Magnetic performance and microstructural characterization of coldsprayed ferromagnetic materials

Cold Spray Additive manufacturing of metals has garnered significant attention in recent years due to its unique advantages over traditional manufacturing methods. This technology also offers considerable benefits in terms of optimization of manufacturing and logistics processes, particularly for the production of high-performance parts made from Fe, Ni, Si, Co, and Al alloys. These advantages make it an increasingly popular technology in sectors such as aerospace, medicine, and automotive, where performance and innovation are critical. This process not only allows for the production of larger-scale parts but also maintains the material in its nanocrystalline state throughout the operation, enabling better control over the quality, thermomechanical, and magnetic properties of the parts. These benefits largely explain the growing interest in recent years, although research in this area is still in its early stages. In particular, studies on nickel-iron alloys (FeNi) produced by the cold spray process, applied to fields such as miniaturized electrotechnics, telecommunications, thermal compensation, power electronics, and electrical safety devices, are few and almost non-existent. We then present some advancements on the manufacture of samples using CSAM technology, starting with a ferromagnetic iron-nickel powder with a Fe50-Ni50 composition, and to characterize their magnetic, thermomechanical, and microstructural properties.