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Fabrication and Characterization of Fe 16 N 2 Micro‐Flake Powders and Their Extrusion‐Based 3D Printing into Permanent Magnet Form
Author(s) -
Zirhli Onur,
Gunduz Akdogan Nilay,
Odeh Yazan N.,
Misirlioglu I. Burc,
Devlin Eamon,
Akdogan Ozan
Publication year - 2020
Publication title -
advanced engineering materials
Language(s) - English
Resource type - Journals
SCImago Journal Rank - 0.938
H-Index - 114
eISSN - 1527-2648
pISSN - 1438-1656
DOI - 10.1002/adem.202000311
Subject(s) - materials science , magnet , ball mill , extrusion , flake , fabrication , composite number , chemical engineering , metallurgy , nanotechnology , composite material , mechanical engineering , medicine , alternative medicine , pathology , engineering
Fe 16 N 2 is a compound with giant saturation magnetization approaching or exceeding that of rare‐earth‐based permanent magnets. The abundance of its elements and low‐cost synthesis of this compound has made it highly attractive to replace rare‐earth‐based permanent magnets that are becoming ever more expensive to utilize in applications. Herein, its synthesis from Fe flakes by surfactant‐assisted high energy ball milling is demonstrated. The synthesized Fe flakes are then reduced under forming gas (Ar/H 2 ), followed by nitridation at low temperatures under ammonia (NH 3 ) gas. The formation of Fe 16 N 2 phase exceeding 50% by volumetric fraction is observed and confirmed by X‐ray diffraction and Mössbauer analysis. Following the Fe 16 N 2 flake synthesis, extrusion‐based 3D printing is used to check the feasibility of incorporation of the flakes into functional polymer matrix composites. For this purpose, an ink of intermixed synthesized powder with photoresist SU8 is used. Using the prescribed method, a prototype Fe 16 N 2 permanent magnet composite is successfully produced using an additive manufacturing approach. Such efficient production of Fe 16 N 2 powders via routes already applicable to magnet production and the consolidation of the powders with 3D printing are expected to open up new possibilities for next‐generation permanent magnet applications.