Abstract: A system and method of making an additively manufactured, metal near net shape part includes introducing a metallic-element-bearing feedstock into a melt zone of an additive manufacturing printhead. The metallic-element-bearing feedstock is mixed in the melt zone with a flux composition to form a slag bath mixture upon melting. The metallic-element-bearing feedstock is refined in-situ by melting the slag bath mixture with the application of thermal energy to the slag bath mixture to form a phase-separated product including a slag phase and a metal-rich liquid phase. The metal-rich liquid phase is simultaneously deposited to form a first metal layer that is one of a plurality of iteratively deposited metal layers of an additive build according to a three-dimensional digital model. The additive build has successive layers of the deposited, solidified metal-rich liquid that form a near net shape metallic part.

Abstract: A method and apparatus for additive manufacturing that includes a nozzle and/or barrel for extruding a plastic material and a supply of polymeric working material provided to the nozzle, wherein the polymeric working material is magnetically susceptible and/or electrically conductive. A magneto-dynamic heater is provided for producing a time varying, high flux, frequency sweeping, alternating magnetic field in the vicinity of the nozzle to penetrate into and couple the working material to heat the material through at least one of an induced transient magnetic domain and an induced, annular current.

Abstract: Systems and methods for synthesizing continuous graphene sheets are provided. The systems and methods include passing a catalyst substrate through a heated chemical vapor deposition chamber and exposing the substrate to a reaction gas mixture of hydrogen and hydrocarbon at a preselected location within the chamber. The reaction gas mixture can include hydrogen having a partial pressure of between about 0 Torr and 20 Torr, hydrocarbon having a partial pressure of between about 20 mTorr and about 10 Torr, and one or more buffer gases. The buffer gases can include argon or other noble gases to maintain atmospheric pressure within the chemical deposition chamber. The resulting graphene can be made with continuous mono and multilayers (up to six layers) and have single crystalline hexagonal grains with a preselected nucleation density and domain size for a range of applications.

Abstract: A coating steel component with a pattern of an iron based matrix with crystalline particles metallurgically bound to the surface of a steel substrate for use as disc cutters or other components with one or more abrading surfaces that can experience significant abrasive wear, high point loads, and large shear stresses during use. The coated component contains a pattern of features in the shape of freckles or stripes that are laser formed and fused to the steel substrate. The features can display an inner core that is harder than the steel substrate but generally softer than the matrix surrounding the core, providing toughness and wear resistance to the features. The features result from processing an amorphous alloy where the resulting matrix can be amorphous, partially devitrified or fully devitrified.

Abstract: A method of forming a metal-carbon composite, the method comprising subjecting a precursor composition to a curing step followed by a carbonization step, the precursor composition comprising: (i) a phenolic component, (ii) a crosslinkable aldehyde component, (iii) a polymerization catalyst, and (iv) metal-containing particles, wherein said carbonization step comprises heating the precursor composition at a carbonizing temperature of at least 300° C. for sufficient time to convert the precursor composition to said metal-carbon composite. The produced metal-carbon composite, devices incorporating them, and methods of their use (e.g., in capacitive deionization and lithium ion batteries) are also described.

Abstract: A composite stainless steel composition is composed essentially of, in terms of wt. % ranges: 25 to 28 Cr; 11 to 13 Ni; 7 to 8 W; 3.5 to 4 Mo; 3 to 3.5 B; 2 to 2.5 Mn; 1 to 1.5 Si; 0.3 to 1.7 C; up to 2 O; balance Fe. The composition has an austenitic matrix phase and a particulate, crystalline dispersed phase.

Abstract: A method and apparatus for additive manufacturing that includes a nozzle and/or barrel for extruding a plastic material and a supply of polymeric working material provided to the nozzle, wherein the polymeric working material is magnetically susceptible and/or electrically conductive. A magneto-dynamic heater is provided for producing a time varying, high flux, frequency sweeping, alternating magnetic field in the vicinity of the nozzle to penetrate into and couple the working material to heat the material through at least one of an induced transient magnetic domain and an induced, annular current.

Abstract: A robotic, prosthetic or orthotic member includes a body formed of a solidified metallic powder. At least one working fluid cylinder is formed in the body. A piston is provided in the working fluid cylinder for pressurizing a fluid in the cylinder. At least one working fluid conduit receives the pressurized fluid from the cylinder. The body, working fluid cylinder and working fluid conduit have a unitary construction. A method of making a robotic member is also disclosed.

Abstract: A coating steel component with a pattern of an iron based matrix with crystalline particles metallurgically bound to the surface of a steel substrate for use as disc cutters or other components with one or more abrading surfaces that can experience significant abrasive wear, high point loads, and large shear stresses during use. The coated component contains a pattern of features in the shape of freckles or stripes that are laser formed and fused to the steel substrate. The features can display an inner core that is harder than the steel substrate but generally softer than the matrix surrounding the core, providing toughness and wear resistance to the features. The features result from processing an amorphous alloy where the resulting matrix can be amorphous, partially devitrified or fully devitrified.

Abstract: A coating steel component with a pattern of an iron based matrix with crystalline particles metallurgically bound to the surface of a steel substrate for use as disc cutters or other components with one or more abrading surfaces that can experience significant abrasive wear, high point loads, and large shear stresses during use. The coated component contains a pattern of features in the shape of freckles or stripes that are laser formed and fused to the steel substrate. The features can display an inner core that is harder than the steel substrate but generally softer than the matrix surrounding the core, providing toughness and wear resistance to the features. The features result from processing an amorphous alloy where the resulting matrix can be amorphous, partially devitrified or fully devitrified.

Abstract: A robotic, prosthetic or orthotic member includes a body formed of a solidified metallic powder. At least one working fluid cylinder is formed in the body. A piston is provided in the working fluid cylinder for pressurizing a fluid in the cylinder. At least one working fluid conduit receives the pressurized fluid from the cylinder. The body, working fluid cylinder and working fluid conduit have a unitary construction. A method of making a robotic member is also disclosed.

Abstract: A composite stainless steel composition is composed essentially of, in terms of wt. % ranges: 25 to 28 Cr; 11 to 13 Ni; 7 to 8 W; 3.5 to 4 Mo; 3 to 3.5 B; 2 to 2.5 Mn; 1 to 1.5 Si; 0.3 to 1.7 C; up to 2 0; balance Fe. The composition has an austenitic matrix phase and a particulate, crystalline dispersed phase.

Abstract: A method of forming a carbon and titanium containing composite that includes mixing a titanium-containing powder with carbon and forming the mixture of the titanium-containing-powder and carbon into a composite structure at a temperature of less than 1500° C. The forming process provides a net shape having dimensions within 90% or greater than the final shape of the product. The binder of the composite is provided by the titanium, and the dispersed phase of the composite is provided by the carbon. The carbon and titanium containing composite may be employed as in applications including capacitive deionization (CDI), gas separation, chromatography, catalysis and electrode.

Abstract: A coating steel component with a pattern of an iron based matrix with crystalline particles metallurgically bound to the surface of a steel substrate for use as disc cutters or other components with one or more abrading surfaces that can experience significant abrasive wear, high point loads, and large shear stresses during use. The coated component contains a pattern of features in the shape of freckles or stripes that are laser formed and fused to the steel substrate. The features can display an inner core that is harder than the steel substrate but generally softer than the matrix surrounding the core, providing toughness and wear resistance to the features. The features result from processing an amorphous alloy where the resulting matrix can be amorphous, partially devitrified or fully devitrified.

Abstract: A coating steel component with a pattern of an iron based matrix with crystalline particles metallurgically bound to the surface of a steel substrate for use as disc cutters or other components with one or more abrading surfaces that can experience significant abrasive wear, high point loads, and large shear stresses during use. The coated component contains a pattern of features in the shape of freckles or stripes that are laser formed and fused to the steel substrate. The features can display an inner core that is harder than the steel substrate but generally softer than the matrix surrounding the core, providing toughness and wear resistance to the features. The features result from processing an amorphous alloy where the resulting matrix can be amorphous, partially devitrified or fully devitrified.

Abstract: A coating steel component with a pattern of an iron based matrix with crystalline particles metallurgically bound to the surface of a steel substrate for use as disc cutters or other components with one or more abrading surfaces that can experience significant abrasive wear, high point loads, and large shear stresses during use. The coated component contains a pattern of features in the shape of freckles or stripes that are laser formed and fused to the steel substrate. The features can display an inner core that is harder than the steel substrate but generally softer than the matrix surrounding the core, providing toughness and wear resistance to the features. The features result from processing an amorphous alloy where the resulting matrix can be amorphous, partially devitrified or fully devitrified.