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Abstract <p>The influence of laser path rotation on the microstructure and multifunctional properties of high-silicon steel fabricated by powder bed fusion-laser beam was investigated using a high-throughput approach. Four laser path rotation angles were incorporated within a single build to directly correlate processing, structure, and coupled properties. Grain morphology and crystallographic texture were strongly governed by the laser path. A 90° rotation promoted elongated columnar grains with a pronounced ⟨001⟩ fiber texture along the build direction, whereas the 0° condition produced narrower columnar grains with largely random orientation. These variations resulted in distinct functional responses: the as-printed 90° condition exhibited the lowest coercivity of 81 A/m, while the 0° condition showed the highest electrical resistivity of 228 µΩ·cm and hardness of 416 HV. Annealing at 1150°C reduced coercivity to ~35 A/m while retaining high magnetization and elevated resistivity. These findings demonstrate that laser path engineering enables tunable magnetic, electrical, and mechanical performance in high-silicon steel.</p> Impact Statement <p>Additive manufacturing is often associated with geometric freedom, but its deeper potential lies in controlling how materials solidify and evolve. This work shows that laser path design can be used to program microstructure within a single material, without altering composition. By isolating laser path rotation within a single build, a clear link is established between scan strategy, crystallographic texture, grain morphology, and functional response. The results highlight how texture alignment and grain-boundary density govern domain wall motion and electrical transport in Fe–6.5 wt% Si.</p> <p>This shifts process-path design from a secondary parameter to a primary tool for materials engineering, comparable to composition or heat treatment. Such control enables spatial tuning of anisotropy and multifunctional properties within a single component. For electrical machines, this opens new possibilities to locally balance magnetic softness and electrical resistivity, reducing energy losses without added materials or complex architectures. More broadly, the study points toward a future where manufacturing strategies are used not only to shape components, but to embed functionality directly into their internal structure, supporting more efficient and sustainable energy technologies.</p> Graphical abstract <p></p>

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Laser path engineering of microstructure and multi-properties in additively manufactured high-silicon steel

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月6日

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  • Mukesh Murali,
  • Eduard Hryha,
  • Uta Klement,
  • Varun Chaudhary

摘要

Abstract

The influence of laser path rotation on the microstructure and multifunctional properties of high-silicon steel fabricated by powder bed fusion-laser beam was investigated using a high-throughput approach. Four laser path rotation angles were incorporated within a single build to directly correlate processing, structure, and coupled properties. Grain morphology and crystallographic texture were strongly governed by the laser path. A 90° rotation promoted elongated columnar grains with a pronounced ⟨001⟩ fiber texture along the build direction, whereas the 0° condition produced narrower columnar grains with largely random orientation. These variations resulted in distinct functional responses: the as-printed 90° condition exhibited the lowest coercivity of 81 A/m, while the 0° condition showed the highest electrical resistivity of 228 µΩ·cm and hardness of 416 HV. Annealing at 1150°C reduced coercivity to ~35 A/m while retaining high magnetization and elevated resistivity. These findings demonstrate that laser path engineering enables tunable magnetic, electrical, and mechanical performance in high-silicon steel.

Impact Statement

Additive manufacturing is often associated with geometric freedom, but its deeper potential lies in controlling how materials solidify and evolve. This work shows that laser path design can be used to program microstructure within a single material, without altering composition. By isolating laser path rotation within a single build, a clear link is established between scan strategy, crystallographic texture, grain morphology, and functional response. The results highlight how texture alignment and grain-boundary density govern domain wall motion and electrical transport in Fe–6.5 wt% Si.

This shifts process-path design from a secondary parameter to a primary tool for materials engineering, comparable to composition or heat treatment. Such control enables spatial tuning of anisotropy and multifunctional properties within a single component. For electrical machines, this opens new possibilities to locally balance magnetic softness and electrical resistivity, reducing energy losses without added materials or complex architectures. More broadly, the study points toward a future where manufacturing strategies are used not only to shape components, but to embed functionality directly into their internal structure, supporting more efficient and sustainable energy technologies.

Graphical abstract