Abstract: A method of additive manufacturing an object by applying metal layerwise on a base with an application device successively aligned with different processing zones in relation to the base includes locally applying liquid metal in a processing zone. The liquid metal solidifies in the processing zone and precise adjustment of local material properties of the object are controlled by influencing or controlling temperature development as a function of time of the solidified metal with at least one thermal influencing device aligned with the processing zone and fixed relative to the application device. The thermal influencing device is at least one of a heating device and a cooling device.

Abstract: An energy coupling device for coupling energy into molten metal. The energy coupling device includes a cavitation source which supplies energy through a cooling medium and through a receptor in contact with the molten metal. The cavitation source includes a probe disposed in a cooling channel. The probe has at least one injection port for injection of a cooling medium between a bottom of the probe and the receptor. The probe under operation produces cavitations in the cooling medium. The cavitations are directed through the cooling medium to the receptor.

Abstract: Large steel ingot casting is accomplished with a top suspended induction heating device supplied with variable power and variable frequency from a power source. By the induction heating and stirring provided by the top suspended induction heating device, metal solidification advances progressively upwards from bottom to top, and the upper molten metal in a riser part compensates for shrinkage of the lower solidified metal in the main part. Inclusions are selectively moved out of the molten metal by a variable electromagnetic stirring force and the formation of casting defects is suppressed.

Abstract: A vacuum arc remelt apparatus comprising a crucible having a wall, said wall having an interior and an exterior opposite said interior; an electrode within the crucible proximate the interior; an ingot within the crucible and below the electrode, wherein said ingot includes a crown and shelf; and a vibration source at the exterior of the crucible proximate the crown and shelf.

Abstract: An organic release agent is vacuum deposited over a substrate and surface treated with a plasma or ion-beam source in a gas rich in oxygen-based functional groups to harden a very thin layer of the surface of the deposited layer in passivating environment. Aluminum is subsequently vacuum deposited onto the hardened release layer to form a very flat and specular thin film. The film is exposed to a plasma gas containing oxygen or nitrogen to passivate its surface. The resulting product is separated from the substrate, crushed to break up the film into aluminum flakes, and mixed in a solvent to separate the still extractable release layer from the aluminum flakes. The surface treatment of the release layer greatly reduces wrinkles in the flakes, improving the optical characteristics of the flakes. The passivation of the flake material virtually eliminates subsequent corrosion from exposure to moisture.

Abstract: A method of forming a metal structure. The method comprises providing a dispersion of metal nanoparticles and a solution comprising a transient polymer and solvent. The dispersion of metal nanoparticles and the solution are formed by coaxially electrospinning into a fiber comprising the metal nanoparticles and the transient polymer. The fiber is heated to decompose the transient polymer and form a metallic structure.

Abstract: In a method of processing a substrate in accordance with an embodiment, a trench may be formed in the substrate, a stamp device may be disposed at least in the trench; at least one part of the trench that is free from the stamp device may be at least partially filled with trench filling material; and the stamp device may be removed from the trench.

Abstract: A method of forming particles that includes performing a strong force attenuation of a mixture to form pre-particles. The mixture including a base compound and a dielectric additive having an elevated dielectric constant dispersed therein. The pre-particles are then dielectrically spun in an electrostatic field to further attenuate the pre-particles and form the particles.

Abstract: Described herein is a feedstock comprising BMG. The feedstock has a surface with an average roughness of at least 200 microns. Also described herein is a feedstock comprising BMG. The feedstock, when supported on a support during a melting process of the feedstock, has a contact area between the feedstock and the support up to 50% of a total area of the support. These feedstocks can be made by molding ingots of BMG into a mole with surface patterns, enclosing one or more cores into a sheath with a roughened surface, chemical etching, laser ablating, machining, grinding, sandblasting, or shot peening. The feedstocks can be used as starting materials in an injection molding process.

Abstract: Microfabricated particles are dispersed throughout a matrix to create a composite. The microfabricated particles are engineered to a specific structure and composition to enhance the physical attributes of a composite material. The microfabricated particles are generated by forming a profile extrudate. A profile extrudate is an article of indefinite length that has a cross sectional profile of a desired structure with micro-scale dimensions. Upon or after formation, the profile extrudate may be divided along its length into a plurality of microfabricated particles.

Abstract: A composition suitable for use as a target containing antimony to be irradiated by accelerated charged particles (e.g., by protons to produce tin-117m) comprises an intermetallic compound of antimony and titanium which is synthesized at high-temperature, for example, in an arc furnace. The formed material is powdered and melted in an induction furnace, or heated at high gas pressure in gas static camera. The obtained product has a density, temperature stability, and heat conductivity sufficient to provide an appropriate target material.

Abstract: A method of fabricating a metal part by selectively melting a powder, the method including: building up layer by layer on a plate and simultaneously with the part, at least one holder and support element for the part, the element being spaced apart and distinct from the part and being separated therefrom by a gap filled with non-melted powder; after the part has been made completely, removing at least some of the powder remaining in the gap between the part and the element, for example by suction, blowing, or vibration; and separating the part from the plate.

Abstract: A component or coupon for use in a thermal machine under extreme thermal and mechanical conditions comprises an alloy material having a controllable grain size (d). A grain size distribution (d(X,Y,Z)) of the component or coupon corresponds to at least one of an expected temperature distribution (T(X,Y,Z)), an expected stress distribution (?(X,Y,Z)) and an expected strain distribution (?(X,Y,Z)), which vary with geometrical coordinates (X,Y,Z) of the component or coupon, such that a lifetime of the component or coupon is improved with respect to a similar component or coupon having a substantially uniform grain size.

Abstract: A manufacturing method is provided. The manufacturing method includes forming one or more grooves in a component that comprises a substrate with an outer surface. The substrate has at least one interior space. Each groove extends at least partially along the substrate and has a base and a top. The manufacturing method further includes processing an intermediate surface of the component to plastically deform the surface adjacent at least one edge of a respective groove, such that the distance across the top of the groove is reduced. Another manufacturing method is provided and includes processing an intermediate surface of the component to facet the intermediate surface in the vicinity of the groove.

Abstract: A method of molding a platform opening includes the steps of providing a main body core and a platform core, with the main body core having a portion that forms a portion of the platform. The platform core has at least one side portion that will form a side opening. Molten metal is directed around the cores within a mold and solidifies. The cores are removed, leaving cavities where the cores were within the molten metal, and includes an opening in a side face formed by the side portion of the platform body core. Lost core components are also disclosed and claimed.

Abstract: A method of producing an extremely low carbon steel cast slab characterized by casting molten steel obtained by reducing the carbon concentration of the molten steel to 0.005 mass % or less, then adding Cu, Nb, and B to the molten steel, furthermore, and adjusting the concentration of dissolved oxygen in the molten steel to 0.01 mass % to 0.06 mass % and extremely low carbon steel plate comprised of steel containing C: 0.005 mass % or less, acid soluble Al: 0.005 mass % or less, and further Cu, Nb, and B, characterized in that the steel has fine oxides of a diameter of 0.5 ?m to 30 ?m dispersed in it in an amount of 1000 particles/cm2 to 1,000,000 particles/cm2.

Abstract: The present invention relates to a sputtering target of a multi-component single body, a preparation method thereof, and a method for fabricating a multi-component alloy-based nanostructured thin film using the same. The sputtering target according to the present invention comprises an amorphous or partially crystallized glass-forming alloy system composed of a nitride forming metal element, which is capable of reacting with nitrogen to form a nitride, and a non-nitride forming element which has no or low solid solubility in the nitride forming metal element and does not react with nitrogen or has low reactivity with nitrogen, wherein the nitrogen forming metal element comprises at least one element selected from Ti, Zr, Hf, V, Nb, Ta, Cr, Y, Mo, W, Al, and Si, and the non-nitride forming element comprises at least one element selected from Mg, Ca, Sc, Ni, Cu, Ag, In, Sn, La, Au, and Pb.

Abstract: A piston with a cast bi-metallic dome feature and a method of making the piston. In one form, the piston is for use in a diesel engine, while in another, the piston is for use in a gasoline engine. The dome feature may include a laminate of a relatively high-temperature material (such as stainless steel) and a relatively low temperature material (such as aluminum or aluminum alloys) such that the portion of the dome made from the relatively high-temperature material is directly exposed to combustion within a cylinder into which the piston is placed. In another form, an aluminum coated stainless steel layer is used to form the dome. In one form, an ablation casting process may be used to manufacture the dome.

Abstract: Provided is a method of producing an aluminum structure using a porous resin molded body having a three-dimensional network structure, with which it is possible to form an aluminum structure having a low oxide content in the surface of aluminum (i.e., having an oxide film with a small thickness), and in particular, it is possible to obtain an aluminum porous body that has a large area. The method includes a step of preparing an aluminum-coated resin molded body in which an aluminum layer is formed, directly or with another layer therebetween, on a surface of a resin molded body composed of urethane, and a step of decomposing the resin molded body by bringing the aluminum-coated resin molded body into contact with concentrated nitric acid with a concentration of 62% or more.

Abstract: A turbine blade includes a first side wall including a first tip edge, a second side wall opposite the first side wall and including a second tip edge, a tip wall between the first and second side walls, the tip wall recessed from the first tip edge of the first side wall and the second tip edge of the second side wall forming a coolant cavity, a tip recess cavity, a first parapet wall on the first side wall, and a second parapet wall on the second side wall, the coolant cavity defined by the tip wall, and the tip recess cavity defined by the tip wall, and the first and second parapet walls, a step formed between the first tip edge and the tip wall, a cooling hole through the first parapet wall, the step, and the tip wall, the cooling hole including an open and a closed channel section.

Abstract: Disclosed is a QR (Quick Response) code. The QR code is a square block composed of message unit blocks arranged without gaps according to a predetermined rule. The message unit blocks include black blocks and white blocks. The white message unit blocks of the QR code are bright planes formed on a metal surface through die casting. Each bright plane of white message unit block is set at an identical inclination angle with respect to a horizontal plane. The black message unit blocks of the QR code are formed as scattering planes on the metal surface and are set on an identical plane parallel to the horizontal plane. The QR code is highly stable, readable and identifiable. A method for manufacturing the QR code is also provided.

Abstract: Disclosed is a method for dislodging a mold from a casting formed within the mold. The mold may be removed from the casting by scoring the mold and applying a force sufficient to cause the mold to fracture and break into pieces. Additionally, the mold may be fractured by either explosive charges placed in the mold pack or by high energy pulsations directed at the mold. Once the mold is fractured and broken into various pieces it may then be dislodged from the casting.

Abstract: A gear housing for a bevel gear having a surface which is made up of sections and attachment faces. The sections are convexly curved along at least one surface curve.

Abstract: Method such as can be used, for example, for producing molded articles from metallic glasses. Method and apparatus are provided in which a good mold filling during casting is achieved in addition to high cooling rates. The method includes introducing a metal-containing melt into an electrically conducting casting mold, the metal-containing melt and the mold being connected in an electrically conducting manner to the outputs of the same voltage source during the introduction into a casting mold, so that a preset current flows through the boundary interface between the melt and the mold. Apparatus is also provided in which there is an electrically conducting connection to a voltage source between a metal-containing melt and an electrically conducting mold for the melt.

Abstract: A brake disc arrangement has a mounting portion formed of a metal, with a plurality of radial protuberances extending radially outward therefrom. The radial protuberances each have a radially distal tip portion, and a ceramic coating is applied to the radially distal tip portion of the radial protuberances. The brake plate portion is cast so as to surround the radially distal tip portions. However, it is isolated therefrom by the ceramic coating. At least some of the radially distal tip portions are formed of metal having a microstructure created by electrical discharge machining to increase dampening. A sand core within a core box holds the mounting portion in a predetermined fixed orientation. The molten metal is poured into the core box mold, and the metal brake plate portion is prevented by the ceramic coating from welding to any of the plurality of radial protuberances.

Abstract: A corrosion resistance system is disclosed that can be used in conjunction with a leaching device for removal of a mold from a cast component. The corrosion resistance system includes a container having a working fluid, such as a caustic fluid. A cast component and mold is placed within the container and a power supply is coupled to the component. During operation of the corrosion resistance system the cast component can be configured as an anode or as a cathode to provide for anodic or cathodic corrosion resistance. In one form the power supply is connected with an electrical conductor to the container and the cast component placed in electrical coupling with the container. An inert gas purge can supply an inert gas to the container. A vacuum pump can be used to remove gas from the container. Furthermore, an oxygen getter can be used in some embodiments.

Abstract: A method of making a drill bit having the following steps: placing matrix material in a bit body mold; placing a metal blank in the bit body mold; placing a binder material in the bit body mold with the binder material proximate the matrix material and the metal blank; and exposing hinder material to microwave radiation, whereby hinder material and other constituents is heated to a selected temperature to allow hinder material to melt and to infiltrate matrix material. A method of heating selected portions of a drill bit comprising: placing the drill bit in an insulative oven having a wave guide of microwave radiation from a microwave generator; positioning a portion of the drill bit to be heated proximate the wave guide; and exposing the portion of the drill bit to be heated to microwave radiation, wherein the portion of the drill bit is heated without overheating remaining portions of the drill bit.

Abstract: A method for manufacturing a sputtering target includes the steps of: providing a highly pure matrix material containing a magnetic metal, and a highly pure precious metal ingot material; cleaning the surfaces of the matrix material and the precious metal ingot; vacuum melting the matrix material and the precious metal ingot to obtain a molten alloy; pouring the molten alloy in a mold having a cooling system while maintaining a surface of the molten alloy at a molten state by arc heating until the pouring is finished, thereby forming the molten alloy into a cast blank; hot working the cast blank; and annealing the cast blank after the hot working.

Abstract: A method and apparatus involve positioning an insert within a cavity of a mold, heating an insert wall within the cavity of the mold, and casting a molten metal into the cavity adjacent the insert. A surface of the insert absorbs heat from the molten metal to melt and fuse to the molten metal.

Abstract: The invention provides foams of desired cell sizes formed from metal or ceramic materials that coat the surfaces of carbon foams which are subsequently removed. For example, metal is located over a sol-gel foam monolith. The metal is melted to produce a metal/sol-gel composition. The sol-gel foam monolith is removed, leaving a metal foam.

Abstract: A metal matrix composite (MMC) material that is castable, or can be rendered castable, is melted and cast into a mold or crucible, and at least a portion of the plurality of reinforcement bodies is permitted to at least partially settle out of their suspension in the molten matrix metal. The casting is solidified, and the sparsely loaded supernatant is separated from the zone of the casting containing the sediment—either by cutting, sawing, etc., or by decanting the supernatant when the casting was still in a molten condition. In a preferred embodiment, during the settling and/or the solidification process, mechanical energy, such as in the form of oscillations, is applied to the MMC melt. The applied energy permits the reinforcement bodies to nestle and pack more efficiently, thereby increasing their volumetric loading in the cast composite.

Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles.

Abstract: Disclosed is a method for dislodging a mold from a casting formed within the mold. The mold may be removed from the casting by scoring the mold and applying a force sufficient to cause the mold to fracture and break into pieces. Additionally, the mold may be fractured by either explosive charges placed in the mold pack or by high energy pulsations directed at the mold. Once the mold is fractured and broken into various pieces it may then be dislodged from the casting.

Abstract: In accordance with the invention, features can be directly imprinted into the surface of a solid substrate. Specifically, a substrate is directly imprinted with a desired pattern by the steps of providing a mold having a molding surface to imprint the pattern, disposing the molding surface adjacent or against the substrate surface to be imprinted, and irradiating the substrate surface with radiation to soften or liquefy the surface. The molding surface is pressed into the softened or liquefied surface to directly imprint the substrate. The substrate can be any one of a wide variety of solid materials such as semiconductors, metals, or polymers. In a preferred embodiment the substrate is silicon, the laser is a UV laser, and the mold is transparent to the UV radiation to permit irradiation of the silicon workpiece through the transparent mold. Using this method, applicants have directly imprinted into silicon large area patterns with sub-10 nanometer resolution in sub-250 nanosecond processing time.

Abstract: A method for making sand particle foundry mold members. Sand particles are coated with an aqueous dispersion of a suitable binder material such as a gelatin gel. The moist gelatin coated particles are gravity fed into a pattern box for the mold member and subjected to multi-axis vibration to pack the sand in the pattern box. The moist sand is then heated with radio frequency energy to promote binder flow to the corners of the particles, and air flow is initiated to transport water from the mass of particles to harden the mass of particles into the mold member.

Abstract: To prevent, in a cooled ring carrier (1) for pistons, durinh Alfin bonding, the formation of oxides induced by air that escapes due to porous ring carrier material and, as a consequence, an impairment of the ring carrier bond. To this end, the cooled ring carrier, once the ring carrier part and the sheet metal part (3) have been linked, is subjected to negative pressure in a vacuum tank.

Abstract: A method of operating a hot-chamber diecasting machine is provided in which, after the filling of the mold, a compressional vibration is generated which prevents the molten metal from rapidly solidifying at least in the narrowest cross-section of the feed orifice between the ascending bore and the mouthpiece and the mold. In this manner, it becomes possible to increase the afterpressure upon the molten metal in the mold in comparison to conventional hot-chamber diecasting processes in order to achieve cast parts of a higher quality.

Abstract: Disclosed is a method for dislodging a mold from a casting formed within the mold. The mold may be removed from the casting by scoring the mold and applying a force sufficient to cause the mold to fracture and break into pieces. Additionally, the mold may be fractured by either explosive charges placed in the mold pack or by high energy pulsations directed at the mold. Once the mold is fractured and broken into various pieces it may then be dislodged from the casting.

Abstract: An apparatus for supplying molten steel and a continuous casting method therewith are described. The apparatus is equipped with a tundish 1 having an upper nozzle 2 at the bottom, a flow control mechanism 3 disposed below the upper nozzle 2, an immersion nozzle 4 formed by a refractory material having a good electrical conductivity, one electrode 5 disposed in the inner space of the tundish 1, the other electrode 6 disposed in the immersion nozzle 4, and a power supply 7 connected to the electrodes 5 and 6. In the method, the molten steel is supplied into a mold in the state of supplying an electric current between the inner surface of the immersion nozzle 4 and the molten steel 8 passing through the inside thereof by utilizing the apparatus for supplying molten steel. The deposition of the Al oxide or the like in the molten steel onto the inner surface of the immersion nozzle and others can be prevented, and thereby the generation of the surface defects in the products can also be prevented.

Abstract: Method for producing metal matrix composites. The method includes the steps of placing a substantially liquid metal in the vicinity of a reinforcement material and in the vicinity of the source of a transient magnetic field sufficient to produce an electromagnetic body force within the metal. The magnetic field is activated thereby propelling the substantially liquid metal into the reinforcement material thereby producing metal matrix composites.

Abstract: A method and apparatus for the accurate formation of a three-dimensional article comprises providing a first quantity and a second quantity of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. Each quantity of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment means which repels each droplet toward an axis extending through the alignment means. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without a mold of the shape of the three-dimensional article. The droplets of the first quantity and the second quantity are supplied at different distances, whereby the droplets of the first quantity bond to each other and the droplets of the second quantity do not bond to each other or to the first quantity of droplets.

Abstract: A method for the accurate formation of a three-dimensional article comprises providing a supply of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. The supply of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment mechanism which repels each droplet toward an axis extending through the alignment mechanism. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without the use of a mold of the shape of the three-dimensional article.

Abstract: High-quality castings are formed by:(a) placing a molten material in contact with a first electrode formed from a conductive material and a second electrode formed from a semiconductive metal oxide, and(b) passing an electric current between the first second electrodes while the molten material is cooling at a current density of from 10 to 500 mA/cm.sup.2.

Abstract: An apparatus for centrifugal casting of hollow articles in particular pipes. The apparatus has an elongate generally cylindrical hollow mould with a center conductor extending along the longitudinal axis so that the combination acts as a coaxial waveguide. A microwave source and waveguide system are provided to direct substantially TEM mode radiation into one end of the mould. The mould and center conductor are terminated at the other end by a short circuit to microwave radiation so that standing waves are established in the mould. The invention also provides a method for centrifugal casting of such articles in which a casting composition is placed in a hollow rotating mould and microwave radiation is directed into the mould to heat the casting composition.

Abstract: An apparatus for preparing metallic radioactive waste material for storage is disclosed. The radioactive waste material is placed in a radiation shielded enclosure. The waste material is then melted with a plasma torch and cast into a plurality of successive horizontal layers in a mold to form a radioactive ingot in the shape of a spent nuclear fuel rod storage canister. The apparatus comprises a radiation shielded enclosure having an opening adapted for receiving a conventional transfer cask within which radioactive waste material is transferred to the apparatus. A plasma torch is mounted within the enclosure. A mold is also received within the enclosure for receiving the melted waste material and cooling it to form an ingot. The enclosure is preferably constructed in at least two parts to enable easy transport of the apparatus from one nuclear site to another.

Abstract: A method for forming a fiber-reinforced metal sheet including the steps of preparing a wire preform in which fibers and a matrix are combined together; arranging regularly a plurality of wire preforms in a predetermined direction in a side-by-side relation; irradiating simultaneously using a CO.sub.2 laser beam, and a YAG laser beam the regularly arranged wire preforms to elevate the temperature of the wire preforms; and pressing the wire preforms by rollers while the wire preforms are at the elevated temperature.

Abstract: A mold or parts of the mold are removed from a casting following solidification and cooling by immersing the casting with mold or mold particles still attached in a liquid such as oil or water and focusing shock waves onto interface portions to obtain ablation and spalling of the mold material to be removed from the casting.

Abstract: The invention relates to a method of and a device for simultaneously generating heat energy and oscillation energy. In the method heat is generated by induction heating and oscillations are created by means of at least piezoelectric elements. Previously a resonance circuit formed by a series connection of an inductive component and a capacitive, piezoelectric component has been used for the generation of oscillations only. A disadvantage of this kind of circuit has been that the circuit is difficult to control on account of the narrow resonance region of the piezoelectric element. This advantage is avoided in the solution according to the invention in such manner that one and the same resonance circuit formed by a series connection of an inductive and capacitive element generates both heat energy and oscillation energy.

Abstract: Hardened metals are produced by subjecting molten metals to the action of an electrostatic field of at least 1000 volts during the cooling and solidification of the metal.

Abstract: Nonmetallic inclusions and like contaminants are removed from a metal charge by melting the charge to form a molten pool on which the inclusion contaminants float and directing an electron beam onto a preselected first portion of the pool surface, said selective beam impingement causing the floating contaminants to segregate to other portion not subjected to beam impingement. Removal of molten metal from the impinged surface portion while the inclusion contaminants are confined elsewhere on the pool surface provides a clean molten metal product. Apparatus for use with the process is also disclosed. The invention finds special application in the master melting or remelting of metals and alloys for conversion to ingot shapes or high purity molten metal for powder making, investment casting, forging and the like.