Abstract: A method of pressure forming a brown part from metal and/or ceramic particle feedstocks includes: introducing into a mold cavity or extruder a first feedstock and one or more additional feedstocks or a green or brown state insert made from a feedstock, wherein the different feedstocks correspond to the different portions of the part; pressurizing the mold cavity or extruder to produce a preform having a plurality of portions corresponding to the first and one or more additional feedstocks, and debinding the preform. Micro voids and interstitial paths from the interior of the preform part to the exterior allow the escape of decomposing or subliming backbone component substantially without creating macro voids due to internal pressure. The large brown preform may then be sintered and subsequently thermomechanically processed to produce a net wrought microstructure and properties that are substantially free the interstitial spaces.

Abstract: A method of making a degradable alloy includes adding one or more alloying products to an aluminum or aluminum alloy melt; dissolving the alloying products in the aluminum or aluminum alloy melt, thereby forming a degradable alloy melt; and solidifying the degradable alloy melt to form the degradable alloy. A method for manufacturing a product made of a degradable alloy includes adding one or more alloying products to an aluminum or aluminum alloy melt in a mold; dissolving the one or more alloying products in the aluminum or aluminum alloy melt to form a degradable alloy melt; and solidifying the degradable alloy melt to form the product. A method for manufacturing a product made of a degradable alloy includes placing powders of a base metal or a base alloy and powders of one or more alloying products in a mold; and pressing and sintering the powders to form the product.

Abstract: Systems and methods for forming near net-shape metal parts from binderless metal powder are disclosed. Systems include a mold die that defines a die cavity and may include one or more ultrasonic transducers operatively coupled to the mold die. Systems may be configured to introduce binderless metal powder into a die cavity and/or to compact the binderless metal powder within the die cavity. Methods include introducing binderless metal powder into a die cavity of a mold die and compacting the binderless metal powder within the die cavity to form a green part within the die cavity. The binderless metal powder may include spheroidal metal particles and angular metal particles. The methods may further include separating the green part from the mold die and sintering the green part, after separating, to form a sintered near net-shape metal part.

Abstract: An orthopedic prosthesis and a method for rapidly manufacturing the same are provided. The orthopedic prosthesis includes a solid bearing layer, a porous bone-ingrowth layer, and an interdigitating layer therebetween. A laser sintering technique is performed to manufacture the orthopedic prosthesis.

Abstract: Provided is a powder for a magnetic core (1), including a soft magnetic metal powder (2); and an insulating coating film (3) covering a surface of the soft magnetic metal powder (2), in which the insulating coating film (3) is formed of an aggregate of crystals (4) obtained by cleaving a layered oxide. The crystals (4) are obtained by, for example, cleaving a swellable smectite-group mineral, which is one kind of swellable layered clay mineral as the layered oxide.

Abstract: Additive manufacturing methods for fabricating a fiber-reinforced composite objects include providing at least a first layer of powder material, disposing a fiber material adjacent the at least first layer of powder material to form a fiber reinforcement layer, and applying a laser energy to the at least first layer of powder material so as to fuse the powder material into at least a first laser fused material layer adjacent the fiber reinforcement layer of the fiber-reinforced composite object.

Abstract: A method of making a worm gear is provided. The method comprises forming a gear hub from a powdered metal material. Thereafter an outer surface of the gear hub is sealed.

Abstract: A method for producing silver powder wherein a silver solution containing a silver complex and a reductant solution are continuously mixed to provide a reaction liquid, the method including: a step of preparing a silver nucleus solution wherein a silver solution for nucleation which contains a silver complex, a solution containing a strong reductant, and a dispersant are mixed to provide the silver nucleus solution; a step of preparing a reductant solution containing nuclei wherein the silver nucleus solution obtained and a weak reductant having a standard electrode potential higher than that of the strong reductant are mixed to obtain the reductant solution containing nuclei; and a step of growing particles wherein the reductant solution containing nuclei and a silver solution for particle growth containing a silver complex are continuously mixed to provide a reaction solution, in which the silver complex is reduced to thereby grow silver particles.

Abstract: Provided are an apparatus for manufacturing a compound powder, a method of manufacturing an iron-boron compound powder by using the apparatus, a boron alloy powder mixture, a method of manufacturing the boron alloy powder mixture, a combined powder structure, a method of manufacturing the combined powder structure, a steel pipe, and a method of manufacturing the steel pipe The method of manufacturing the boron alloy powder mixture includes: preparing a mixed powder including a boron iron alloy powder and a target powder; heat-treating the mixed powder to boronize at least a portion of the target powder and de-boronize at least a portion of the boron iron alloy powder, thereby de-boronizing the boron iron alloy powder to reduce the melting point of the boron iron alloy powder.

Abstract: A method for manufacturing a cutting insert having a through-hole that extends in a direction that is non-parallel to the main pressing direction. The method includes the steps of moving first and second punches within a die cavity toward each other along a first pressing axis and compacting a powder around a core rod into a cutting insert green body, wherein, during at least a portion of the compaction step, the core rod is turned a predetermined angle in alternating direction around its longitudinal axis.

Abstract: A method provides a device having a feeder vessel, a building vessel with a bottom and a fabrication plate that is movable in vertical translation, a transfer system suitable for depositing powder from the feeder vessel to the building vessel as a powder layer of constant thickness, and a high energy beam optical system suitable for scanning the surface of the deposited powder layer. A powder is placed in the feeder vessel. A first series of powder layers is deposited on the fabrication plate. The particles of powder are melted or sintered to form a plurality of columns of material that are separated from one another by particles of powder. A second series of layers of powder is deposited on the first series of layers of powder particles to form a single-piece element. A thermal insulation platform is formed between the fabrication plate and said single-piece element.

Abstract: An apparatus for manufacturing an article from powder material includes a canister, a sorter, a plurality of hoppers and at least one valve. The canister has a predetermined internal shape to define the shape of the powder metal article. The sorter sorts the powder material by the size of the powder particles, the shape of the powder particles and/or the flow characteristics of the powder particles. The hoppers contain powder material with different sizes of powder particles, different shapes of powder particles and/or powder particles with different flow characteristics. The hoppers are arranged to supply the sorted powder material to the canister. The at least one valve controls the proportions of the different powder materials supplied from the one or more of the different hoppers into the canister to control the packing density of the powder material in the canister at all positions in the canister.

Abstract: A composite magnetic material contains metal magnetic powder composed of metal magnetic particles, and mica interposed between the metal magnetic particles as an inorganic insulator. The mica has an Fe content of 15 wt % or less per 100 wt % of the mica in terms of Fe2O3. To manufacture the composite magnetic material, first, mixed powder is prepared by mixing the metal magnetic powder and the mica so as to be dispersed into each other. Next, a compact is formed by pressure-molding the mixed powder. Finally, the compact is heat-treated.

Abstract: The present invention provides a method for producing an R-T-B-M sintered magnet having an oxygen content of less than 0.07 wt. % from R-T-B-M raw materials. The composition of R-T-B-M includes R being at least one element selected from a rare earth metal including Sc and Y. The composition also includes T being at least one element selected from Fe and Co. B in the composition is defined as Boron. The composition further includes M being at least one element selected from Ti, Ni, Nb, Al, V, Mn, Sn, Ca, Mg, Pb, Sb, Zn, Si, Zr, Cr, Cu, Ga, Mo, W, and Ta. The present invention provides for a step of creating an inert gas environment in the steps of casting, milling, mixing, molding, heating, and aging to prevent the powder from reacting with the oxygen in anyone of the above mentioned steps.

Abstract: A hardfacing composition for downhole well tools, such as earth-boring bits, contains sintered ultrahard particles. The ultrahard particles consist of tungsten carbide grains, cobalt and vanadium. The ultrahard particles are dispersed within a matrix metal of iron, nickel or alloys thereof. The composition may also have sintered tungsten carbide particles of a larger size than the ultrahard particles. The ultrahard particles have a greater hardness than the sintered tungsten carbide particles. The ultrahard particles and the sintered tungsten carbide particles may be in a spherical pellet form. Other hard metal particles may be in the composition.

Abstract: A sintered bearing has a structure in which Ni—P alloy particles having an average diameter of 10 to 100 ?m are dispersed in an amount of 1 to 20% by mass in a Cu-based sintered alloy base, a Fe—Cu-based sintered alloy base or a Cu—Ni-based sintered alloy base. The Ni—P alloy particles are derived from a raw material powder comprising 1 to 12% by mass of P; and a remainder composed of Ni and inevitable impurities. The Cu-based sintered alloy base contains no less than 40% by mass of Cu. The Fe—Cu-based sintered alloy base contains no more than 50% by mass of Fe. The Cu—Ni-based sintered alloy base contains 20 to 40% by mass of Ni and 0.1 to 1.0% by mass of P; or contains 10 to 25% by mass of Ni, 10 to 25% by mass of Zn and 0.1 to 1.0% by mass of P.

Abstract: A composite article (1; 10; 40) comprises a plurality of inclusions (5) of a magnetocalorically active material embedded in a matrix (4) of a magnetocalorically passive material. The inclusions (5) and the matrix (4) have a microstructure characteristic of a compacted powder.

Abstract: A bearing having improved wear resistance has a bearing material of a copper-tin-bismuth alloy which may also include phosphorus which has excellent strength, due to the solid solution of copper, tin and phosphorus (when used), attached to a steel backing shell. The material also has good lubricity as a result of the presence of the bismuth which also promotes tin mobilization and formation of a layer of tin on the bearing surface upon use of the bearing. The addition of small amounts of relatively small hard particles in the copper-tin-matrix, particularly Fe3P, MoSi2 or a mixture thereof, provides a suitable hard surface artifact to improve the wear resistance of the bearing material. The bearing includes a sintered powder compact bearing material of a copper-tin-bismuth alloy powder and a metal compound powder which is bonded to a steel backing shell, wherein the metal compound powder has an average particle size of less than 10 ?m.

Abstract: A component, such as a SOFC interconnect, and methods of making the component are provided using various chromium powders, including powder particles with a chromium core covered with an iron shell, a pre-alloyed Cr—Fe powder or a chromium powder produced by hydrogen reduction with hydrogen.

Abstract: The oil-impregnated sintered bearing made of iron-copper sintered alloy consisting of 10-59% of Cu, 0.5-3% of Sn, and balance of Fe and impurities, includes pores in the iron-copper sintered alloy matrix of not less than 800 per mm2, has pores exposed at 20-50% by area ratio at the inner circumferential surface with diameters greater than 100 ?m, not more than 0.5%, respectable to the total pores number. The pores number with diameters greater than 80 ?m and not greater than 100 ?m, not more than 0.1%, respectable to the total pores number with diameters greater than 60 ?m and not greater than 80 ?m is 0.5-1.5%, respectable to the total pores number, with diameters greater than 40 ?m and not greater than 60 ?m is 0.8-3% respectable to the total pores number, and the remainder pores are with diameters less than 40 ?m.