Abstract: Metal-metal or metal-ceramic/carbide composite materials are fabricated by combination of powder injection molding and infiltration. This is achieved by first forming a composite system having a matrix component and an infiltrant layer. The matrix component is formed from a metal or ceramic/carbide powder, that is of a higher melting point, admixed with a first binder. The infiltrant layer is formed from a metal powder, that is of a lower melting point, admixed with a second binder. The first and second binders are subsequently removed from the composite system during a debinding process. The composite system is then heated in a sintering furnace to coalesce the matrix component into a matrix phase having a network of interconnected pores, and to effect infiltration of the infiltrant layer into these pores to form the composite material of the present invention.

Abstract: The invention relates to a method of forming an article from an alloy, such as a tin-containing alloy or titanium-containing alloy. Elemental metal powders of metal constituents of the alloy are injected into a pre-heated die and pressure is applied to form a green part. The green part is then alloyed at a predetermined temperature for a pre-determined time period to form the article. The invention also relates to an article formed by such a method.

Abstract: Metal-metal or metal-ceramic/carbide composite materials are fabricated by combination of powder injection molding and infiltration. This is achieved by first forming a composite system having a matrix component and an infiltrant layer. The matrix component is formed from a metal or ceramic/carbide powder, that is of a higher melting point, admixed with a first binder. The infiltrant layer is formed from a metal powder, that is of a lower melting point, admixed with a second binder. The first and second binders are subsequently removed from the composite system during a debinding process. The composite system is then heated in a sintering furnace to coalesce the matrix component into a matrix phase having a network of interconnected pores, and to effect infiltration of the infiltrant layer into these pores to form the composite material of the present invention.

Abstract: A method of bonding two powder components having different shrinkage factors, one of which is metal powder, is disclosed herein. In the preferred method, at step 1.1, each powder component is separately mixed with a powder binder to substantially match the other powder component's shrinkage factor. Then at steps 1.2 to 1.4, the powder component mixtures are compacted in a die set to form a green compact. Next at step 1.5, the green compact is debindered and at step 1.6, the green compact is sintered in a furnace while applying pressure on a surface of the green compact during the sintering process. In this way, the two powder components can be bonded directly without a need for an intermediate gradient zone and a double-layer metal sheet can be thus formed.