Abstract: A method for manufacturing a wrought metallic article from metallic-powder compositions comprises steps of (1) compacting the metallic-powder composition to yield a compact, having a surface, a cross-sectional area, and a relative density of less than 100 percent, (2) reducing the cross-sectional area of the compact via an initial forming pass of a rotary incremental forming process so that the compact has a decreased cross-sectional area, and (3) reducing the decreased cross-sectional area of the compact via a subsequent forming pass of the rotary incremental forming process by a greater percentage than that, by which the cross-sectional area of the compact was reduced during the initial forming pass.

Abstract: A method is provided for manufacturing an article. The method comprises depositing by additive friction stir deposition a wear-resistant material on a surface of a preform to provide an intermediate article. The preform comprises a first composition and the wear-resistant material comprises a second composition. The second composition is substantially different from the first composition. The method also comprises machining the intermediate article to remove therefrom at least a portion of the wear-resistant material.

Abstract: A material compatibility test design system and method, allowing for the testing of characteristics of behavior of materials in extreme environments, the method including concurrently exposing a test specimen to a first environment and a second environment, the test specimen having an outside surface and an inside surface, the inside surface defining an internal volume, includes exposing the outside surface of the test specimen to the first environment for a predetermined period of time, the first environment comprising a first temperature, a first pressure and a first composition. The method further includes exposing the inside surface of the test specimen to the second environment for a second predetermined period of time, the second environment comprising a second temperature, a second pressure and a second composition.

Abstract: Implementations provide gas atomized metal matrix composite (“GAMMC”)-based feedstock for cold spray additive manufacturing (“CSAM”) enabling complex structural repairs. The feedstock is prepared by arranging a metal matrix composite (MMC) material in a gas atomization system, wherein the MMC material includes metal particles and ceramic particles. The feedstock is further prepared by performing gas atomization of the MMC material using the gas atomization system to atomize the MMC material, and producing a feedstock powder comprised of metal particles that are embedded with the ceramic particles from the atomized MMC material. The GAMMC-based feedstock comprises metallic (for binding to the substrate of the damaged part) and ceramic (for reinforcement) particles bonded together such that the ceramic particles bond directly to and within the metallic particles.

Abstract: A multilayered material system includes at least one of a liner sheet and a cellular core, and a multilayered composite joined to the at least one of a liner sheet and a cellular core. The multilayered composite includes hollow microspheres dispersed within a metallic matrix material.

Abstract: Implementations provide gas atomized metal matrix composite (“GAMMC”)-based feedstock for cold spray additive manufacturing (“CSAM”) enabling complex structural repairs. The feedstock is prepared by arranging a metal matrix composite (MMC) material in a gas atomization system, wherein the MMC material includes metal particles and ceramic particles. The feedstock is further prepared by performing gas atomization of the MMC material using the gas atomization system to atomize the MMC material, and producing a feedstock powder comprised of metal particles that are embedded with the ceramic particles from the atomized MMC material. The GAMMC-based feedstock comprises metallic (for binding to the substrate of the damaged part) and ceramic (for reinforcement) particles bonded together such that the ceramic particles bond directly to and within the metallic particles.

Abstract: A multilayered material system includes at least one of a liner sheet and a cellular core, and a multilayered composite joined to the at least one of a liner sheet and a cellular core. The multilayered composite includes hollow microspheres dispersed within a metallic matrix material.

Abstract: An envelope portion of an airborne craft comprises a metallic outer wall and a metallic inner wall arranged interior to the outer wall. The outer and inner walls delimit an inter-wall volume configured to support a flow of coolant to cool the outer wall during atmospheric heating of the outer wall.

Abstract: An interlayered structure for joining of dissimilar materials, includes a first material substrate, a second material substrate having a composition dissimilar from a composition of the first material substrate, and a plurality of interlayers disposed between the first material substrate and the second material substrate, including a first interlayer nearest to the first material substrate and a last interlayer nearest to the second material substrate. The first interlayer has a composition selected to have a maximum solid solubility within the composition of the first material substrate that is greater than or equal to the other interlayers' solubility within the composition of the first material substrate. The last interlayer has a composition selected to have a maximum solid solubility within the composition of the second material substrate that is greater than or equal to the other interlayers' solubility within the composition of the second material substrate.

Abstract: A fuel cell stack is described. The fuel cell stack comprises an interconnect assembly comprising a cathode-side interface coupled to an interconnect via a first joint, and an anode-side interface coupled to the interconnect via a second joint, the interconnect assembly having a first coefficient of thermal expansion (CTE) at an interface side of the interconnect assembly. The fuel cell stack further comprises a fuel cell element coupled to the interconnect assembly at the interface side via a hermetic seal, the fuel cell element having a second CTE at the interface side, the first CTE and the second CTE satisfying a predetermined CTE matching condition.

Abstract: A metallic material manufactured by a method including steps of (1) subjecting a semifinished metallic billet having at least one of a nanocrystalline microstructure and an ultrafine-grained microstructure to a rotary incremental forming process to form an intermediate wrought metallic billet and (2) subjecting the intermediate wrought metallic billet to a high rate forming process, wherein the high rate forming process includes a high rate forming process average equivalent strain rate, the high rate forming process average equivalent strain rate being at least about 0.1 s?1.

Abstract: A method for manufacturing a wrought metallic article from metallic-powder compositions comprises steps of (1) compacting the metallic-powder composition to yield a compact, having a surface, a cross-sectional area, and a relative density of less than 100 percent, (2) reducing the cross-sectional area of the compact via an initial forming pass of a rotary incremental forming process so that the compact has a decreased cross-sectional area, and (3) reducing the decreased cross-sectional area of the compact via a subsequent forming pass of the rotary incremental forming process by a greater percentage than that, by which the cross-sectional area of the compact was reduced during the initial forming pass.

Abstract: A compositionally-graded structure including a body having a first major surface and a second major surface opposed from the first major surface along a thickness axis, the body including a metallic component and a ceramic component, wherein a concentration of the ceramic component in the body is a function of location within the body along the thickness axis, wherein transitions of the concentration of the ceramic component in the body are continuous such that distinct interfaces are not macroscopically established within the body, and wherein the concentration of the ceramic component is at least 95 percent by volume at at least one location within the body along the thickness axis.

Abstract: A fuel cell stack is described. The fuel cell stack comprises an interconnect assembly comprising a cathode-side interface coupled to an interconnect via a first joint, and an anode-side interface coupled to the interconnect via a second joint, the interconnect assembly having a first coefficient of thermal expansion (CTE) at an interface side of the interconnect assembly. The fuel cell stack further comprises a fuel cell element coupled to the interconnect assembly at the interface side via a hermetic seal, the fuel cell element having a second CTE at the interface side, the first CTE and the second CTE satisfying a predetermined CTE matching condition.

Abstract: A method is provided for manufacturing an article. The method comprises depositing by additive friction stir deposition a wear-resistant material on a surface of a preform to provide an intermediate article. The preform comprises a first composition and the wear-resistant material comprises a second composition. The second composition is substantially different from the first composition. The method also comprises machining the intermediate article to remove therefrom at least a portion of the wear-resistant material.

Abstract: A multilayered material system includes at least one of a liner sheet and a cellular core, and a multilayered composite joined to the at least one of a liner sheet and a cellular core. The multilayered composite includes hollow microspheres dispersed within a metallic matrix material.

Abstract: A graded multilayered composite comprises a metal matrix material having a first side and a second side opposite the first side. A first layer of microspheres is dispersed on the first side of the metal matrix material. A second layer of microspheres is dispersed on the second side of the metal matrix material.

Abstract: Implementations provide gas atomized metal matrix composite (“GAMMC”)-based feedstock for cold spray additive manufacturing (“CSAM”) enabling complex structural repairs. The feedstock is prepared by arranging a metal matrix composite (MMC) material in a gas atomization system, wherein the MMC material includes metal particles and ceramic particles. The feedstock is further prepared by performing gas atomization of the MMC material using the gas atomization system to atomize the MMC material, and producing a feedstock powder comprised of metal particles that are embedded with the ceramic particles from the atomized MMC material. The GAMMC-based feedstock comprises metallic (for binding to the substrate of the damaged part) and ceramic (for reinforcement) particles bonded together such that the ceramic particles bond directly to and within the metallic particles.

Abstract: A method for manufacturing a component having a spatially graded property includes providing a first layer of particulate matter, the first layer having first material characteristics, and providing a second layer of particulate matter, the second layer having second material characteristics different from the first material characteristics. The method further includes providing an interlayer between the first layer and the second layer and heating the first layer, the second layer, and the interlayer to bond the first layer with the second layer.

Abstract: A compositionally-graded structure including a body having a first major surface and a second major surface opposed from the first major surface along a thickness axis, the body including a metallic component and a ceramic component, wherein a concentration of the ceramic component in the body is a function of location within the body along the thickness axis, wherein transitions of the concentration of the ceramic component in the body are continuous such that distinct interfaces are not macroscopically established within the body, and wherein the concentration of the ceramic component is at least 95 percent by volume at at least one location within the body along the thickness axis.