Abstract: A method for producing an additively manufactured, graded composite transition joint (AM-GCTJ) includes preparing a grating or lattice pattern from a first alloy A; the grating or lattice pattern includes pores in the grating or lattice patterns. The grating pattern is built from a first end to a second end being denser on the first end than on second end, and gradually reduces density by increasing the pore size and/or reducing density of the grating or lattice pattern; adding a second alloy B powder to the second end of grating or lattice pattern. The second alloy B powder is filled towards the first end. A composite is formed of first alloy A and second alloy B powder in the AM-GCTJ. The composite is subjected to hot isostatic pressing (HIP) to densify the composite. The second alloy B is graduated from the first end to the second end O of AM-GCTJ.

Abstract: A powder including a plurality of particulates, each particulate including a soft magnetic metallic core coated with a continuous dielectric coating having a thickness selected from a range of 100 nanometers to 100 micrometers. The particulates have a mean particle size selected from a range of 100 nanometers to 250 micrometers. Methods for forming the powder are disclosed. A soft magnetic composite component includes a soft magnetic material in a dielectric matrix, wherein (i) the soft magnetic material comprises a plurality of particulates comprising metallic cores, (ii) each metallic core is coated by a continuous dielectric coating covering >90% of a surface area of the metallic core, (iii) the metallic cores are electrically isolated from each other, and (iv) the dielectric coatings of adjacent metallic cores are consolidated together. Methods for formation of the soft magnetic component by additive manufacturing and hot isostatic pressing are disclosed.

Abstract: A method for fabricating an article includes forming a billet consisting essentially of a stainless steel composition of manganese 2.00 wt. %-24.00 wt. % chromium 19.00 wt. %-30 wt. % molybdenum 0.50 wt. %-4.0 wt. % nitrogen 0.25 wt. %-1.10 wt. % carbon ?1 wt. % phosphorus ?0.03 wt. % sulfur ?1 wt. % nickel <22 wt. % cobalt <0.10 wt. % silicon ?1 wt. % niobium ?0.80 wt. % oxygen ?1 wt. % copper ?0.25 wt. % balance iron. The billet is annealed and cold worked to form an article. Without annealing of the article, the article is subsequently case hardened at a single case hardening temperature to form a surface layer on a top surface thereof. Articles formed with the indicated stainless steel composition with case hardened surface layers are also provided.

Abstract: Closed-loop metal powder management methods for additive manufacturing. Virgin metal powder is provided in a closed powder container comprising at least one sensor, tracker, or optical device. The metal powder is transferred to an additive manufacturing system, a portion of a metal powder layer is consolidated, and excess metal powder is transferred from the additive manufacturing system to the powder container, a second powder container, or an internal powder container. Virgin metal powder or a second metal powder are added to the excess metal powder, a quality of the mixed powder is validated, the process is repeated at least once, and powder physical transfer data associated with at least one of the steps is collected and stored in a data repository. Powder material parameters may be measured and assessed, and may be also be stored in the data repository.

Abstract: A bonded soft magnet object comprising bonded soft magnetic particles of an iron-containing alloy having a soft magnet characteristic, wherein the bonded soft magnetic particles have a particle size of at least 200 nm and up to 100 microns. Also described herein is a method for producing the bonded soft magnet by indirect additive manufacturing (IAM), such as by: (i) producing a soft magnet preform by bonding soft magnetic particles with an organic binder, wherein the magnetic particles have an iron-containing alloy composition with a soft magnet characteristic, and wherein the particles of the soft magnet material have a particle size of at least 200 nm and up to 100 microns; (ii) subjecting the preform to an elevated temperature sufficient to remove the organic binder to produce a binder-free preform; and (iii) sintering the binder-free preform at a further elevated temperature to produce the bonded soft magnet.

Abstract: A Ti-6A1-4V titanium powder alloy composition having enhanced strength resulting from the addition of one or more of the following elements without requiring an increase in oxygen content: Aluminum Iron Nitrogen Carbon The composition may also be used for Ti-6A1-4V titanium alloy starting bar stock.

Abstract: A magnetic iron alloy and process of making the same. The alloy includes iron, approximately 2 wt. % to approximately 8 wt. % cobalt, approximately 0.05 wt. % to approximately 5 wt. % manganese, and approximately 0.05 wt. % to approximately 5 wt. % silicon. The alloy may also include up to approximately 0.3 wt. % chromium, up to approximately 2 wt. % vanadium, up to approximately 1 wt. % nickel, up to approximately 0.05 wt. % niobium, and up to approximately 0.02 wt. % carbon.

Abstract: A Ti-6A1-4V titanium powder alloy composition having enhanced strength resulting from the addition of one or more of the following elements without requiring an increase in oxygen content: Aluminum Iron Nitrogen Carbon The composition may also be used for Ti-6A1-4V titanium alloy starting bar stock.

Abstract: A magnetic iron alloy and process of making the same. The alloy includes iron, approximately 2 wt. % to approximately 10 wt. % cobalt, approximately 0.05 wt. % to approximately 5 wt. % manganese, and approximately 0.05 wt. % to approximately 5 wt. % silicon. The alloy may also include up to approximately 3 wt. % chromium, up to approximately 2 wt. % vanadium, up to approximately 1 wt. % nickel, up to approximately 0.05 wt. % niobium, and up to approximately 0.02 wt. % carbon.

Abstract: A high strength, high fracture toughness steel alloy consisting essentially of, in weight percent, about______________________________________ C 0.2-0.33 Mn 0.20 max. Si 0.1 max. P 0.008 max. S 0.004 max. Cr 2-4 Ni 10.5-15 Mo 0.75-1.75 Co 8-17 Ce Effective amount-0.030 La Effective amount-0.01 Fe Balance ______________________________________and an article made therefrom are disclosed. A small but effective amount of calcium can be present in this alloy in substitution for some or all of the cerium and lanthanum. The alloy is an age-hardenable martensitic steel alloy which provides a unique combination of tensile strength and fracture toughness. The alloy provides excellent mechanical properties when hardened by vacuum heat treatment with inert gas cooling and has a low ductile-to-brittle transition temperature.

Abstract: A duplex stainless steel having a good combination of galling resistance and corrosion resistance is disclosed containing in weight percent about:______________________________________ Broad Intermediate Preferred ______________________________________ C 0.1 Max. 0.05 Max. 0.025 Max. Mn 0-6 1-4 1-3 Si 2.5-6 3-6 4-5 Cr 16-24 17-22 18-21 Ni 2-12 6-10 7-9 Mo 4 Max. 0.5-3 1.0-2 N 0.07-0.30 0.10-0.25 0.15-0.20 ______________________________________and the balance of the alloy is essentially iron. In the annealed condition the alloy is limited to about 15-50% v/o ferrite. To attain its good galling resistance, the alloying elements are balanced so that the % Ni+0.68 (% Cr)+0.55 (% Mn)+0.45 (% Si)+(% C+% N)+% Mo+0.2 (% Co), is at least about 27.5, and the Ni/Si ratio is not more than about 2.5.

Abstract: An austenitic, non-magnetic, stainless steel alloy and articles made therefrom are disclosed which, in the wrought condition, are essentially ferrite-free and have a relative magnetic permeability of less than about 1.02, a room temperature 0.2% yield strength of at least about 100 ksi, and good resistance to stress corrosion cracking in chloride environments. Broad, intermediate, and preferred ranges are disclosed as follows:______________________________________ w/o Broad Intermediate Preferred ______________________________________ C 0.08 max. 0.05 max. 0.035 max. Mn 14-19 15-18 16-18 Si 1 max. 1 max. 0.75 max. Cr 12-21 14-19.5 16-18 Ni 3.5 2.5 max. 1.5 max. Mo 0.5-4 0.75-2.5 1.0-2.0 Cu 2.0 max. 1.5 max. 1.0 max. N 0.2-0.8 0.3-0.7 0.4-0.6 B 0.06 max. 0.005 max. 0.005 max. ______________________________________the balance being iron. The alloy is balanced to be essentially ferrite-free and is further balanced according to Equations 1 and 2 (Eqs.

Abstract: A ferritic alloy, having an improved combination of magnetic properties and corrosion resistance, contains, in weight percent, about______________________________________ % ______________________________________ Carbon 0.03 max. Manganese 0.5 max. Silicon 0.5 max. Phosphorus 0.03 max. Sulfur 0-0.5 Chromium 10-13.0 Molybdenum 0-1.5 Nitrogen 0.05 max. Titanium 0.01 max. Aluminum 0.01 max. ______________________________________and the balance is essentially iron. The alloy, and articles made therefrom, provide higher saturation induction than known corrosion resistant, magnetic alloys.

Abstract: This invention provides a non-magnetic, austenitic, corrosion resistant stainless steel alloy having improved machinability, a consistently reproduceable coefficient of thermal expansion, and an essentially ferrite-free structure. The alloy contains about 0.04-0.10 w/o C, 0.03-0.07 w/o N, 2.00 w/o max. Mn, 1.00 w/o max, Si, 0.045 w/o max. P, 0.015-0.10 S, 19.00-24.00 Cr, 0.75 w/o max. Mo, 12.00-18.00 w/o Ni, and the balance iron. The alloy is balanced so that no more than about 2 v/o ferrite as determined by the DeLong diagram is present and so that the coefficient of thermal expansion is about 14.5.times.10.sup.-6 to 16.5.times.10.sup.-6 per C..degree. within the temperature range of about -51 to 121 C.This invention further provides articles, including a non-magnetic tube in a magnetically biased accelerometer having good corrosion resistance, a coefficient of thermal expansion of about 14.5.times.10.sup.-6 to 16.5.times.10.sup.-6 per C..degree. within the temperature range of about -51 to 121 C.

Abstract: A high strength, high fracture toughness structural steel alloy consisting essentially of, in weight percent, about______________________________________ C 0.2-0.33 Cr 2-4 Ni 10.5-15 Mo 0.75-1.75 Co 8-17 Fe Balance ______________________________________and an article made therefrom are disclosed. The alloy is an age-hardenable martensitic steel alloy whcih provides a unique combination of tensile strength and fracture toughness. The alloy provides excellent mechanical properties when hardened by vacuum heat treatment with inert gas cooling and has a low ductile-to-brittle transition temperature.

Abstract: A thermally respective, monometallic article is isclosed which obviates the need for bonding of dissimilar metals as in a bimetal. The thermally responsive article is formed of an alloy or a metal and has at least two portions. The two portions are characterized by different coefficients of thermal expansion over a given temperature range, the difference being sufficiently large to result in deflection of the article when heated or cooled. In the preferred form of the article, the alloy or metal is present in a first phase in one portion of the article and in a second phase in the other portion. The process for obtaining the dual phase arrangement includes subjecting one portion of an intermediate form to cold treatment, cold reduction, decarburization, or a combination thereof, depending on the material used. A cathode ray tube employing the thermally responsive article as a temperature compensating device is also disclosed.

Abstract: A heat resisting, controlled thermal expansion, nickel-iron base alloy consisting essentially of, in weight percent, about:______________________________________ C 0.1 max. Mn 0.5 max. a small but effective amount up to Si 0.7 P 0.015 max. S 0.010 max. Cr 0.8 max. Ni 32-52 Mo 0.5 max. Co 0-20 Ti 1-3 Al 0.2 max. Nb 5-7 V 0.5 max. Zr 0.1 max. B 0-0.02 Cu 0.8 max. W 0.5 max. Fe Bal. ______________________________________and an article formed therefrom are disclosed. The alloy provides an outstanding combination of elevated temperature tensile properties and notch rupture ductility by close control of the niobium and titanium in the alloy. Within the compositional range of the alloy niobium and titanium are balanced such that(a) % Nb.gtoreq.6.7-0.5(% Ti), for Ti.ltoreq.1.5%;(b) % Nb.gtoreq.18.3-8.2(% Ti), for Ti.gtoreq.1.5%; and(c) % Ti.ltoreq.0.67(% Nb-1.3). Furthermore, the sum, % Mn+% Cr+% Mo+% V+% Cu+% W.ltoreq.2.

Abstract: This invention provides a process for improving, to at least a predetermined level, the stress rupture life and/or stress rupture ductility of precipitation hardenable nickel and nickel-iron base alloys containing nickel, niobium, and silicon when said alloys have less than a predetermined level of these stress rupture properties when worked and aged by a primary heat treatment. This improvement in properties is accomplished by controlled precipitation of a sufficient quantity of a (Ni, Nb, Si)-containing intermetallic phase.

Abstract: In a process for making a low thermal expansion, high thermal conductivity member or article suitable for bonding to a support member at a predetermined bonding temperature and for facilitating heat transfer therefrom, and in the member made thereby, first and second metal powders are combined in volumetric proportions to provide an approximation to desired thermal expansion and thermal conductivity characteristics. The powder mixture is then consolidated in a controlled manner to provide a shaped member having a thermal expansion characteristic curve that essentially matches that of the support member from about 30.degree. C. up to the bonding temperature. Consolidation of the metal powder mixture is controlled by selecting a density for the consolidated powder that results in the close expansion match over the temperature range and then consolidating the metal powder mixture to that density.

Abstract: A heat, corrosion and wear resistant austenitic steel and article made therefrom is disclosed containing in weight percent about______________________________________ w/o ______________________________________ Carbon 0.35-1.50 Manganese 3.0-10.0 Silicon 2.0 max. Phosphorus 0.10 max. Sulfur 0.05 max. Chromium 18-28 Nickel 3.0-10.0 Molybdenum Up to 10.0 Vanadium Up to 4.0 Boron Up to 0.03 Nitrogen 0.25 min. Tungsten Up to 8.0 Niobium 1.0 max. ______________________________________the balance being essentially iron. To attain the unique combination of properties provided by the present alloy w/o C+w/o N must be at least about 0.7, w/o V+0.5 (w/o Mo)+0.25 (w/o W) must be about 0.8-9.0.