Fe-6.5 wt.% Si alloy offers promising soft magnetic properties such as high permeability, low iron loss, and near-zero magnetostriction, making it attractive for high-speed motors, high-frequency transformers, and aerospace electromagnetic devices. However, when the Si content approaches 6.5 wt.%, B2 and D03 ordered phases readily form during cooling, significantly increasing room-temperature brittleness and limiting conventional rolling and processing. Laser powder bed fusion (LPBF) provides a new route for integrated manufacturing of complex high-silicon steel components, and its high cooling rate can suppress ordered phase formation, but the alloy's inherent high crack susceptibility leads to cracks and porosity during forming. The related research was published in the Journal of Materials Research and Technology. The researchers prepared Y2O3/Fe-6.5 wt.% Si composite powders by low-energy mechanical mixing and used LPBF to fabricate samples with different Y2O3 addition levels. The study notes that under intense LPBF laser irradiation (>2500 °C) and violent Marangoni convection, metallic rare-earth elements tend to selectively evaporate and be lost, and to segregate along grain boundaries to form coarse brittle intermetallic compounds. In contrast, pre-synthesized Y2O3 has a high melting point (about 2410 °C) and high thermodynamic stability, and is expected to regulate columnar grain boundary migration through particle-grain boundary interactions, accommodate local strain concentration, and provide Zener pinning pressure during high-temperature annealing to control grain growth. The results show that an appropriate Y2O3 addition (0.1 wt.% equivalent Y content) increased relative density from 98.64% to 99.86%, reduced crack length density from 0.633 mm/mm2 to 0.465 mm/mm2, and refined the average grain size from 89.24 μm. This research directly links the LPBF process in metal additive manufacturing with metal powder materials: mechanically mixed Y2O3/Fe-6.5 wt.% Si composite powder is used as the LPBF feedstock, and the study examines the effects of powder modification on densification, crack suppression, grain evolution, and soft magnetic properties, falling within the scope of metal powder preparation and metal additive manufacturing process materials.