Low-cost magnetic powder synthesis and near-net shape processing
Introduction
Modern engineering advances depend on a wide range of engineered components, each of which typically requires different levels of precision and accuracy within a tight tolerance and repeatability. In many cases, modern components are typically formed and machined from prefabricated metal powders − a process enabled by low-cost magnetic powder synthesis and near-net shape processing. This technology is the key to enabling rapid prototyping, accelerated product development and mass production of complex shapes, at low cost and with high-accuracy.
Low-cost magnetic powder synthesis
The use of metal powders as a raw material for advanced manufacturing processes is well established, as it enables a wide range of complex geometries and components to be formed and machined. The key to using metal powders for advanced engineering manufacturing processes is low-cost magnetic powder synthesis, to enable the formation of highly homogeneous metal particles of near-monodisperse size and shape.
It has been shown that ferromagnetic particles can be magnetically produced from a low-cost magnetic powder using relatively low cost magnetic fields. This process is called magnetic powder synthesis, and involves a specially designed and tailored field of a specified strength and frequency range. The process enables highly homogeneous magnetic particle size and shape distribution, which is an essential requirement for many engineering applications. It also enables the synthesis of polycrystalline particles, which are highly desired in advanced engineering applications, due to their ability to withstand high loads and produce desired mechanical properties.
Near-net shape processing
Once the magnetic powder synthesis process has been completed, the use of near-net shape processing can enable components with intricate shapes and high levels of complexity to be manufactured. This process involves a variety of forming technologies, including extrusion, machining, sintering and pressing. The process can enable components of diverse shapes and sizes to be formed from the ferromagnetic particles in a reproducible, uniform and efficient manner.
Extrusion is one example of near-net shape processing, which can enable complex geometries and components to be formed from ferromagnetic particles in uniform and consistent shapes. The process relies on the use of a mold or die to define the shape of the component. The ferromagnetic particles are then fed into the mold, which is then heated and pressed to form the desired shape. This process is highly effective in producing components with low complexity and repeatability at relatively low cost.
Sintering is another example of near-net shape processing that can enable highly intricate components to be formed from magnetic particle synthesis. The process relies on the use of a high temperature sintering process to fuse the particles together into a finished product. Sintering provides an effective way of producing components with sharp details and intricate patterns at low cost.
Conclusion
In summary, low-cost magnetic powder synthesis and near-net shape processing are key processes in modern engineering manufacturing and offer a highly efficient and cost-effective way of producing components with intricate shapes and high levels of complexity. This technology enables components to be formed and machined from prefabricated metal powders, thus reducing the cost and lead-time of product development. The use of magnetic powder synthesis and near-net shape processing is essential in the development of low-cost engineered components, and will continue to evolve in applications across a range of engineering disciplines.
