CPC H01F 1/055 (2013.01) [B33Y 80/00 (2014.12); C22C 38/005 (2013.01); C22C 38/06 (2013.01); C22C 38/08 (2013.01); C22C 38/105 (2013.01); C22C 38/30 (2013.01); H01F 1/0577 (2013.01); H01F 7/021 (2013.01); H01F 7/0278 (2013.01); H01F 13/003 (2013.01); H01F 41/0266 (2013.01); H01F 41/0273 (2013.01); C22C 2202/02 (2013.01)] | 22 Claims |
1. A method of making a magnet with tailored magnetism by additive manufacturing, said method comprising:
(a) providing a feedstock composition containing base particles and one or more surface-modifying particles that are chemically and/or physically disposed on surfaces of said base particles, wherein said surface-modifying particles are magnetic or magnetically susceptible;
(b) exposing a first amount of said feedstock composition to an energy source for melting in a scan direction, thereby generating a first melt layer;
(c) solidifying said first melt layer in presence of an externally applied magnetic field, thereby generating a magnetic metal layer containing a plurality of individual voxels;
(d) optionally repeating steps (b) and (c) a plurality of times to generate a plurality of solid layers by sequentially solidifying a plurality of melt layers in a build direction, thereby generating a plurality of magnetic metal layers; and
(e) recovering a magnet comprising said magnetic metal layer,
wherein said externally applied magnetic field has a magnetic-field orientation, defined with respect to said scan direction, that is selected to control a magnetic axis within said magnetic metal layer.
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