Upscaled laser synthesis of copper nanoparticles in acetone to correlate the surface modification of Nd-Fe-B feedstock properties with part properties after full melting and rapid solidification

The possibilities of nanoadditivation to achieve finer, more equiaxed grains unlock huge potential for the application field of functional materials, e.g. Nd-Fe-B magnets, where the control of the microstructure and the composition is of significant importance. The surface modification of hard magnetic microparticles by non-magnetic nanoparticles (NPs) opens a novel field of research. Here, especially Cu NPs with low amounts of oxides are of high relevance as colloidal nano-additive material. To increase the productivity of surfactant-free, laser-generated Cu NPs, we performed a process parameter study via laser ablation in acetone aiming for the highest possible productivity, increasing the throughput of NP additivation on the surface of functional feedstock micro powders. By optimizing the process parameters of laser power, laser fluence, repetition rate, volume flow, and spot size, a productivity of 0.19 µg/J of Cu NPs in acetone was achieved. Then we investigated how a fine microstructure of the magnet powder MQP-S can be retained to some extent along the process chain, throughout the melting and resolidification process during suction casting. A loading series of Cu NP nanoadditivation on magnet micro powders of 0.1, 0.5, 1.0, and 2.5 wt.% was analyzed regarding magnetic properties and microstructure of the as-built part. Using full melting conditions of MQP-S by producing samples via suction casting modified with different amounts of Cu NP additions leads to finer grains, but increasing α-Fe content. Overall, the results enable higher production rates of Cu NPs in acetone and provide insights into the influence of NP-supporting characteristics on the properties of permanent magnet micro powders after full melting and resolidification.