Publications

An additive manufacturing design approach to achieving high strength and ductility in traditionally brittle alloys via laser powder bed fusion

Babuska, Tomas F.; Johnson, Kyle J.; Verdonik, Trevor; Subia, Samuel R.; Krick, Brandon A.; Susan, D.F.; Kustas, Andrew K.

Additive Manufacturing (AM) presents unprecedented opportunities to enable design freedom in parts that are unachievable via conventional manufacturing. However, AM-processed components generally lack the necessary performance metrics for widespread commercial adoption. We present a novel AM processing and design approach using removable heat sink artifacts to tailor the mechanical properties of traditionally low strength and low ductility alloys. The design approach is demonstrated with the Fe-50 at.% Co alloy, as a model material of interest for electromagnetic applications. AM-processed components exhibited unprecedented performance, with a 300 % increase in strength and an order-of-magnitude improvement in ductility relative to conventional wrought material. These results are discussed in the context of product performance, production yield, and manufacturing implications toward enabling the design and processing of high-performance, next-generation components, and alloys.