, amorphous magnetic materials, metal-metalloid systems (metallic glasses), or alloys or combinations thereof. These metals and alloys are soft magnetic, having relatively high permeabilities, low coercivities, and high saturation induction properties, which enable them to switch magnetization easily and with relatively low core loss in comparison to permanent, or “hard” magnetic materials. The soft magnetic metallic core may have a coercivity ranging from, for example, 0.01 Oe to 50 Oe.

[0130] In some embodiments, the continuous dielectric coating includes a first surface layer that includes or consists of a first dielectric material, such as a hydride, an oxide, a nitride, a sulfide, a carbide, a boride, a fluoride, a polymer, phosphorus, and/or combinations thereof. These materials are selected for their high dielectric constant, a property of insulating materials which enables them to electrically isolate the soft magnetic cores with very low thicknesses of dielectric between cores.

[0131] A suitable hydride is MgH.sub.2, MBH.sub.4 (M=Li, Ca, Mg, Na, K), MNH.sub.2 (M=Li and Mg), MBH.sub.4+′MH.sub.2 (M=Li, Ca, Mg; ′M=Li, Mg, Ca), or MNH.sub.2+′MH.sub.2 (M=Li, Mg; ′M=Li), and/or combinations thereof.

[0132] A suitable oxide is BaTiO.sub.3, Al.sub.2O.sub.3, HfO.sub.2, HfSiO.sub.4, α-TiO.sub.2, α-SiO.sub.2, ZrO.sub.2, CeO.sub.2, CoO, Cr.sub.2O.sub.3, MgO, Al.sub.2O.sub.3, SnO.sub.2, NiO.sub.2, GaO, GeO.sub.2, Li.sub.2O, Y.sub.2O.sub.3, La.sub.2O.sub.3, ZnO, ZrO.sub.2, WO.sub.3, TiO.sub.2, Sc.sub.2O.sub.3, BaO, Eu.sub.2O.sub.3, SiO.sub.2, Cs.sub.2O, MoO.sub.3, Nb.sub.2O.sub.5, TeO.sub.2, Bi.sub.2O.sub.3, BaO, SrO, Ta.sub.2O.sub.5, copper oxides, iron oxides, iron-cobalt oxides, iron-nickel oxides, and/or combinations thereof.

[0133] The oxide may have a perovskite crystal structure (ABO.sub.3).

[0134] A suitable nitride is AlN, BaN, BN, TiN, VN, CrN, and/or combinations thereof.

[0135] The continuous dielectric coating may include a second surface layer. The second surface layer may include a second dielectric material including an oxide, with the second dielectric material being different from the first dielectric material. For example, the oxide of the second dielectric material may be, a low melting point glass oxide including at least one of, e.g., B.sub.2O.sub.3, Bi.sub.2O.sub.3, PbO, V.sub.2O.sub.5, TeO.sub.2, Na.sub.2O, K.sub.2O, MoO.sub.3. and/or combinations thereof. These oxides have a low melting point in comparison to the first surface layer, e.g., Al.sub.2O.sub.3, which has a high melting point.

[0136] Accordingly, using these oxides in a second surface layer may help facilitate sintering/densification/consolidation of the particles.

[0137] In some embodiments, the first surface layer may include an oxide (A), and a second surface layer may be disposed on the first surface layer and include an oxide (B). The combination (B-A) may be, e.g., B.sub.2O.sub.3—Al.sub.2O.sub.3, B.sub.2O.sub.3—GeO.sub.2, B.sub.2O.sub.3—SiO.sub.2, B.sub.2O.sub.3—WO.sub.3, B.sub.2O.sub.3—Cr.sub.2O.sub.3, B.sub.2O.sub.3—MoO.sub.3, B.sub.2O.sub.3—Nb.sub.2O.sub.5, B.sub.2O.sub.3—Li.sub.2O.sub.3, B.sub.2O.sub.3—BaO, B.sub.2O.sub.3—ZnO, B.sub.2O.sub.3—La.sub.2O.sub.3, B.sub.2O.sub.3—CoO, B.sub.2O.sub.3—Cs.sub.2O, B.sub.2O.sub.3—K.sub.2O, K.sub.2O—GeO.sub.2, K.sub.2O—SiO.sub.2, K.sub.2O—WO.sub.3, K.sub.2O—MoO.sub.3, K.sub.2O—Nb.sub.2O.sub.5, Na.sub.2O—GeO.sub.2, Na.sub.2O—SiO.sub.2, Na.sub.2O—WO.sub.3, Na.sub.2O—MoO, Na.sub.2O—Nb.sub.2O.sub.5, MoO.sub.3—Cs.sub.2O, MoO.sub.3—Li.sub.2O, MoO.sub.3—WO.sub.3, Cs.sub.2O—SiO.sub.2, Cs.sub.2O—Nb.sub.2O.sub.5, B.sub.2O.sub.3—Al.sub.2O.sub.3, B.sub.2O.sub.3—GeO.sub.2, B.sub.2O.sub.3-SaO.sub.2, B.sub.2O.sub.3—WO.sub.3, B.sub.2O.sub.3—Cr.sub.2O.sub.3, B.sub.2O.sub.3—MoO.sub.3, B.sub.2O.sub.3—Nb.sub.2O.sub.5, B.sub.2O.sub.3—Li.sub.2O.sub.3, B.sub.2O.sub.3—BaO, B.sub.2O.sub.3—ZnO, B.sub.2O.sub.3—La.sub.2O.sub.3, B.sub.2O.sub.3—CoO, B.sub.2O.sub.3—Cs.sub.2O, B.sub.2O.sub.3—K.sub.2O, K.sub.2O—GeO.sub.2, K.sub.2O—SiO.sub.2, K.sub.2O—WO.sub.3, K.sub.2O—MoO.sub.3, K.sub.2O—Nb.sub.2O.sub.5, Na.sub.2O—GeO.sub.2, Na.sub.2O—SiO.sub.2, Na.sub.2O—WO.sub.3, Na.sub.2O—MoO, Na.sub.2O—Nb.sub.2O.sub.5, MoO.sub.3—Cs.sub.2O, MoO.sub.3—Li.sub.2O, MoO.sub.3—WO.sub.3, Cs.sub.2O—SiO.sub.2, or Cs.sub.2O—Nb.sub.2O.sub.5. Suitable combinations of oxides may be chosen based on their ability to adhere to one another; for example based upon similar lattice parameters, or the ability to form inter-diffusion layers with a range of chemical composition and stoichiometry.

[0138] A suitable sulfide is Al.sub.2S.sub.3, Sb.sub.2S.sub.3, As.sub.2S.sub.3, BaS, BeS, Bi.sub.2S.sub.3, B.sub.2S.sub.3, CdS, CaS, CeS, Ce.sub.2S.sub.3, WS, Cr.sub.2S.sub.3, CoS, CoS.sub.2, Cu.sub.2S, CuS, Dy.sub.2S.sub.3, Er.sub.2S.sub.3, EuS, Gd.sub.2S.sub.3, Ga.sub.2S.sub.3, GeS, GeS.sub.2, HfS.sub.2, Ho.sub.2S.sub.3, In.sub.2S, InS, FeS, FeS.sub.2, La.sub.2S.sub.3, LaS.sub.2, La.sub.2O.sub.2S, PbS, Li.sub.2S, MgS, MnS, HgS, MoS.sub.2, Nd.sub.2S.sub.3, S, NdS, K.sub.2S, Pr.sub.2S.sub.3, Sm.sub.2S.sub.3, Sc.sub.2S.sub.3, SiS.sub.2, Ag.sub.2S, Na.sub.2S, SrS, Tb.sub.2S, Tl.sub.2S, ThS.sub.2, Tm.sub.2S.sub.3, SnS, SnS.sub.2, TiS.sub.2, WS.sub.2, US.sub.2, V.sub.2S.sub.3, Yb.sub.2S.sub.3, Y.sub.2S.sub.3, Y.sub.2O.sub.2S, ZnS, ZrS.sub.2, and/or combinations thereof.

[0139] A suitable carbide is CaC.sub.2, SiC, WC, Fe.sub.3C, TiC, ZrC, VC, NbC, TaC, Cr.sub.3C.sub.2, Mo.sub.2C, HfC, and/or combinations thereof.

[0140] A suitable boride is of TiB.sub.2, ZrB.sub.2, HfB.sub.2, VB.sub.2, NbB, TaB, TaB.sub.2, CrB.sub.2, Mo.sub.2B.sub.5, W.sub.2B.sub.5, Fe.sub.2B, FeB CoB, Co.sub.2B NiB, Ni.sub.2B, Al.sub.3Mg.sub.3B.sub.56, and/or combinations thereof.

[0141] A suitable fluoride is LiF.sub.3,LiF.sub.2, NdF.sub.3, NdF.sub.2, NdOF, LiOFMg, MgF.sub.2, NdF.sub.3, NdF.sub.2, NdOF, MgOFCa, CaF.sub.2 NdF.sub.3 NdF.sub.2, NdOF, CaOFLa, LaF.sub.3, LaF.sub.2, NdF.sub.3, NdF.sub.2, NdOF, LaOFCe, CeF.sub.3, CeF.sub.2, NdF.sub.3, NdF.sub.2, NdOF, CeOFPr, PrF.sub.3, PrF.sub.2, NdF.sub.3, NdF.sub.2, NdOF, PrOFNd, NdF.sub.3, NdF.sub.3, NdF.sub.2, NdOF, NdOFSm, SmF.sub.3, SmF.sub.2, NdF.sub.3, NdF.sub.2, NdOF, SmOFEu, EuF.sub.2, NdF.sub.3, NdF.sub.2, NdOF, EuOF, and/or combinations thereof.

[0142] A suitable polymer is, e.g., a phenolic resin, an epoxy resin, an amide, a phosphoramide, a sulfonamide, a saturated fatty acid amide, an unsaturated fatty acid amide, and/or combinations thereof.

[0143] In some embodiments, the continuous dielectric coating may include a plurality of heterogeneous surface layers. Each of the surface layers may include an oxide, a nitride, a sulfide, a carbide, a boride, a fluoride, a polymer, phosphorus, and/or combinations thereof, as described above.

[0144] A first layer may function as an insulator and a second layer may function as a mechanical integrator.

[0145] The continuous dielectric coating may have an amorphous structure or a crystalline structure.

[0146] The particulates may include nanoparticles having a particle size ranging from 100 nm to 1000 nm.

[0147] A ratio of a thickness of the dielectric coating to a diameter of the magnetic metallic core may be less than 1:1. For example, a diameter of the metallic core may be 1 micrometer and the dielectric coating may have a thickness of 1 micrometer. A ratio of a thickness of the dielectric coating to a diameter of the magnetic metallic core may be less than 1:10. For example, a diameter of the metallic core may be 1 micrometer and the dielectric coating may have a thickness of 100 nanometers. An advantage of such ratios is the reduction of the volume fraction of dielectric material within the composite, thus increasing saturation induction and other soft magnetic properties. The dielectric coating preferably has a thickness of at least 100 nanometers to enable full electrical isolation of the core soft magnetic material.

[0148] A ratio of a thickness of the dielectric coating to a diameter of the magnetic metallic core may be less than 1:1,000. For example, a diameter of the metallic core may be 100 micrometers and the dielectric coating may have a thickness of 100 nanometers. An advantage of such a low ratio is the further reduction of the volume fraction of dielectric material within the composite, which further increases saturation induction and other soft magnetic properties. However, below 100 nanometers, the dielectric coating may not fully electrically insulate the substrate particles in consolidated form.

[0149] The surface coverage of the dielectric coating is conformal and may cover more than 90% of the surface area of the metallic core.

[0150] Each particulate may have a shape of spherical, angular, needle-like, or platelet/flakes. The advantage of spherical powders is in packing density and flowability for spreading and feeding powders within additive manufacturing techniques. The advantage of non-spherical powders such as angular, needle-like, or platelet are the lower cost of production and higher particle-to-particle contact, which enhances further the green and sintered density of the additively manufactured parts along with magnetic and mechanical responses. A combination of spherical and platelets/flakes and/or needle-like and/or irregular particles also helps increase the density of the additively manufactured parts.

[0151] The coating is preferably strongly bonded to the core, i.e., a strong interfacial bond is formed by chemical or physical bonding. In general, chemical bonding is preferred such that the dielectric forms a covalent or ionic bond to the core metallic material, since the adherence of the coating is more robust as compared to physical attachment via van der Waals attractive forces.

[0152] In an embodiment, the core may have a particle size ranging from 10 nm to several 100 micrometers. For example, a suitable core may be, e.g., Fe65-Co35, inert gas atomized powder with a particle size of less than 45 μm. The shell may be amorphous aluminum oxide of approximately 100-1000 nm thickness formed by atomic layer deposition (ALD).

[0153] Each particulate may include a metal layer disposed over the dielectric coating. The metal or metal alloy layer may include or consist essentially of iron, cobalt, nickel, and/or alloys thereof. A suitable metal is one that can diffuse easily at the sintering temperature range, e.g., greater than 1000° C., and can offer good mechanical responses. Ideally, the metal or alloy is ferromagnetic with a high magnetic saturation induction, thereby increasing an average saturation of a composite formed from the particulate.

[0154] The powder may have a powder flowability suitable for additive manufacturing. For example, the powder flowability may be a flow rate of at least one of greater than 50 grams per 25 seconds in a Hall flow test conducted to the ASTM B213 standard. In some embodiments, the powder flowability is greater than 50 grams per 5 seconds in a Carney flow test conducted to the ASTM B964 standard.

[0155] Moreover, as another indicator of powder flowability, the particulates may have an avalanche angle less than or equal to 45° as measured in a rotating, transparent drum filled with a known amount of powder.

[0156] Such powder flowabilities may be achieved as follows. The size of the particulates is selected to generally avoid very small particles which increase friction. In some embodiments, a shape of the particulates is generally spherical, as angular or spongy-type powders may have many interface points, thereby reducing flowability. Furthermore, as moisture content affects flow, a moisture content may preferably be below 50-60% relative humidity. Finally, surface coatings of inorganic materials can improve flowability, since they have inherently lower surface friction.

[0157] Fabrication of Powder

[0158] The powder including a plurality of particulates, as described above, may be fabricated as follows. First, the magnetic metallic cores of the particulates are formed. The magnetic metallic cores include a soft magnetic pure metal or an alloy thereof, and may be formed by methods known to one of skill in the art, e.g., gas atomization, water atomization, plasma atomization, rotating electrode, centrifugal atomization, spinning water atomization process (S.W.A.P.), melt spinning, quenching, attrition, milling, hydrogen reduction, electrolysis, carbonyl iron, or carbonyl nickel processes. The cores may include a plurality of particles of, e.g., Fe, Co, Ni, Fe—Co, Fe—Ni, Fe—Si, FeCoSiB, amorphous magnetic materials, metal-metalloid systems (metallic glasses), alloys and/or combinations thereof. The particles may have a mean size ranging from 100 nm to 250 micrometers, e.g., 0.05 micrometers to 250 micrometers, or 5 micrometers to 200 micrometers or 10 micrometers to 100 micrometers. In some embodiments, each core may include a plurality of particles.

[0159] In one embodiment, Fe65-Co35 powder is manufactured by vacuum induction melt gas atomization using argon, nitrogen, or helium gas as the atomization medium. This fabrication method produces approximately spherical, uniform particles with a mean size ranging from 100 nanometers to 250 micrometers or more. Such particles are suitable for additive manufacturing because, e.g., their sphericity and uniformity allow them to be spread in additive manufacturing powder bed fusion techniques. Moreover, their lack of internal porosity allows high-density components to be fabricated. Finally, the purity of the atomization gas leads to clean particle surfaces, devoid of oxides or contaminating particles or layers, enabling such powders to be coated consistently with dielectric material using a range of chemical and physical deposition methods.

[0160] A continuous dielectric coating may be formed on the magnetic metallic cores by a conformal coating process, also known as surface functionalization. The continuous dielectric coating may have a thickness less than or equal to 100 micrometers, e.g., 100 nanometers to 100 micrometers, include at least one surface layer, and provide >90% surface coverage of the core.

[0161] The coating process may be any mechanism for forming a conformal, strongly bonded thin/nanolayer coating on the core surface. Suitable conformal coating processes include, e.g., formation of a native oxide by surface oxidation, atomic layer deposition (ALD), molecular layer deposition, physical vapor deposition, sol-gel, chemical vapor deposition (CVD), metal organic chemical vapor deposition (MOCVD), plasma torch synthesis, spray forming or coating, high velocity oxygen fuel coating, arc coating, co-precipitation, epoxy coating, a supercritical CO.sub.2 method, high pressure coating, and combinations thereof.

[0162] In one embodiment, the surfaces of Fe65-Co35 powders with particle size distribution less than 45 micrometers are coated with amorphous aluminum oxyhydroxide or oxide using atomic layer deposition (ALD). An advantage of ALD is that it yields fully conformal surface layers, with thicknesses that can be easily controlled due to the layer-by-layer, self-limiting sequential chemical reaction (separate saturating gas-solid reaction) process. The ALD process may be performed within a fluidized bed, rotating drum, blender, or other device that continuously moves or agitates the powder particles so that they are conformally coated. Particle ALD appropriate for the fabrication of soft magnetic composites described herein may be performed using commercially-available equipment at ALD Nanosolutions, Inc. or an equivalent provider.

[0163] Referring to FIG. 3, in some embodiments, forming the continuous dielectric coating includes functionalizing core material (soft magnetic metal or alloy) including a plurality of magnetic metallic cores 110 (with diameter of, e.g., 10-250 μm) by applying 300 a plurality of dielectric nanoparticles (with diameter of e.g., 100-5000 nm) to the core to form surface-functionalized particulates 310. The dielectric nanoparticles may be densified to form the continuous dielectric coating, e.g., in the same densification process used to densify consolidated material made from the powder by additive manufacturing.

[0164] Functionalizing each magnetic metallic core may include, e.g., (i) rapid mixing of a plurality of the magnetic metallic cores with the plurality of dielectric nanoparticles, (ii) ball milling of the magnetic metallic cores with the dielectric nanoparticles, and/or (iii) plasma spraying of dielectric nanoparticles onto the magnetic metallic cores.

[0165] After functionalization of the metallic core, a powder including a plurality of surface-functionalized particulates may be processed 320 by additive manufacturing, followed by consolidation/densification to form a core-shell soft magnetic composite 330.

[0166] The dielectric nanoparticles may be formed from any of the materials disclosed herein for the dielectric coatings.

[0167] Suitable compositions for the dielectric coating are described above. A thickness of the coating may range from 100 nm to 100 micrometers, e.g., 100 nm to 200 nm. Thinner coatings may help to improve the permeability and magnetic material volume percentage, while thicker coatings may help to improve the particle-particle eddy current losses and mechanical responses of the finished parts.

[0168] The coating may be an amorphous or crystalline dielectric. Amorphous coatings are generally preferred as they are more reactive, or catalytic, meaning that during the consolidation or densification phase of forming the soft magnetic composite, a stronger inter-particle bond may be formed. This has a beneficial influence on overall component strength, as well as ability to achieve greater densification of the component during sintering.

[0169] In another embodiment, the coating may be an in-situ thin oxide coating formed during the atomization process in which the core is formed. This may be achieved by including a fraction (<50%) of oxygen entrained in the high-pressure gas flow within an inert gas atomizer to self-passivate the soft magnetic material droplets as they freeze. Particles produced by such a mechanism are highly spherical and free of agglomerates, or satellites. Alternatively, self-passivation may be achieved using water gas atomization; however this has the disadvantage of producing angular or sponge-like powder shapes, which is typically detrimental to spreadability in the additive manufacturing process and powder apparent density.

[0170] The powder preferably has a unimodal particle size distribution, which is attained by screening and classifying as-atomized powders to remove large- and small-diameter particles, respectively, within the desired particle size range. In some embodiments, the powder may have a multi-modal particle size distribution.

[0171] In some embodiments, the particulates may be milled or rolled from an approximately spherical particle shape into a flat particle shape.

[0172] Additive Manufacturing Methods Using Novel Powders

[0173] The powders described above, e.g., powders that include a plurality of particulates, with each particulate having a soft magnetic metallic core coated with a continuous dielectric coating with a thickness of at least 100 nanometers and no more than 100 micrometers, may be utilized in additive manufacturing processes to fabricate soft magnetic composite components, including components with highly complex shapes.

[0174] Accordingly, in an embodiment, a component may be made from the powder by additive manufacturing. Providing the powder to the additive manufacturing system may include forming the powder as discussed above. Alternatively, the powder may be provided to the additive manufacturing system by a user obtaining the powder from a manufacturer; the user may subsequently perform an additive manufacturing step with the powder.

[0175] In some embodiments, the powder may have a bimodal particle size distribution, with a smaller mean particle size of the powder ranging from 1 micrometer to 100 micrometers, e.g., 1 micrometer to 50 micrometers, and a larger mean particle size ranging from 15 micrometers to 250 micrometers, e.g., 15 micrometers to 150 micrometers. These particle sizes are selected to maximize the packing density of the powder in a powder bed additive manufacturing system, therefore facilitating the post-processing sintering, or densification, step.

[0176] In some embodiments, the powder may also include a plurality of uncoated soft magnetic particulates, with a smaller mean particle size of the powder being a mean particle size of the uncoated soft magnetic particulates and a larger mean particle size being a mean particle size of the coated particulates, with, for example, the uncoated soft magnetic particulates in the 1-60 vol. % range and the coated particulates in the 50-99 vol. % range including same alloy. The uncoated particles within the plurality of coated particles can aid in the sintering step, by filling the interstitial spaces or voids between coated particles, while avoiding further dilution of the overall saturation induction of the composite, since no further dielectric material is added to the volume.

[0177] Suitable additive manufacturing methods may be any of the seven categories of additive manufacturing identified by ASTM, i.e., Binder Jetting, Directed Energy Deposition, Mask-Image-Projection-Based Stereolithography, Material Extrusion, Material Jetting, Powder Bed Fusion, and Sheet Lamination, as defined in STM F2792-12a, published by the ASTM Committee F42 on Additive Manufacturing Technologies. Moreover, derivatives and combinations may be used. A suitable additive manufacturing method may include fabrication with nanoparticles, such as with a nanoparticle additive manufacturing system, such as NanoParticle Jetting.

[0178] In one embodiment, the soft magnetic composite component or article is fabricated in a binder jet additive manufacturing system, such as an ExOne Innovent system, using Fe65-Co35 powder of particle size distribution below 45 micrometers and coated with 100 nm of amorphous aluminum oxide. The particles are bound together using conventional, commercially available organic binder fluid (e.g., available from ExOne Inc.). This method has the advantage of maintaining a relatively low temperature during the fabrication of complex-shaped components, therefore maintaining the integrity of the core-shell structure in the solid state.

[0179] After the component is fabricated by additive manufacturing, the component may be densified to form a high density magnetic composite component. Suitable densification methods include high temperature sintering, hot isostatic pressing (HIP), densification via crucible compaction process by canning and sealing the soft magnetic composite green body component along with microbeads or particles of ceramic material followed by HIP'ing, hot pressing, sintering, compaction, cold isostatic pressing, spark plasma sintering, direct current sintering, and/or microwave sintering. Generally, high temperature sintering may be performed with any type of heating, e.g., microwave, IR, conventional sintering, etc. In some embodiments, high temperature sintering may be followed by hot isostatic pressing. Considerations include sintering time, temperature, reaction gases, inert gases, and other parameters.

[0180] In one embodiment, Fe65-Co35 powder of particle size distribution below 45 micrometers and coated with 100 nm of amorphous aluminum oxide may be sintered using direct current sintering at 1000-1300° C. and 20-100 MPa uniaxial pressure to achieve over 99% dense component.

[0181] In one embodiment, a component is fabricated by binder jet additive manufacturing from Fe65-Co35 powder of particle size distribution below 45 micrometers and coated with 100 nm of amorphous aluminum oxide; this component may subsequently be cured in air at 150-200° C. to remove organic binder and then sintered in a vacuum furnace (or argon or other atmosphere) at 1100-1450° C. for 2 or more hours.

[0182] After the additive manufacturing and optional densification steps, the magnetic composite component has a porosity of less than 5%. The advantage of such low porosity is to maximize the magnetic responses of the component or device fabricated from the soft magnetic material, since air gaps deteriorate magnetic and mechanical properties of the device. The pores may be isolated, which enables the component to be further densified using hot isostatic pressing or another densification method.

[0183] In some embodiments, the magnetic composite component has a high tensile breaking strength, e.g., breaking strength of greater than 150 MPa. This is attained by sufficient densification of the material (i.e., low porosity), and forming strong adherence of the dielectric layers between particles to each other during the sintering and densification process. High strength is desirable in many applications of electromagnetic devices, specifically in rotating components such as motor or generator rotors.

[0184] The magnetic composite component includes the dielectric material of the continuous dielectric coating, i.e., the dielectric material of the powder does not decompose nor does it lose conformality to the particulates during additive manufacturing and densification steps.

[0185] Soft Magnetic Component Made by Additive Manufacturing with Novel Powders

[0186] The soft magnetic component fabricated by additive manufacturing and subsequent post-processing steps from the novel powders includes consolidated, soft magnetic particles surrounded by a three-dimensional, interconnected film or continuous network of electrically insulating (i.e., highly dielectric) material.

[0187] The microstructure in two-dimensional view (e.g., via optical or electron microscopy) is characterized by continuously connected prior-particle boundaries of approximately twice the thickness of the original dielectric coating, interspersed by grains of soft magnetic material. See, e.g., the Examples described below.

[0188] The soft magnetic grains of the consolidated material are approximately equivalent in size to the feedstock particle sizes since the material does not coarsen significantly during sintering. The dielectric layers prevent interdiffusion between isolated soft magnetic material. For example, for unimodal particle size distribution feedstock the consolidated material has approximately equiaxed grains. Alternatively, for a bimodal powder distribution, the component grain sizes are also bimodally distributed.

[0189] The desired magnetic properties of the soft magnetic component include magnetic isotropy, high electrical resistivity, high permeability, high saturation, low coercivity, low core loss at medium to high frequency.

[0190] Magnetic composites can be printed using additive manufacturing into components with high geometric complexity, including internal features for more efficient flux pathways, and for example, rounded corners and edges which increases the efficiency of electrical coil winding.

[0191] Functionalization of powders with a thin dielectric (nanometers thick continuous coating) allows higher metallic volume fraction (increased fill factor) and hence superior magnetic saturation induction, lower coercivity, and high permeability.

[0192] Strong adherence of the coating to the core via chemical bonding permits high temperature sintering without film delamination or breakdown, in turn providing greater mechanical integrity and strength due to high density.

[0193] In some embodiments, a soft magnetic composite component includes a magnetic material in a dielectric matrix, with (i) the magnetic material including a plurality of particulates comprising metallic cores, (ii) each metallic core being coated by a continuous dielectric coating covering >90% of a surface area of the metallic core, (iii) the metallic cores being electrically isolated from each other, and (iv) the dielectric coatings of adjacent metallic cores being consolidated together.

[0194] The permeability of the component may range from 100 to 25,000, e.g., 500 to 1500. The permeability is chosen to be maximized for highest sensitivity and response to magnetic fields.

[0195] A saturation flux density of the component may range from 1.0 T-2.4 T. The saturation flux density is selected to be as high as possible, and as close as possible to the corresponding fully dense, pure soft magnetic material (i.e., without the dielectric material coating).

[0196] A ratio of dielectric material to metal in the component may range from 1:1-1:2,500, e.g., 1:100-1:1,000. The ratio may be selected to be as small as possible, while maintaining at least 100 nm of coating, to maximize the volume fill factor of soft magnetic material in the composite.

[0197] A density of the component may range from 90-100%, e.g., 95%-100%. The density is selected to be as close to 100% as possible so as to minimize magnetic loss-inducing air gaps in the composite.

[0198] The pores defined by the particulates may be isolated from one another.

[0199] A surface of the component may include striations having a height selected from a range of 100 nanometers to 250 μm. These striations may be formed during fabrication of the component by an additive manufacturing method.

[0200] The following table indicates parameters characterizing soft magnetic particulates and components formed in accordance with embodiments of the invention.

TABLE-US-00001 Parameter Unit Minimum Typical Maximum Mean Particle size μm 0.1 25-90 250 Coating thickness μm 0.1 0.1-2.0 100 Electrical resistivity μΩ-m 0.6 100 10,000 D.C. Permeability n/a 100 1,000 25,000 Saturation Induction T 0.5 2 2.4 AC core loss at 400 W/kg 5 20 100 Hz and 1.5 T AC core loss at 1000 W/kg 15 60 300 Hz and 1.5 T Coating dielectric n/a 3.9 9 2000 constant K Vol. % of magnetic % 75 95 99 material Packing density % 90% 95% 99.99% Tensile Strength MPa 75 200 700

Examples

[0201] Referring to FIG. 4, a graph illustrates saturation magnetization of a Fe-35Co soft magnetic alloy in particulate form, with particle size distribution of 0-45 μm (“uncoated” solid curve), in comparison to saturation magnetization of the same Fe-35Co alloy in particulate form coated with amorphous aluminum oxyhydroxide or oxide using atomic layer deposition (“coated” dashed curve), in accordance with an embodiment of the invention. The difference in saturation magnetization between the coated and uncoated powders is approximately 1%.

[0202] Referring to FIG. 5a, an electron dispersive spectroscopy (EDS) image illustrates Fe-35Co soft magnetic alloy in particulate form coated with amorphous aluminum oxide by atomic layer deposition (ALD), with particle size distribution of 0-45 μm. The image confirms the uniformity of the formation of particles including metallic cores and dielectric shells, in accordance with embodiments of the invention. Various images correspond to signals from different chemical elements, with each particle showing conformal consistency of the chemical constituents Fe (FIG. 5b), Co (FIG. 5c), O (FIG. 5d), and Al (FIG. 5e).

[0203] Referring to FIGS. 6a and 6g, electron dispersive spectroscopy (EDS) images illustrate a Fe-35Co soft magnetic alloy formed from metallic cores coated with amorphous aluminum oxide by atomic layer deposition (ALD), following consolidation of the particulates into solid component form, via densification under pressure of 30-100 MPa and temperature of 1100-1300° C., in accordance with embodiments of the invention. Additional images correspond to signals from different chemical elements Fe (FIGS. 6d and 6j), Co (FIGS. 6b and 6h), Al (FIGS. 6e and 6k), and 0 (FIGS. 6f and 6l). The soft magnetic particles of Fe-35Co are isolated in a three-dimensional network of dielectric material Al.sub.2O.sub.3, with the thickness of dielectric between each particle being approximately 100 nm.

[0204] Referring to FIGS. 7a and 7b, two photographs illustrate examples of soft magnetic composite components fabricated by binder jet additive manufacturing, in accordance with embodiments of the invention. The components are fabricated into near-net shape without the need for tooling, allowing complex, three-dimensional shapes to be fabricated.

[0205] Referring to FIGS. 8a and 8b, SEM micrographs are provided of a component formed of Fe—Co soft magnetic alloy coated with two different amorphous aluminum oxide thickness by atomic layer deposition (ALD), after additive manufacturing by binder jet, curing, and densification by sintering in argon atmosphere at 1100-1400° C. for 2-4 hours, in accordance with an embodiment of the invention. FIG. 8a is a micrograph showing an example a component formed from particulates with an aluminum oxide coating of less than 100 nm that can be seen as dark lines between the soft magnetic particles. One can see that in this case, the insulation coating becomes discontinuous, leading to an uninterrupted electrical pathway between the soft magnetic Fe—Co particles. The circles indicate regions of coating discontinuity, while the arrows indicate potential inter-particle electrical pathway between the metallic particles due to insulation coating discontinuity. FIG. 8b is a micrograph showing consolidated material with greater than 100 nm aluminum oxide coating. In this case, the coating is continuous and the soft magnetic particles are electrically and physically isolated by the dielectric layers, which can be seen as dark lines. The circles indicate regions of coating discontinuity, while the arrows indicate intra-particle electrical pathway due to existence of insulation coating on most of the particles. The achievement of a continuous coating after high temperature and/or high pressure consolidation is important for reducing the inter-particle eddy current losses at higher frequencies. The consolidated parts may be subject to further heat treatment in the 600-1200° C. temperature range in dry hydrogen or high vacuum (at pressures less than 10.sup.−2 torr) or in argon atmosphere in order to improve the AC and DC magnetic properties.

[0206] A complex shaped component may be manufactured from the coated powder materials by the use of controlled pressure and temperature. Suitable densification methods include hot isostatic pressing (HIP) As shown in FIG. 9, a HIP container/can 900 may be filled with coated metallic alloy (for example, Fe—Co, Fe—Ni, Fe—Si based alloy crystalline or amorphous powder materials) powders and the HIP container/can evacuated/outgassed to remove moisture and oxygen content from the coated powder feedstock. The required vacuum level is in the range of 10.sup.−3 torr or more preferably 10.sup.−5 torr. After reaching the required vacuum level, the HIP container/can may be sealed under vacuum using a torch. The sealed HIP can may then be pressurized in a HIP furnace at pressure between 20 MPa to 500 MPa and temperature between 900° C. to 1400° C. to achieve high packing density greater than 95%.

[0207] FIG. 10 is an example of an experimental temperature—pressure HIP profile as a function of time for making samples with >99% density. The top profile 104 indicates the pressure, while the bottom profile 1178 indicates the temperature. The figure indicates a pressure of 104 MPa and temperature of 1178° C. has been maintained for about 4 hrs. to achieve a consolidated sample with >99% density.

[0208] Referring to FIGS. 11a and 11b, in another exemplary process in accordance with an embodiment of the invention, a binder jet processed complex shaped soft magnetic composite specimen 1100 is placed inside a HIP container 900 filled with a refractory powder (for example Al.sub.2O.sub.3, ZrO.sub.2, SiO.sub.2 and/or combinations thereof) as a consolidating medium. The resultant assembly is placed and loaded in a HIP unit. The pressure is varied between 20 MPa and 500 MPa and temperature is varied between 900° C. to 1400° C. to achieve packing density greater than 95%, for example as shown in FIG. 10. The binder jet specimen is heated in the vacuum to a temperature sufficient to burn off binders before the specimen is placed in the HIP can filled with refractory powders. The temperature is then raised, and a pressing load is applied to produce deformation of the refractory metal powders and the deformation continues until the composite specimen densifies to greater than 99%, locking the specimen geometry in place.

[0209] The consolidated HIP samples are then heat treated in vacuum at preferably below 10.sup.−2 torr pressure or in dry hydrogen atmosphere with dew point of −40° C. or lower to achieve desired magnetic responses. The heat treatment is done in between 600° C. to 1200° C. for about 30 minutes to about 6 hours with a cooling ramp rate in between 50° C./hour to 300° C./hour. This heat treatment helps in phase transformation along with stress relieving and improves the permeability, induction, and core loss responses.

[0210] Referring to FIG. 12, the hot isostatic pressing processes described above can be summarized as follows:

[0211] 1) Preparing a HIP can for HIP'ing;

[0212] 2) Filling the HIP can with a soft magnetic composite powder, vacuuming and sealing the HIP can under vacuum or in an inert atmosphere; and

[0213] 3) Performing the HIP process with appropriate pressure, temperature, and time.

[0214] While the present invention has been described herein in detail in relation to one or more preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements; the present invention being limited only by the claims appended hereto and the equivalents thereof.