Producing soft magnetic alloys by additive manufacturing has the potential to overcome cracking and brittle fracture issues associated with conventional thermomechanical processing. Fe-Co alloys exhibit high magnetic saturation but low ductility that makes them difficult to process by commercial methods. Ni-Fe alloys have good ductility and high permeability in comparison to Fe-Co, but they suffer from low magnetic saturation. Functional grading between Fe-Co and Ni-Fe alloys through blown powder directed energy deposition can produce soft magnetic materials that combine and enhance properties beyond the strengths of the individual magnetic materials. This work focuses on the microstructure, crystal structure, and magnetic properties of functionally graded Fe49Co49V2/Ni80Fe16Mo4 coupons. The grading between the two materials is found to refine the microstructure, thereby improving the mechanical hardness without the use of a nonmagnetic element. Postbuild thermal treatments are found to recrystallize the microstructure and increase the grain size, leading to improved magnetic properties. Analysis of crystal structures provides an understanding of the solubility limits and phase equilibria between the BCC (Fe-Co) and FCC (Ni-Fe) structures. Success in functional grading of soft magnets may provide a pathway toward improving energy conversion efficiency through strategic combinations of high saturation and high strength materials.
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