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Aluminum/SmCo5 composites for structural and magnetic applications

  • Composites & nanocomposites
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Abstract

Metal-bonded magnetic composites (MBMCs) present a promising alternative to dense sintered magnets, particularly for intricate components. Compared to polymer-based bonded magnets, MBMCs have wider applicability in harsh environments. In this paper, we demonstrate a solid-state shear-based manufacturing technique to introduce localized magnetization into a paramagnetic aluminum matrix by embedding SmCo5 permanent magnet particles. Our magnetic composites display hard magnetic behavior with a coercivity of 13 kOe and a remanent magnetization of 4.32 emu/g. In addition to magnetization, we also report a 9% improvement in Young’s modulus. Despite the local temperature rise during processing, the magnetic phases didn’t decompose into unwanted phases, preserving the composite’s hard magnetic properties. Creation of an interfacial metallurgical bond with the matrix ensured the suitability of the composites for structural applications. Our study investigates the mechanical, and functional properties of composites, paving the way for lightweight structural magnetic composites with a transformative potential in the aerospace, nuclear, and automotive applications. This work underscores the potential for further optimization and development to drive innovations in magnet and equipment design.

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Acknowledgements

The research is supported by ONR under grant N00014-23-1-2758 and was performed at the Center for Additive Manufacturing and Logistics (CAMAL) of North Carolina State University. The microstructural characterization was performed at the Analytical Instrumentation Facility (AIF) at North Carolina State University, which is supported by the State of North Carolina and the National Science Foundation (award number ECCS-2025064). The AIF is a member of the North Carolina Research Triangle Nanotechnology Network (RTNN), a site in the National Nanotechnology Coordinated Infrastructure (NNCI). The authors acknowledge the Manufacturing Technology Inc. friction stir processing facility available at the Center for Friction Stir Processing (CFSP) at the University of North Texas. The authors are very grateful to Anurag Gumaste at the University of North Texas for helping with the friction-stir experiments. ME acknowledges support from U.S. DOE, Vehicle Technologies Office, through the Powertrain Materials Core Program. Pacific Northwest National Laboratory is operated by Battelle for the U.S. Department of Energy (DOE) under contract DE-AC05-76RL01830.

Funding

Office of Naval Research Global, N00014-23-1-2758, Bharat Gwalani, National Science Foundation, ECCS-2025064.

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Authors and Affiliations

  1. Department of Materials Science and Engineering, North Carolina State University, Raleigh, NC, 27695, USA

    Farhan Ishrak, Michael Lastovich, Aniruddha Malakar, Huimin Qiao, Matthew Clary, Joseph Tracy, Nina Balke & Bharat Gwalani

  2. Department of Mechanical Engineering, University of North Texas, Denton, TX, 76203, USA

    Ravi Sankar Haridas

  3. Advanced Light Source, Lawrence Berkeley National Laboratory, Berkeley, CA, 94720, USA

    Arun J. Bhattacharjee & Harrison P. Lisabeth

  4. Lawrence Berkeley National Laboratory, Energy Geosciences Division, Berkeley, CA, 94720, USA

    Arun J. Bhattacharjee & Harrison P. Lisabeth

  5. Department of Materials Science and Engineering, University of North Texas, Denton, TX, 76203, USA

    Rajiv Mishra

  6. Energy and Environment Directorate, Pacific Northwest National Laboratory, Richland, WA, 99352, USA

    Mert Efe

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  1. Farhan Ishrak
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Correspondence to Bharat Gwalani.

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Ishrak, F., Lastovich, M., Malakar, A. et al. Aluminum/SmCo5 composites for structural and magnetic applications. J Mater Sci (2024). https://doi.org/10.1007/s10853-024-10208-3

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