Relating laser powder bed fusion process parameters to (micro)structure and to soft magnetic behaviour in a Fe-based bulk metallic glass

Abstract

This work aims to establish fundamental processing-(micro)structure-property links in a commercial Fe-based Kuamet6B2 bulk metallic glass (BMG) processed by laser powder bed fusion (LPBF). With that purpose, amorphous powders were processed using a pulsed-wave system and a simple meander strategy. The laser power, the scan speed, and the hatch distance were varied over wide intervals within the conduction regime. The processability window leading to samples with good dimensional accuracy and mechanical stability was determined. Within this window, the manufactured samples were crystalline/amorphous composites and the crystalline regions were formed by equiaxed ultrafine and nanograins with random orientations. Processing parameters yielding the densest prints caused severe crystallization while, conversely, parameter sets allowing the material to retain a high amorphous fraction led to significant lack-of-fusion defects and residual cracking along directions perpendicular to crystalline/amorphous interfaces. Comparatively, for a fixed hatch distance, the scanning speed had a stronger effect than the laser power in the resulting amorphous fraction due to its stronger influence on the melt pool size and, in turn, on the corresponding HAZ volume. The saturation magnetization and the coercive field were inversely related to the amorphous fraction. This work allows to derive fundamental guidelines for the successful additive manufacturing of soft magnetic Fe-based bulk metallic glasses (BMGs) by laser powder bed fusion (LPBF).