University of Pittsburgh scientists have developed novel techniques using lasers to process amorphous and nanocrystalline soft magnetic alloys. This includes both pulsed laser patterning for precise engineering of magnetic domains and continuous wave (CW) rapid annealing compatible with continuous in-line processing. This innovative approach offers precise control over the microstructure and magnetic structure of soft magnetic alloys, enabling tailored manipulation of magnetic properties and material structure. With applications spanning power electronics and electric vehicles, this technology promises enhanced scalability, performance, and efficiency.
Annealing with a continuous wave (CW) or pulsed laser can control the temperature of the exposed material both spatially and temporally, enabling spatially optimized thermal processing.
Description
Laser processing harnesses rapid heating/cooling rates to induce localized changes in the internal structure of alloys. Pulsed laser patterning enables tailored domain structures, minimizing energy losses and maximizing magnetic efficiency, while CW annealing improves magnetic efficiency and mechanical properties. This technology is compatible with large-scale manufacturing, catering to diverse industry needs.
Applications
• Precision engineering of magnetic properties
• Tailored manipulation of amorphous and nanocrystalline alloys
• Manufacturing, including power electronics and electric vehicles
Advantages
Control of alloy structure is an essential part of manufacturing in a broad range of industries. Rapid annealing provides distinct benefits to magnetic and mechanical properties compared to conventional annealing, and CW laser annealing is more compatible with in-line processing than other rapid techniques such as flash annealing. Using superior heating and cooling rates of laser patterning allows for even finer control and customization of microstructures. Extremely fast heating and cooling rates of 106–108 K/s can lead to unprecedented levels of spatial control and produce microstructures of the required magnetic properties. These intricate structures can be sculpted to have improved magnetic properties and reduced energy loss. This approach is scalable and has great potential for industry.
Invention Readiness
Recent work found that heating amorphous ribbons with pulsed and continuous lasers at varying power levels could control the microstructure and magnetic properties of alloys. Additionally, crystalline peaks of nanometer scale diameter were observed suggesting intermetallic phases could be formed. Further work is required to optimize and refine this approach for tailored microstructures of amorphous and nanocrystalline alloys and for large scale manufacturing.
IP Status
https://patents.google.com/patent/WO2024145508A2Related Publication(s)
Talaat, A., Greve, D. W., Leary, A., Liu, Y., Wiezorek, J., & Ohodnicki, P. R., Jr. (2022). Laser patterning assisted devitrification and domain engineering of amorphous and nanocrystalline alloys. AIP Advances, 12(3). https://doi.org/10.1063/9.0000314
