With the rapid expansion of additive manufacturing (AM) technologies, designing magnetic materials through AM process has gained significant traction in recent years. However, challenges persist, particularly concerning the inhomogeneity in morphology, thermal-mechanical and magnetic hysteresis behaviors of AM-produced magnets. These challenges arise from complex, interactive physical effects across broad chronological and spatial scales [1,2,3]. Understanding their dependency on processing parameters and conditions [4,5] is crucial for the successful production of AM magnets. Given that establishing process-property relationships requires a substantial volume of data, often accompanied by extensive trial-and-error efforts, establishing a simulation-powered framework is increasingly gaining attention in delivering or augmenting the necessary data.

In this study, we developed a powder-resolved multiphysics-multiscale simulation framework for the AM-based hysteresis tailoring , facilitating a data-driven exploration of the processing-property relationship. This framework explicitly considers and integrates the underlying physical effects, including the coupled thermal-structural evolution, chemical order-disorder transitions, and associated thermo-elasto-plastic behaviors, while accounting for their chronological and spatial scale differences. We placed a special focus on the hierarchical impact of processing parameters, particularly beam power and scan speed, analyzing them across different scales. This includes examining the geometry of the fusion zone, the evolution of residual stress and plastic strain accumulation, and the resultant coercivity in the manufactured components.

[1] Y. Yang, npj Comput. Mater, 2023, 9, 103
[2] M. Yi, Comput. Mech., 2019, 64, 917.
[3] A. R. Balakrishna, npj Comput. Mater, 2021, 8, 4.
[4] Y. Yang, npj Comput. Mater, 2019, 5, 81.
[5] Y. Yang, npj Comput. Mater, 2024, under review.