Abstract: Three-dimensional printing processes are disclosed which utilize printable fluids comprising a carrier fluid, a polymeric binder, and nanoparticles. The three-dimensional printing processes are useful for making articles from a build material powder, e.g., a ceramic, metal, metal alloy, or intermetallic powder. The nanoparticles enable low temperature interparticle bonding of the build material powder particles, e.g., by forming bridging bonds between adjacent powder particles, and/or increasing the interparticle friction between the build material powder particles to enhance the structural strength of the as-built article during a thermal treatment over at least a part of the temperature range which has as its low end the temperature at which the structural strength due to the binder becomes insubstantial and as its high end the temperature at which the structural strength due to interparticle sintering of the build material powder becomes substantial, i.e., the article's debile temperature range.

Abstract: Three-dimensional printing processes are disclosed which utilize printable fluids comprising a carrier fluid, a polymeric binder, and nanoparticles. The three-dimensional printing processes are useful for making articles from a build material powder, e.g., a ceramic, metal, metal alloy, or intermetallic powder. The nanoparticles enable low temperature interparticle bonding of the build material powder particles, e.g., by forming bridging bonds between adjacent powder particles, and/or increasing the interparticle friction between the build material powder particles to enhance the structural strength of the as-built article during a thermal treatment over at least a part of the temperature range which has as its low end the temperature at which the structural strength due to the binder becomes insubstantial and as its high end the temperature at which the structural strength due to interparticle sintering of the build material powder becomes substantial, i.e., the article's debile temperature range.

Abstract: Methods are presented for making sintered articles from water-atomized nickel-based superalloy powders. Three-dimensional binder jet printing is used to make a printed article from the powder. The printed article is liquid phase sintered without slumping at a temperature at which at least fifteen volume percent of the powder is liquid during sintering.

Abstract: Methods and systems (2) are disclosed for making articles (114) by three-dimensional printing. The methods include selectively printing by jet deposition on successive layers (4) of a build material powder (10) at least one of a first binder fluid and a second binder fluid. At least one of the first and second binder fluids includes a particulate matter (16) having mean particle size diameter which is less than that of the build material powder (10). The first binder fluid is characteristically different from the second binder fluid. The particulate matter (16) selectively deposited with a binder fluid can be used to locally tailor the physical properties of the article (114), e.g. by alloying with the build material powder, increasing densification, acting as a local infiltrant or infiltrant stop during heat treatment, locally modulating the local stress fields (e.g. by a mismatch of thermal coefficients of expansion), etc.

Abstract: Methods and systems (20) are disclosed for making articles by three-dimensional printing. The methods include three-dimensionally printing articles by selectively jet-depositing a particle-bearing binder fluid (14) upon successive layers (4) of a build material powder (10) such that the particles (16) deposited with the binder fluid (14) increase the apparent density of the as-printed article. The particulate matter (16) of the binder fluid (12) is smaller than the mean particle size of the build material powder (10). Preferably, this jet-deposited particulate matter (16) has a mean particle size that is larger than about 1 to and smaller than or equal to 50 microns. The jet-deposited matter (16) acts to fill in the interparticle interstices of the build material powder (10) thereby simultaneously increasing the density of the printed article and improving its surface roughness and contour resolution, which in turn, improves the surface finish of the final article.

Abstract: Methods are disclosed for making a hot isostatic pressing container for hot isostatic pressing a powder material to form an article comprising three-dimensionally printing the container from a build powder, the container having a cavity for receiving the powder material and an outer section having an outer surface, the cavity having a surface and being shaped and sized so that hot isostatic pressing the container with the powder material within the cavity results in the production of the article. Methods are also disclosed for making the hot isostatically pressed article using the container.

Abstract: There is provided a seal configuration for use in connection with vacuum systems. The seal configuration finds particular use in vacuum waste flush systems, such as those used in passenger transport vehicles that have on-board lavatories with vacuum toilet systems. The seal configuration generally provides an offset configuration, which can result in a larger seal on the vacuum side. This can slightly delay the opening of the waste side seal with respect to the vacuum side seal of the system, proving an improved vacuum environment. This can also give the flow of waste a more direct transition across a vacuum plate as it flows through a flush valve.

Abstract: Three-dimensional printing processes are disclosed which utilize printable fluids comprising a carrier fluid, a polymeric binder, and nanoparticles. The three-dimensional printing processes are useful for making articles from a build material powder, e.g., a ceramic, metal, metal alloy, or intermetallic powder. The nanoparticles enable low temperature interparticle bonding of the build material powder particles, e.g., by forming bridging bonds between adjacent powder particles, and/or increasing the interparticle friction between the build material powder particles to enhance the structural strength of the as-built article during a thermal treatment over at least a part of the temperature range which has as its low end the temperature at which the structural strength due to the binder becomes insubstantial and as its high end the temperature at which the structural strength due to interparticle sintering of the build material powder becomes substantial, i.e., the article's debile temperature range.

Abstract: Gas permeable molds and mold segments having open porosity (60) are disclosed. Blind vents (56) in the mold wall's (54) outside surface (52) allow for an uninterrupted molding surface (62) while enhancing the gas permeability provided by the open porosity (60). Methods of making such gas permeable molds include forming them from sintered material. Methods also include the use of solid free-form fabrication followed by sintering. Also disclosed are unitary structures (150), for use in EPS bead molding, having a steam chest portion (152) with gas impermeable walls (156) and a mold section (154) having a gas permeable mold wall (172) having open porosity (176), and, optionally, open and/or blind vents (180, 178). Methods for making such unitary structures (150) include the use of solid free-form fabrication.

Abstract: A thermally and chemically inert valve seat is provided. The valve seat includes a sharp edge located on the periphery of the valve seat body, wherein the edge digs into a surface within the valve body to secure the valve seat. The valve seat may be case hardened to provide additional strength and sealing ability. The inner diameter of the valve seat may be flush against the valve fluid passageway, thereby decreasing the contact area between the diaphragm and the valve seat.

Abstract: High localized loading, galling, and high torque forces have been generally eliminated or greatly reduced in a two ferrule tube fitting assembly through suitable modification of the rear ferrule so as to redirect the reaction forces acting between the front ferrule and the drive nut. The rear ferrule has a cylindrical interior wall that closely surrounds the tube end and is provided on the interior cylindrical wall with a circumferentially continuous radial recess that is located between the nose and rear wall of the rear ferrule. The rear ferrule also has a radially external wall that is substantially conical and additionally shaped to extend radially outward toward the enlarged diameter portion or flange of the rear ferrule. The rear ferrule further includes a contoured face on the rear driven surface of the ferrule that engages the drive surface of the drive nut.

Abstract: The present invention relates to methods for producing articles by solid free-form fabrication processes. In particular, the present invention relates to such methods incorporating holistic optimization of the product and process design.

Abstract: A thermal isolator for a valve and an actuator includes a coupler that is adapted to be disposed between the valve and the actuator and to connect the actuator to the valve. The thermal isolator is adapted to increase the temperature gradient between the valve and the actuator when one of the valve and the actuator is exposed to an elevated or reduced temperature.

Abstract: A structural panel for building structures such as residential houses or the like comprises a honeycomb or other cellular core sandwiched between two metal face sheets and surrounded by a metal frame. Frame members of the frame form mechanical interlocking connections with the face sheets of the panel. Side frame members of the panel define interlocking protrusions and channels for making interlocking joints between panels. A building structure employing the panels for forming floor and roofs includes brackets that extend into a gap between the side frame members of the panel at the panel joints and attach to the side frame members. The brackets are used for attaching the panels to other parts of the structure.

Abstract: A structural panel for building structures such as residential houses or the like comprises a honeycomb or other cellular core sandwiched between two metal face sheets and surrounded by a metal frame. Frame members of the frame form mechanical interlocking connections with the face sheets of the panel. Side frame members of the panel define interlocking protrusions and channels for making interlocking joints between panels. A building structure employing the panels for forming floor and roofs includes brackets that extend into a gap between the side frame members of the panel at the panel joints and attach to the side frame members. The brackets are used for attaching the panels to other parts of the structure.

Abstract: A method of reducing the thickness of a slab of metal under conditions that tend to produce alligator defects in the ends of the slab, the method comprising the steps of tapering at least one end of the slab and directing the same into a rolling mill. The tapered end of the slab is reduced in thickness in the mill, the amount of reduction increasing as the tapered end passes through the mill. The slab continues through the mill to reduce the thickness of the same. The end of the slab is again tapered and directed again through a rolling mill, with each of said tapers providing combinations of entry thickness to thickness reduction such that the reduction taken in the area of each taper is in an entry thickness to thickness reduction zone that does not produce alligatoring in the ends of the slab. The remaining untapered portion of the slab is reduced in thickness in the mill in an entry thickness to thickness reduction zone in which alligator formation tends to occur.

Abstract: A method for reducing the thickness of a slab of metal under conditions which tend to cause alligator defects to occur. The method comprises the steps of directing a relatively thick slab of metal several times through a rolling mill or mills to incrementally reduce the thickness of the slab until the thickness approaches a value that tends to produce a longitudinal and lateral fracture in one or both ends of the slab. The thickness of the slab is further reduced by passing the same several times again through a rolling mill or mills, with each of the passes of the slab taking a decreasing amount of reduction in thickness until a predetermined thickness value is reached. The next step involves passing the slab again through a rolling mill to further reduce the thickness thereof, the amount of reduction in this step and pass being substantially greater than that of the last pass immediately preceding this step.