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Additive manufacturing (AM) offers an unprecedented opportunity for the quickproduction of complex shaped parts directly from a powder precursor. But itsapplication to functional materials in general and magnetic materials inparticular is still at the very beginning. Here we present the first attempt tocomputationally study the microstructure evolution and magnetic properties ofmagnetic materials (e.g. Fe-Ni alloys) processed by selective laser melting(SLM). SLM process induced thermal history and thus the residual stressdistribution in Fe-Ni alloys are calculated by finite element analysis (FEA).The evolution and distribution of the $\gamma$-Fe-Ni and FeNi$_3$ phasefractions were predicted by using the temperature information from FEA and theoutput from CALculation of PHAse Diagrams (CALPHAD). Based on the relationbetween residual stress and magnetoelastic energy, magnetic properties of SLMprocessed Fe-Ni alloys (magnetic coercivity, remanent magnetization, andmagnetic domain structure) are examined by micromagnetic simulations. Thecalculated coercivity is found to be in line with the experimentally measuredvalues of SLM-processed Fe-Ni alloys. This computation study demonstrates afeasible approach for the simulation of additively manufactured magneticmaterials by integrating FEA, CALPHAD, and micromagnetics.

Computational study on microstructure evolution and magnetic property of laser additively manufactured magnetic materials