Existing magnetic materials and manufacturing methods are inadequate for producing large-diameter Hall-effect thrusters (HETs) with adequate mechanical strength while achieving the desired magnetic properties. Cobalt-iron soft ferromagnetic alloys are desirable for soft magnetic applications, including Hall-effect thrusters, due to their unparalleled magnetic saturation, elevated permeability, high curie temperature, and extreme strength. Unfortunately, these alloys suffer from manufacturability problems due to low ductility and an inability to produce such alloys in large form factors. While Co-Fe soft magnetic products can be readily produced in sheets, production of large billets results in weak, brittle, and inhomogeneous materials Elementum 3D is proposing to develop an additive manufacturing (AM) process and material feedstock, suitable for fabrication of large-diameter HETs, from cobalt-iron based soft magnetic material. The ability for AM to produce these large structures directly from powder feedstock would overcome the unavailability of sufficiently sized iron-cobalt billets. Other AM advantages for production of Co-Fe soft magnetic products include, a favorable fly-to-buy ratio, improved design freedom, and an increase in thrust-to-weight ratio. The principle objective of the Phase I effort is to research, develop, and demonstrate a soft magnetic feedstock material and additive production process that is suitable for production of large-diameter Hall-effect thrusters, meeting the magnetic and mechanical performance targets. Potential NASA Applications (Limit 1500 characters, approximately 150 words): The major NASA applications include: Hall-effect thrusters, grapple fixtures, tool changers, and general purpose switchable magnets Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words): Some non-NASA applications include: airplane engines, privately owned spaceships, and transformers for power systems Duration: 6
