Galfenol alloys show promise as a new magnetically activated smart material based on their unique combination of
relatively high magnetostrictive performance and good mechanical robustness. Investigations of aluminum additions to
single crystal iron-gallium alloys have been done previously, and the magnetostrictive response seems to follow the rule
of mixtures with decreasing saturation magnetostriction with increasing aluminum content. Aluminum is assumed to
substitute for Ga directly in the alloy. Directionally solidified polycrystalline Galfenol alloys with aluminum additions
were produced to determine the effects on the magnetic properties. Iron-gallium-aluminum alloys were investigated for
two primary reasons: (1) Fe-Al alloys are well established and are typically manufactured using conventional thermo-mechanical
processing techniques such as rolling; it is anticipated that aluminum additions will aid in the development
of Galfenol alloy rolled sheets (2) Gallium prices continue to rise and a cost effective alternative needs to be
investigated.
Several Fe-Ga-Al alloy compositions were prepared using the Free Stand Zone Melting (FSZM) directional
solidification technique. Alloy composition ranges investigated include: Fe80.5GaxAl19.5-x (4.9≤x≤13), Fe81.6GayAl18.4-y
(4.6≤y≤13.8), and Fe85GazAl15-z (3.75≤z≤11.25). Alloys were studied using EDS (chemistry verification), EBSD
(crystallite orientation), and magnetic characterization techniques to determine the effect of aluminum addition on the
polycrystalline binary Fe-Ga system. Magnetic properties such as saturation magnetostriction (λsat), piezomagnetic
constant (d33), and relative magnetic permeability (μr) of directionally solidified Fe-Ga-Al polycrystalline alloys will be compared to binary Fe-Ga alloys including investigations into the crystal orientation effects on these properties. Results suggest that up to 50% aluminum can be substituted in the alloy while maintaining considerable saturation
magnetostriction, > 200 ppm.
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