Magnetic Field-Assisted Additive Manufacturing Processes
Summary
Magnetic field–assisted additive manufacturing (MF-AM) integrates external magnetic fields into metal 3D-printing processes to exert precise control over melt-pool dynamics and solidification. By applying static or time-varying fields during layer-by-layer fusion, Lorentz forces and magnetohydrodynamic effects can suppress undesirable convection, refine grain structures and modify crystallographic textures. These mechanisms promote more uniform cooling, reduce porosity, and enable transitions from columnar to equiaxed grains, resulting in enhanced mechanical strength, ductility and surface integrity.
This approach spans several powder- and wire-based techniques, including laser powder bed fusion and directed energy deposition. Static fields are typically used to stabilise melt flows, while oscillating or gradient fields can tailor solute redistribution and residual stresses. The ability to manipulate microstructure in situ opens pathways for high-performance alloys in aerospace, biomedical implants and energy systems. Furthermore, MF-AM offers a non-contact, post-processing-free strategy to meet stringent global demands for reliability, customisation and material efficiency.
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Magnetic Field-Assisted Additive Manufacturing Processes publication trend
The graph below shows the total number of articles in magnetic field-assisted additive manufacturing processes across all publications each year (not limited to Nature Index journals).
Technical terms
Static magnetic field: A constant magnetic field applied during the AM process to influence molten-metal behaviour and solidification patterns.
Laser powder bed fusion: An additive manufacturing technique in which a laser selectively fuses successive layers of metal powder to build three-dimensional parts.
Direct energy deposition: A form of AM where a focused energy source melts material as it is deposited, allowing for targeted addition and repair of metal structures.
Lorentz force: The force exerted on moving charged particles in a magnetic field, driving fluid motion within the melt pool.
Marangoni effect: Flow induced by gradients in surface tension, which can cause uneven solidification if not controlled.
References
- Simultaneously enhanced strength and ductility of AlSi7Mg alloy fabricated by laser powder bed fusion with on-line static magnetic field. Virtual and Physical Prototyping (2023).
- Simulation of surface deformation control during selective laser melting of AlSi10Mg powder using an external magnetic field. AIP Advances (2019).
- Modification of Mechanical Properties in Directed Energy Deposition by a Static Magnetic Field: Experimental and Theoretical Analysis. Materials (2021).
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