Abstract: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder, a wetting agent, and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite forming a porous preform structure and infiltrating the porous preform structure with a molten second aluminum base alloy to form the three-dimensional object with near theoretical density. The wetting agent assists in wetting during infiltration. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder, a wetting agent, and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite forming a porous preform structure and infiltrating the porous preform structure with a molten second aluminum base alloy to form the three-dimensional object with near theoretical density. The wetting agent assists in wetting during infiltration. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: A paste composition, including a binding agent charged with metallic powder, to be used in a solid freeform fabrication procedure, comprising: a) a solidifiable binding agent comprised of at least one polymerizable resin, with a viscosity of less than 4000 mPa.s, measured at 25° C.; b) at least one initiator, in a concentration greater than about 0.1% by mass with respect to the mass of the resin; and c) a mixture of at least two metallic powders, said mixture having a volumetric concentration greater than 40% with respect to the composition, wherein said mixture of metal powders is either i) a bimodal or trimodal mixture in nature, or ii) is a majority of stainless steel with an amount of NiB or NiP and combinations thereof effective to lower the sintering temperature.

Abstract: A paste composition, including a binding agent charged with metallic powder, to be used in a solid freeform fabrication procedure, comprising:

Abstract: A composite, light weight vehicular bumper material is disclosed which has a surface layer of stainless steel, a principal layer of a heat treatable aluminum and an intermediate layer of essentially commercially pure aluminum. The stainless steel provides the desired surface finish and durability; the surface can be flash chromed if desired to provide a suitable bright, specular appearance. The layer of heat treatable aluminum is the principal structural component and provides the high ratio of strength to weight needed for the application. The intermediate layer of pure aluminum serves as a transition zone between the principal and surface layers aiding in the development of the maximum bond strength between those two components. In its application the composite is heat treated to obtain desired mechanical strength characteristics.