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.
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 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.
The major NASA applications include: Hall-effect thrusters, grapple fixtures, tool changers, and general purpose switchable magnets
Some non-NASA applications include: airplane engines, privately owned spaceships, and transformers for power systems