Shape-controlled crystal growth of Fe-Ga alloys to apply a magnetostrictive vibration energy harvester

Highlights: • Shape-controlled Fe-Ga alloy crystals were successfully grown using the μ-PD method. • High growth rate achieves high concentration homogeneity along the growth direction. • The as-grown Fe-Ga alloys shown the magnetostriction 3/2λ = 286 ppm. • A prototype vibration energy harvester showed good performance. Cross-sectional shape-controlled Fe-Ga alloy crystals for energy harvester applications were grown using the micro pulling down (μ-PD) method. The investigation of material concentrations along the growth direction reveals that a high growth rate of 5.0 mm/min raises the effective segregation coefficient of Ga, k_eff (Ga), and ensures high concentration homogeneity. However, the high growth rate was speculated as causing non-preferentially oriented portion formation that decreases the magnetostrictive property. The magnetostriction 3/2λ = 286 ppm was achieved for a good oriented sample (i.e. the misorientations from 100 were less than 7.5°.) with the Ga concentration of 16.8 at%. A prototype vibration energy harvester using a plate-shaped Fe-Ga alloy grown at 5.0 mm/min showed comparable or superior performance to the device using commercially available alloys. By leveraging the advantages of near net-shape controlling and a higher growth rate than other crystal growth techniques, the μ-PD method is expected to emerge as a new technique for mass-producing Fe-Ga alloys as materials for energy harvester applications.