Salah, Mohammad2025-01-242025-01-242025-01-23vt_gsexam:42422https://hdl.handle.net/10919/124335The presented research explores the Wire-Laser Direct Energy Deposition of Fe17Co alloy for soft magnetic applications. Process parameters starting from power, feed speed, and feed/scan ratios were optimized where a high confidence multi-factor regression model was developed correlating the processing parameters to final bead dimensions. The model showed that increasing feed speeds led to an increase in bead height and a reduction in bead width while increasing feed/scan ratio resulted in an increase of bead height and width. Interlayer cooling time for multi-layer deposition was tested and revealed, through thermal camera measurement, that increasing interlayer cooling time leads to a higher cooling rate, and generally more stable printing process. Printed samples showed single phase BCC with fine equiaxed structure and high density (>98.5%) with no pores or cracks. ASTM A773 sample rings were printed and showed that for decreasing input energy (by decreasing power or increasing feed speed) leads to a finer grain structure. The average diameter grain size of the printed samples was 18.7 microns and grew to an average of 26.5 microns after a pre-anneal heat treatment at 700°C for 2 hours followed by 850°C for 10 hours. Furthermore, using interlayer cooling time, the thermal gradient of the samples throughout the printing was increased and lead to even finer grain structure. However, this lead to increased grain growth post annealing. Printed samples showed good magnetic properties, but slightly less than that of the commercial wrought material.ETDenIn CopyrightAdditive ManufacturingSoft MagneticsCobalt IronHall ThrustersThesis