Abstract: A method of forming a wrought material having a refined grain structure is provided. The method comprises providing a metal alloy material having a depressed solidus temperature and a low temperature eutectic phase transformation. The metal alloy material is molded and rapidly solidified to form a fine grain precursor that has fine grains surrounded by a eutectic phase with fine dendritic arm spacing. The fine grain precursor is plastic deformed at a high strain rate to cause recrystallization without substantial shear banding to form a fine grain structural wrought form. The wrought form is then thermally treated to precipitate the eutectic phase into nanometer sized dispersoids within the fine grains and grain boundaries and to define a thermally treated fine grain structure wrought form having grains finer than the fine grains and the fine dendritic arm spacing of the fine grain precursor.

Abstract: A method of forming a wrought material having a refined grain structure is provided. The method comprises providing a metal alloy material having a depressed solidus temperature and a low temperature eutectic phase transformation. The metal alloy material is molded and rapidly solidified to form a fine grain precursor that has fine grains surrounded by a eutectic phase with fine dendritic arm spacing. The fine grain precursor is plastic deformed at a high strain rate to cause recrystallization without substantial shear banding to form a fine grain structural wrought form. The wrought form is then thermally treated to precipitate the eutectic phase into nanometer sized dispersoids within the fine grains and grain boundaries and to define a thermally treated fine grain structure wrought form having grains finer than the fine grains and the fine dendritic arm spacing of the fine grain precursor.

Abstract: An alloy feedstock for semi-solid metal injection molding. The alloy feedstock is an alloy material in particulate form and has a heterogeneous structure, a temperature range at 20% of the height of the peak of the main melting reaction greater than 40° C., and having a ratio of the height of the peak of the eutectic reaction to the height of the main melting reaction of less than 0.5.

Abstract: An alloy feedstock for semi-solid metal injection molding. The alloy feedstock is an alloy material in particulate form and has a heterogeneous structure, a temperature range at 20% of the height of the peak of the main melting reaction greater than 40° C., and having a ratio of the height of the peak of the eutectic reaction to the height of the main melting reaction of less than 0.5.

Abstract: An alloy feedstock for semi-solid metal injection molding. The alloy feedstock is an alloy material in particulate form and has a heterogeneous structure, a temperature range at 20% of the height of the peak of the main melting reaction greater than 40° C., and having a ratio of the height of the peak of the eutectic reaction to the height of the main melting reaction of less than 0.5.

Abstract: An alloy feedstock for semi-solid metal injection molding. The alloy feedstock is an alloy material in particulate form and has a heterogeneous structure, a temperature range at 20% of the height of the peak of the main melting reaction greater than 40° C., and having a ratio of the height of the peak of the eutectic reaction to the height of the main melting reaction of less than 0.5.

Abstract: An alloy feedstock for semi-solid metal injection molding. The alloy feedstock is an alloy material in particulate form and has a heterogeneous structure, a temperature range at 20% of the height of the peak of the main melting reaction greater than 40° C., and having a ratio of the height of the peak of the eutectic reaction to the height of the main melting reaction of less than 0.5.

Abstract: A method of embrittling cleaned steel particles is described, followed by a grinding and sorting operation. Depending on the initial carbon content of the steel scrap, a reducing and carbon-containing atmosphere may be provided to carburize the particles as they are being embrittled. A quenching operation is provided at the end of the process to embrittle the particles and before the particles are ground. The ground grit which is produced may then be sorted by size and used as an abrasive compound, or, alternatively may be further ground and annealed in a subsequent operation to provide suitable powder for forming sintered parts. Prior to annealing the grit may be further ground in a partial oxidizing atmosphere to preoxidize the powder, in order to provide oxygen directly within the powder to react with any residual carbon so that the carbon monoxide gas can be formed and the powder can be substantially free of both carbon and oxides when the reaction is complete.

Abstract: A method and apparatus 10 are disclosed for annealing metal powder so at to decrease the carbon content of the powder while also reducing the oxygen content thereof.