Method to fabricate high density and strength magnetic alloy

High Si electrical steel has the potential to be both efficient and cost effective. Increasing Si content improves magnetic and electrical properties, with 6.5wt.% being optimum. At 6% Si, the steel is too brittle to be cold rolled or stamped. The current manufacturing method diffuses Si into the thin gauge 3.2% Si steel after chemical deposition. Manufacturing cost is high, productivity is limited, and the final product is brittle and difficult to stamp. The main goal of the proposed concept is to design, develop, and implement a scalable manufacturing process to fabricate Fe with 6% Si steel with high magnetization, high electrical resistivity, high permeability and low coercivity. The proposed process uses manufacturing methods to print near net-shape Fe-Si magnets.

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