Crack Intensity Reduction in Fe–6.5Si Alloy by Adding Cr and Controlling the Thermal Gradient

The Fe–6.5 wt.% Si alloy is a promising soft magnetic material for electric motor applications owing to its high electrical resistivity and low core loss. However, the intrinsic brittleness of this alloy precludes fabrication of thin laminates using conventional rolling processes. Laser Powder Bed Fusion (LPBF) has therefore been considered as an alternative manufacturing route, offering both geometric flexibility and the inherent advantages of additive manufacturing. Nevertheless, successful LPBF processing of Fe–6.5 wt.% Si has remained challenging due to its high-silicon content. In this study, the Fe–6.5 wt.% Si alloy was modified by introducing 1 wt.% Cr, and LPBF process variables were optimized to yield defect-free parts. The effect of Cr addition on suppressing the disorder–order phase transformation during solidification was investigated through Thermo-Calc® thermodynamic simulations and quantified via X-ray diffraction phase analysis. Crack morphology analysis from optical micrographs revealed a marked reduction in both solidification and liquation cracks, attributed to the role of Cr in mitigating silicon segregation and consequently lowering the fraction of ordered phases. Preheating the build plate to 200 °C was found to effectively eliminate vertical cracks by reducing thermal stresses within the parts; however, a limited number of horizontal cracks initiated at the sample edges and propagated inward, likely due to elevated thermal gradients at the perimeter. To address this issue, sacrificial walls were introduced at distances of 1.0 mm and 0.2 mm from the cube edges, locally reducing the cooling rates and effectively increasing the primary dendrite arm spacing (PDAS). The reduced cooling rate also led to lower lattice misorientation, confirmed by electron backscatter diffraction (EBSD), and a significant decrease in the crack length from ~2 mm to ~0.7 mm.