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Abstract: Bonded magnets are composite materials consisting of polymer matrix and magnetic powders, prepared by rapid solidification processes from Nd-Fe-B alloys. They are synthesised by the compounding process on a twin-screw extruder, whereby, the finished products of complex shapes can be made from bonded magnets using injection moulding or 3D printing by fused deposition modelling method (FDM). The main advantages of 3D printing are the possibility to produce parts with complex geometries that are not possible with traditional manufacturing techniques and low-cost production of small batches. The aim of the research work was to identify the optimum processing parameters, which would give 3D printed bonded magnets characteristics similar to those produced by injection moulding. The characterization of the microstructure of bonded magnets was made on cryo-fractured, conventionally mechanically prepared and ion beam polished samples. The microstructures of bonded magnets were analysed by stereo, optical and scanning electron microscopy. Additionally, the influence of the 3D printing parameters on the magnetic properties has been examined. The results of the research work have shown that desired magnetic properties of 3D printed bonded magnets can be obtained by optimizing the thickness of the printed layer, printing speed and flowrate. In addition, it was revealed that selection of the materialographic preparation method plays a crucial step for correct microstructural characterization. Namely, the impropriate sample preparation results in artifacts that are mostly misinterpreted as microstructural defects (pores, cracks, non-adherent layers, etc.) accidently caused during 3D printing.
Keywords: bonded magnets, fused deposition modelling, microstructure, Ion beam polishing
Published in DKUM: 03.07.2025; Views: 0; Downloads: 2
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Abstract: Magistrsko delo obravnava razvoj postopka izdelave stelitne zlitine v laboratorijskem okolju, ki se uporablja v zobni protetiki za kovinska ogrodja zobnih protez. Predstavljeni so postopki vakuumskega indukcijskega litja in termo-mehanske obdelave (visokotemperaturno homogenizacijsko žarjenje, mehko žarjenje in kovanje). Obrazložene so mehanske in fizikalne lastnosti ter mikrostruktura stelitnih zlitin v odvisnosti od pogojev, načina litja in termo-mehanske obdelave. Pojasnjena je prednost vakuumskega indukcijskega litja v kovinske kokile v primerjavi z litjem v enkratne peščene forme. Magistersko delo obravnava tudi okoljski vidik vakuumskega indukcijskega taljenja in ulivanje stelitnih zlitin v forme. S svetlobnim in vrstičnim elektronskim mikroskopom je bila v okviru raziskav opravljenih v tem magistrskem delu okarkterizirana mikrostruktura sletitne zlitine. Določene so bile tudi fizikalne in mehanske lastnosti te stelitne zlitine. V sklepnem delu smo dokazali, da je lahko z uporabo vakuumskega indukcijskega litja in naknadne termo-mehanske obdelave zmanjšana prisotnost livarskih napak. To so lunkerji, kristalne in blokovne izceje, razpoke, vključki, plinska in krčilna poroznost. Tako izdelamo stelitno zlitino, ki ustreza lastnostim, ki so za ta tip zlitin podane v standardu ASTM F75
Keywords: Stelitne zlitine, vakuumsko indukcijsko litje, kovinska kokila, poroznost, karbidi, mikrostruktura
Published in DKUM: 05.05.2025; Views: 0; Downloads: 15
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Abstract: A new silver-based alloy with 2 wt.% of lanthanum (La) was studied as a potential candidate for electric contact material. The alloy was prepared by rapid solidification, performed by the melt spinning technique. Microstructural examination of the rapidly solidified ribbons revealed very fine grains of αAg and intermetallic Ag5La particles, which appear in the volume of the grains, as well as on the grain boundaries. Rapid solidification enabled high microstructural refinement and provided a suitable starting microstructure for the subsequent internal oxidation, resulting in fine submicronsized La2O3 oxide nanoparticle formation throughout the volume of the silver matrix (αAg). The resulting nanostructured Ag-La2O3 microstructure was characterised by high-resolution FESEM and STEM, both equipped with EDX. High-temperature internal oxidation of the rapidly solidified ribbons essentially changed the microstructure. Mostly homogeneously dispersed nano-sized La2O3 were formed within the grains, as well as on the grain boundaries. Three mechanisms of internal oxidation were identified: (i) the oxidation of La from the solid solution; (ii) partial dissolution of finer Ag5La particles before the internal oxidation front and oxidation of La from the solid solution; and (iii) direct oxidation of coarser Ag5La intermetallic particles.
Keywords: Ag-La alloy, rapid solidification, metastable microstructure, internal oxidation, characterisation, formation mechanism
Published in DKUM: 20.03.2025; Views: 0; Downloads: 1
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Abstract: The present study reports the development of new polymer bonded magnet containing a Thermoplastic Polyurethane (TPU) – Nylon (PA12) blend as the matrix material and Nd-Fe-B magnetic particles. Two composite materials were explored: one using Nd-Fe-B atomised spherical powder (ASP) and another incorporating Nd-Fe-B melt-spun flakes (MSF). The filaments were formulated by blending TPU, PA12, and one of selected type of Nd-Fe-B particles using a mixing device. The ASP and the MSF were integrated into the matrix via a precise compounding process and 3D printing was used to produce the testing specimens. The preliminary findings indicate that both formulations exhibited promising magnetic properties while maintaining the mechanical characteristics of TPU and PA12. The atomised spherical powder formulation demonstrated worse magnetic behaviour compared to the melt-spun flake formulation. ASP particles enable better fluidity of the composite material during 3D printing. However, the close-packed arrangement of these particles is the cause of much higher porosity and consequently the poorer mechanical and magnetic properties. Optimization of the processing parameters showed significant influence on the final magnetic performance and structural integrity of the printed specimens.
Keywords: bonded magnets, Nd-Fe-B melt spun flakes, Nd-Fe-B atomised powders, material extrusion, additive manufacturing, fused specimen fabrication
Published in DKUM: 08.01.2025; Views: 0; Downloads: 14
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Abstract: The production of personal protective equipment (PPE) has increased dramatically in recent years, not only because of the pandemic, but also because of stricter legislation in the field of Employee Protection. The increasing use of PPE, including disposable surgical masks (DSMs), is putting additional pressure on waste collectors. For this reason, it is necessary to find high-quality solutions for this type of waste. Mechanical recycling is still the most common type of recycling, but the recyclates are often classified as low-grade materials. For this reason, a detailed analysis of the recyclates is necessary. These data will help us to improve the properties and find the right end application that will increase the value of the materials. This work represents an extended analysis of the recyclates obtained from DSMs, manufactured from different polymers. Using surface and morphology tests, we have gained insights into the distribution of different polymers in polymer blends and their effects on mechanical and surface properties. It was found that the addition of ear loop material to the PP melt makes the material tougher. In the polymer blends obtained, PP and PA 6 form the surface (affects surface properties), while PU and PET are distributed mainly inside the injection-molded samples.
Keywords: mechanical recycling, disposable surgical mask, morphology, surface properties, mechanical properties, nonwoven materials, PPE
Published in DKUM: 09.04.2024; Views: 232; Downloads: 25
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