Abstract Exploring the chemical micro- and nanostructure of metal alloys is essential to understand their physical properties, such as magnetism or hardness. Additively manufactured (AM) materials, e.g. via laser powder bed fusion (LPBF) followed by various heat treatments, can raise further questions concerning the printed material. For the in-situ alloyed, spinodal Fe54Cr31Co15 system, the macroscopic magnetic behaviour is greatly influenced by subsequent homogenisation and heat treatment steps. Here we show that the decomposition takes place on the nanometre scale, resulting in ferromagnetic FeCo-rich particles embedded in a Cr-rich matrix. By studying phenomena like chemical homogeneity, grain structure, and texture of the in-situ alloyed material at different scales, we reveal correlations between the heat treatment and the resulting nanostructure and its ferromagnetic properties. We found that the isothermal heating conditions determine the degree of phase segregation and that a homogenization step can be omitted for additively manufactured, in-situ alloyed FeCrCo alloys. The approach thereby offers insight and a path for also tailoring specific manufacturing parameters to provide the right quality printed materials with desired functionalities. For example, magnetic FeCrCo alloys are often used in electric motors or magnetic sensors, and the flexibility of the presented approach can lead to optimal use of the material.
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