In-situ alloying laser powder bed fusion of Ni-Mn-Ga magnetic shape memory alloy using liquid Ga

Ni-Mn-Ga-based magnetic shape memory alloys can exhibit large magnetic field induced strains (MFIS). Recently, additive manufacturing techniques, especially laser powder bed fusion (L-PBF), have been successfully used to manufacture functional polycrystalline Ni-Mn-Ga with complex geometries, such as 'bamboo-grained' lattice structures. However, previous approaches of L-PBF of Ni-Mn-Ga have used pre-alloyed powders, which can limit the compositional freedom of the manufactured devices. This study explores, for the first time, the feasibility of an in-situ L-PBF alloying approach using a powder blend of elemental Ni, Mn, and Ga. Promising results were obtained despite the significant differences between the elemental Ni and Mn powders and the liquid Ga. The microstructure of the as-built sample showed distinct stripe patterns from the 14 M structure confirmed by XRD analysis. Heat-treatment significantly improved chemical homogeneity, dissolved the Ni-rich phase but couldn't dissolve MnO hindering the shape memory effect.