Available Technology

Enhanced Functional Alloys with High Strength and Ductility

Additive manufacturing (AM) offers unprecedented design freedom that can lead to novel materials development. Intermetallic alloys have useful magnetic properties such as high permeability, low coercivity, and high saturation induction that are ideal for electromagnetic devices, particularly those in aerospace applications. However, when they are conventionally manufactured, these alloys are notoriously brittle and have poor mechanical properties that have impeded their commercialization in bulk form.

Researchers at Sandia National Laboratories and Lehigh University developed a technique to tailor the mechanical properties of traditionally low strength and low ductility alloys by introducing removable heat sink artifacts using laser beam powder bed fusion (LB-PBF) additive manufacturing. The technology enables the end-user to circumvent dependence on conventional manufacturing to achieve the desired material structure and function. This potentially impacts aerospace technologies and industries that would benefit from high strength and high ductility soft magnetic alloys, such as power generating units, internal generators for propulsion engines, and magnetic bearings.

Internal Laboratory Ref #: 
SD 15173
Patent Status: 
Pending
Patent Issue Date: 
October 6, 2021
Lab Representatives
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