
Magnetic Hysteresis Tailoring of Additively Manufactured Fe-Ni Permalloy by Multiphysics-multiscale Simulation
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Fe-Ni permalloy has gained extensive attention in recent decades for its potential applications in various technological fields, largely due to its exceptional magneto-electric and mechanical properties. In conjunction with the proliferation of additive manufacturing (AM) technologies, recent research has extensively embraced the concept of designing Fe-Ni permalloy through AM. Nevertheless, concerns persist regarding the inhomogeneity in thermal-mechanical and magnetic behaviors of AM-produced permalloy, which is attributable to the complex and interactive physical processes, including mass and heat transfer, phase transitions, thermo-mechanical and magneto-elastic coupling [1], across a vast chronological and spatial scale. It is imperative to ascertain the dependence of the processing parameters and conditions on the successful production of AM-produced permalloy [2, 3]. In this study, we developed a powder-resolved multiphysics-multiscale phase-field simulation scheme for the AM-based hysteresis tailoring of Fe-Ni permalloy. The underlying physical processes, including the coupled thermal-structural evolution, chemical order-disorder transitions, and associated thermo-elasto-plastic behaviors, are explicitly considered and integrated, taking into account their chronological and spatial differences. The impact of processing parameters, particularly beam power and scan speed, is hierarchically organized and examined at varying scales. These include the geometry of the fusion zone, the evolution of residual stress and accumulated plastic strain, and the resulting coercivity of manufactured parts.