Abstract: A method of forming an object by powder injection molding, the object being formed from an injection molded integral body comprising a green part contiguous with an expendable part, the method comprising debinding the integral body at step 18 to obtain a debound green part contiguous with a debound expendable part; sintering the debound green part at step 20 at a sintering temperature, the debound expendable part configured to at least partially define the debound green part and has a melting point higher than the sintering temperature; and separating the debound expendable part from the sintered debound green part at step 22 to form the object.

Abstract: An alloying system for preparing a titanium alloy, the system comprising a rotating mill to mechanically alloy a mixture of elemental powders in predetermined proportions, the elemental powders including titanium particles, alpha stabilizer particles and beta stabilizer particles; wherein the mixture is mechanically alloyed using low impact energy to layer the titanium particles with beta stabilizer particles whereby sintering of the mechanically alloyed mixture produces alternate layers of alpha and beta stabilizer particles.

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.