Publications
Novel ultrafine grain size processing of soft magnetic materials
High performance soft magnetic alloys are used in solenoids in a wide variety of applications. These designs are currently being driven to provide more margin, reliability, and functionality through component size reductions; thereby providing greater power to drive ratio margins as well as decreases in volume and power requirements. In an effort to produce soft magnetic materials with improved properties, we have conducted an initial examination of one potential route for producing ultrafine grain sizes in the 49Fe-49Co-2V alloy. The approach was based on a known method for the production of very fine grain sizes in steels, and consisted of repeated, rapid phase transformation cycling through the ferrite to austenite transformation temperature range. The results of this initial attempt to produce highly refined grain sizes in 49Fe-49Co-2V were successful in that appreciable reductions in grain size were realized. The as-received grain size was 15 {micro}m with a standard deviation of 9.5 {micro}m. For the temperature cycling conditions examined, grain refinement appears to saturate after approximately ten cycles at a grain size of 6 {micro}m with standard deviation of 4 {micro}m. The process also reduces the range of grain sizes present in these samples as the largest grain noted in the as received and treated conditions were 64 and 26 {micro}m, respectively. The results were, however, complicated by the formation of an unexpected secondary ferritic constituent and considerable effort was directed at characterizing this phase. The analysis indicates that the phase is a V-rich ferrite, known as {alpha}{sub 2}, that forms due to an imbalance in the partitioning of vanadium during the heating and cooling portions of the thermal cycle. Considerable but unsuccessful effort was also directed at understanding the conditions under which this phase forms, since it is conceivable that this phase restricts the degree to which the grains can be refined. Due to this difficulty and the relatively short timeframe available in the study, magnetic and mechanical properties of the refined material could not be evaluated. An assessment of the potential for properties improvement through the transformation cycling approach, as well as recommendations for potential future work, are included in this report.