- Patent Number:
12023,759
- Appl. No:
18/102905
- Application Filed:
January 30, 2023
- نبذة مختصرة :
Some variations provide a method of tailoring the surface of a soft magnet, comprising: depositing an austenite-phase-stabilizing donor material on one or more first surface regions of a ferromagnetic receiver material; not depositing the austenite-phase-stabilizing donor material on one or more second surface regions of the ferromagnetic receiver material; laser melting the austenite-phase-stabilizing donor material into the first surface regions; and solidifying the molten austenite-phase-stabilizing donor material within the first surface regions, thereby selectively alloying the ferromagnetic receiver material in the first surface regions. Laser ablation may be utilized instead of laser melting. The first surface regions have a significantly higher magnetic permeability, following the selective alloying of the donor material, compared to the second surface regions. Soft magnets with surface-tailored magnetic permeability are provided by this technology, which is demonstrated using several examples. One commercial application is selectively alloyed soft magnets for a rotor in an electric motor.
- Inventors:
HRL Laboratories, LLC (Malibu, CA, US)
- Assignees:
HRL Laboratories, LLC (Malibu, CA, US)
- Claim:
1. A method of tailoring the surface of a soft magnetic material, said method comprising: (a) providing a selected ferromagnetic receiver material having a first surface; (b) providing a selected austenite-phase-stabilizing donor material; (c) depositing said selected austenite-phase-stabilizing donor material on one or more first surface regions of said ferromagnetic receiver material, wherein said first surface regions are regions within said first surface; (d) not depositing said selected austenite-phase-stabilizing donor material on one or more second surface regions of said ferromagnetic receiver material, wherein said second surface regions are regions within said first surface, and wherein said first surface regions and said second surface regions collectively form a selective pattern on said first surface; (e) laser melting said selected austenite-phase-stabilizing donor material into said one or more first surface regions, to form molten austenite-phase-stabilizing donor material; and (f) solidifying said molten austenite-phase-stabilizing donor material, to form solid austenite-phase-stabilizing donor material that is situated within said one or more first surface regions of said selective pattern, thereby selectively alloying said ferromagnetic receiver material in said one or more first surface regions, wherein said one or more first surface regions are characterized by a first average magnetic permeability, wherein said one or more second surface regions are characterized by a second average magnetic permeability, and wherein said first average magnetic permeability is higher than said second average magnetic permeability.
- Claim:
2. The method of claim 1 , wherein said method does not employ a mask.
- Claim:
3. The method of claim 1 , wherein said method does not employ a chemical treatment.
- Claim:
4. The method of claim 1 , wherein said selected austenite-phase-stabilizing donor material is deposited in step (c) as powder particles.
- Claim:
5. The method of claim 1 , wherein said selected austenite-phase-stabilizing donor material is deposited in step (c) as a film, foil, or mesh.
- Claim:
6. The method of claim 1 , wherein said selected ferromagnetic receiver material is selected from the group consisting of FeSi, FeNi, FeCo, NiCo, FeSiAl, and combinations thereof.
- Claim:
7. The method of claim 1 , wherein said selected austenite-phase-stabilizing donor material is selected from the group consisting of Ni, Mn, Co, Cr, Si, Mo, Nb, Ti, Mg, Cu, Al, N, C, B, and combinations thereof.
- Claim:
8. The method of claim 1 , wherein in step (c), said selected austenite-phase-stabilizing donor material is deposited on said one or more first surface regions using slurry coating, laser cladding, electron beam cladding, electroplating, electroless plating, wire arc deposition, chemical vapor deposition, physical vapor deposition, thermal spraying, plasma spraying, or a combination thereof.
- Claim:
9. The method of claim 1 , wherein following step (f), said one or more first surface regions have an average thickness from 1 micron to 3000 microns.
- Claim:
10. The method of claim 9 , wherein said average thickness is from 100 microns to 500 microns.
- Claim:
11. The method of claim 1 , wherein said first average magnetic permeability is at least 90% higher than said second average magnetic permeability.
- Claim:
12. The method of claim 1 , wherein said first average magnetic permeability is at least 99% higher than said second average magnetic permeability.
- Claim:
13. A method of tailoring the surface of a soft magnetic material, said method comprising: (a) providing a selected ferromagnetic receiver material having a first surface; (b) providing a selected austenite-phase-stabilizing donor material; (c) depositing said selected austenite-phase-stabilizing donor material on one or more first surface regions of said ferromagnetic receiver material, wherein said first surface regions are regions within said first surface; (d) not depositing said selected austenite-phase-stabilizing donor material on one or more second surface regions of said ferromagnetic receiver material, wherein said second surface regions are regions within said first surface, and wherein said first surface regions and said second surface regions collectively form a selective pattern on said first surface; and (e) laser ablating said selected austenite-phase-stabilizing donor material into said one or more first surface regions, to force said selected austenite-phase-stabilizing donor material to penetrate into said one or more first surface regions of said selective pattern, thereby selectively alloying said ferromagnetic receiver material in said one or more first surface regions, wherein said one or more first surface regions are characterized by a first average magnetic permeability, wherein said one or more second surface regions are characterized by a second average magnetic permeability, and wherein said first average magnetic permeability is higher than said second average magnetic permeability.
- Claim:
14. The method of claim 13 , wherein said method does not employ a mask or a chemical treatment.
- Claim:
15. The method of claim 13 , wherein said selected austenite-phase-stabilizing donor material is deposited in step (c) as powder particles.
- Claim:
16. The method of claim 13 , wherein said selected ferromagnetic receiver material is selected from the group consisting of FeSi, FeNi, FeCo, NiCo, FeSiAl, and combinations thereof.
- Claim:
17. The method of claim 13 , wherein said selected austenite-phase-stabilizing donor material is selected from the group consisting of Ni, Mn, Co, Cr, Si, Mo, Nb, Ti, Mg, Cu, Al, N, C, B, and combinations thereof.
- Claim:
18. The method of claim 13 , wherein in step (c), said selected austenite-phase-stabilizing donor material is deposited on said one or more first surface regions using electrodeposition, chemical vapor deposition, physical vapor deposition, thermal spraying, plasma spraying, or a combination thereof.
- Claim:
19. The method of claim 13 , wherein said one or more first surface regions have an average thickness from 1 micron to 3000 microns.
- Claim:
20. The method of claim 13 , wherein said first average magnetic permeability is at least 90% higher than said second average magnetic permeability.
- Claim:
21. The method of claim 1 , wherein steps (e) and (f) are conducted in the presence of an electromagnetic field.
- Claim:
22. The method of claim 13 , wherein step (e) is conducted in the presence of an electromagnetic field.
- Patent References Cited:
8400038 March 2013 Smith et al.
9715957 July 2017 Wang et al.
10269479 April 2019 Simon et al.
10692635 June 2020 Wang et al.
20060177702 August 2006 Ajan
20080121315 May 2008 Gigliotti et al.
20120021219 January 2012 Gabay et al.
20130045127 February 2013 Sugiyama et al.
20160133369 May 2016 Loginov et al.
20160307678 October 2016 Unosson et al.
20170154713 June 2017 Simon et al.
20170187258 June 2017 Fujikawa et al.
20220032585 February 2022 Zhang
20220044870 February 2022 Yahata et al.
102015212529 January 2017
WO-2009122709 October 2009
- Other References:
International Search Report and Written Opinion, PCT/US2023/011964, dated May 26, 2023. cited by applicant
Bodziony et al., “Magnetic Study of Nanocrystalline TiB2, TiC, B4C Powders Doped to AISI 316L Austenitic Steel”, Acta Physica Polonica A, No. 1, vol. 132, pp. 62-67 (2017). cited by applicant
Lamichhane et al., “Additive manufacturing of soft magnets for electrical machines—a review”, Materials Today Physics 15, 100255 (2020). cited by applicant
- Assistant Examiner:
Mills, Jr., Joe E
- Primary Examiner:
Ross, Dana
- Attorney, Agent or Firm:
O'Connor & Company
O'Connor, Ryan P.
- الرقم المعرف:
edspgr.12023759
Processing Request
No Comments.