Abstract: The invention relates to a process for manufacturing a part, comprising the formation of successive solid metal layers (201 . . . 20n) that are stacked on one another, each layer describing a pattern defined from a numerical model (M)), each layer being formed by depositing a metal (25), referred to as filling metal, the filling metal being subjected to an input of energy so as to melt and form said layer by solidifying, in which process the filling metal is provided in the form of a powder (25), the exposure of which to an energy beam (32) results in melting followed by solidification such that a solid layer (201 . . . 20n) is formed, the process being characterized in that the filling metal (25) is an aluminum alloy comprising at least the following alloying elements: ?2 to 10% by weight of Cr; ?0 to 5% by weight, preferably 0.5 to 5% by weight, of Zr. The invention also relates to a part obtained by this process.

Abstract: The invention relates to a method for producing an electrochemical cell comprising at least one porous electrode (2?), the method comprising at least the following method steps: (a) providing an electrode composition in the form of a homogeneous mixture comprising (i) at least one particulate active material (3); (ii) at least one particulate binder (5); (iii) at least one particulate pore-forming agent (4); and (iv) optionally at least one conducting additive (6); (b) forming a mouldable mass from the electrode composition; (c) applying the electrode composition to at least one surface of a substrate (1) to obtain a compact electrode (2); (d) producing an electrochemical cell comprising at least one compact electrode (2) which comprises the electrode composition according to method step (a); and (e) heating the at least one compact electrode (2) to liquefy the at least one particulate pore-forming agent (4); and/or (f) bringing the compact electrode (2) into contact with at least one liquid electrolyte compo

Abstract: A method for manufacturing a turbomachine component is disclosed, including the steps of producing, by additive manufacturing, a plurality of separate segments of the turbomachine component, having a skin surrounding an empty volume corresponding to a massive part of the turbomachine component; assembling the separate segments of the turbomachine component together forming a semi-finished component, with an empty cavity therein; filling cavity of the semi-finished component with a bulk flowable material; and densifying and solidifying the bulk flowable material in the cavity.

Abstract: The invention relates to a method for manufacturing a three-dimensional component 14 by means of an additive construction method in which the component 14 is constructed by solidifying construction material 9 that can be solidified using radiation 18, especially a selective laser melting method or a selective laser sintering method, in which the component 14 is produced by successively solidifying construction material 9 that can be solidified using the impact of radiation 18 by melting or sintering.

Abstract: A soft magnetic material comprising a soft magnetic metal powder and a resin, wherein the soft magnetic metal powder is constituted from a particle group ? and group ?, when IA is a peak intensity of the particle group ?, IB is a peak intensity of the particle group ?, and IC is a minimum intensity present between the particle group ? and group ?, then an intensity ratio IC/IA satisfies 0.10 or less and an intensity ratio IA/IB satisfies 1.2 or more and 3.0 or less, the particle group ? having a maximum peak intensity in a size distribution of the soft magnetic metal powder, the particle group ? having an peak intensity which is the second largest to the particle group ?, and a peak particle size PA of the particle group ? is larger than a peak particle size PB of the particle group ?.

Abstract: A method includes placing an additively manufactured article having one or more internal channels in a non-reactive liquid to remove remainder powder from within the one or more internal channels, wherein the non-reactive liquid is a gas at room temperature and/or pressure. Placing the additively manufactured article in the non-reactive liquid includes can include placing the additively manufactured article in liquid nitrogen.

Abstract: A method includes placing an additively manufactured article having one or more internal channels in a non-reactive liquid to remove remainder powder from within the one or more internal channels, wherein the non-reactive liquid is a gas at room temperature and/or pressure. Placing the additively manufactured article in the non-reactive liquid includes can include placing the additively manufactured article in liquid nitrogen.

Abstract: A method of making a component of a radial or axial flux electrical machine is provided. An additive manufacturing process is used to manufacture a plurality of laminas, including applying beams of energy to a successive plurality of ferromagnetic material particles and fusing them together to form a ferromagnetic helix or spiral, disposing an insulating material on said ferromagnetic helix or spiral, compressing the ferromagnetic helix or spiral to form a compressed ferromagnetic helix or spiral, and fixing the compressed ferromagnetic helix or spiral. A method of making a component of a transverse flux electrical machine is provided, including using an additive manufacturing process.

Abstract: Provided is a sliding member comprising: a steel back metal layer; and a sliding layer including a porous sintered layer and a resin composition. The porous sintered layer includes Fe or Fe alloy granules and a Ni—P alloy part functioning as a binder for binding the Fe or Fe alloy granules with one another and/or for binding the Fe or Fe alloy granules with the steel back metal layer. The steel back metal layer is made of a carbon steel including 0.05 to 0.3 mass % of carbon, and includes: a non-austenite-containing portion having a structure of a ferrite phase and perlite formed in a central portion in a thickness direction of the steel back metal layer; and an austenite-containing portion having a structure of a ferrite phase, perlite and an austenite phase formed in a surface portion of the steel back metal layer facing the sliding layer.

Abstract: A method for controlling the stationary clutching of an idler gear on a secondary shaft of a parallel shaft gearbox, by movement of a sliding gear constrained to rotate with said shaft towards the idler gear without the intervention of mechanical synchronization members, characterized in that it involves:—activating the translational movement of the sliding gear towards the idler gear without previous synchronization, if the two parts are unable to rotate when clutching is requested, and—activating a rotation of the idler gear following the free flight travel of the sliding gear to position the teeth of one in place of the holes of the other, if the clutch engagement threshold has not been crossed following a time delay.

Abstract: [Task] To provide a method that makes it possible to easily, inexpensively and accurately manufacture a machined part with a simple configuration and an excellent strength. [Means for Solution] In a method for manufacturing a machined part according to the invention, a dislocation is partially introduced (S3), through shot peening, only into a surface layer of a raw material 1 in a region 1a to be machined, graphite is partially deposited (S4), through heating, only in the surface layer of the region 1a to be machined, and then, the surface layer of the region 1a where graphite is deposited is removed, through machining (S5), only by an amount corresponding to a working margin 1c, thereby manufacturing a machined part 1?.

Abstract: In accordance with an exemplary embodiment, a method of forming a oxide dispersion-strengthened alloy metal includes the steps of providing, in a powdered form, an oxide dispersion-strengthened alloy composition that is capable of achieving a dispersion-strengthened microstructure, directing a low energy density energy beam at a portion of the alloy composition, withdrawing the energy beam from the portion of the powdered alloy composition, and cooling the portion of the powdered alloy composition at a rate greater than or equal to about 106° F. per second, thereby forming the oxide dispersion-strengthened alloy metal.

Abstract: Provided are methods for processing a green body that includes compacted metal powder, comprising impacting the green body with a particulate material for a time and under conditions effective to displace a portion of the metal powder from the green body. The present methods can be used to prepare green bodies that have “roughened” surfaces and that can be used to make orthopedic implants displaying low movement relative to bone when installed in situ, which corresponds to higher stability upon implantation and decreases the time required for biological fixation of the implant. Also provided are implants comprising a metallic matrix, and methods comprising surgically installing an implant prepared from a “surface roughened” green body in accordance with the present invention.

Abstract: An additive manufacturing apparatus and process for selectively heating a fluidized bed of powdered material (14), including powdered metal material (14?) and powdered flux material (14?)? with an energy beam (20). The powdered material is held within a chamber (12) to repair or manufacture a component (22). The powdered bed is fluidized by introduction of a non-inert gas into the chamber. Relative movement between the energy beam and component is controlled in accordance with a predetermined shape of the component. As the powdered material is heated, melted and solidified, a layer of slag (32) forms over a deposited metal (38) and is then removed so that fluidized powdered metal settling on a previously deposited metal substrate (34) can be heated, melted and solidified to build up the component.

Abstract: A method of manufacturing an article by hot pressing and ultrasonically inspecting the article comprises forming and filling a canister with powder material and evacuating and sealing the canister. Heat and pressure are applied to the canister to consolidate the powder material to form the article. The article within the canister is ultrasonically inspected by moving a transducer over the whole of the canister. The position of an interface between the article and the canister, and the thickness of the canister, at each position on the surface of the canister and if there are defects within the article are determined. The canister is then removed from the article by machining the canister using a machining tool, the movement of the tool is controlled such that at each position of the canister the tool removes the determined thickness of the canister for the corresponding position on the surface of the canister.

Abstract: The invention relates to a method for producing a strand-like, particularly band-like semi-finished part for electrical contacts, wherein the semi-finished part has a top side intended for making the electrical contact, said top side made from a silver-based composite material in which one or multiple metal oxides or carbon are embedded, and has a carrier layer supporting the composite material made of silver or a silver-based alloy, said method having the following steps: Powder-metallurgic production of a block made from the silver-based composite material, encasing of the block made of the composite material with a powder made primarily of silver, compressing the block, encased by the metal powder, to condense the metal powder, sintering the compressed block, reshaping the sintered block by extrusion pressing, creating a partial strand with a top side made from composite material and a bottom side made from silver or a silver-based alloy.

Abstract: A method of fabricating a three dimensional structure includes delivering a metal material to a printing site; and defining a microstructure of the metal material at the printing site by controlling the delivery of heating energy to the printing site and controlling the delivery of ultrasonic vibrations to the printing site.

Abstract: A sintered gear serving as a mechanical structure component is a mechanical structure component made of a metal sintered body, and includes a base region; and a high density region formed so as to include a maximum stress position at which a maximum tensile stress or a maximum shear stress is applied, and to include a surface, in which the high density region is lower in porosity than the base region. A surface hardened layer is formed in a region including the surface by performing a hardening process.

Abstract: A method for fabricating fine reduced iron powders comprises the following steps: heating fine iron oxide powders having a mean particle size of smaller than 20 ?m to a reduction temperature of over 700° C. to reduce the fine iron oxide powder into iron powders that are partially sintered into iron powder agglomerates; and performing a crushing-spheroidizing process on the iron powder agglomerates to obtain individual iron powders having a mean particle size of smaller than 20 ?m. The method can reduce iron oxide powers into iron powders having a rounded shape and a high packing density and a high tap density, which are suitable for the metal injection molding process and the inductor fabrication process. The reduced iron powder may further be processed using an annealing process and a second crushing-spheroidizing process in sequence to further increase the sphericity, packing density, and tap density of the reduced iron powder.

Abstract: Methods, systems, and apparatus, including computer programs encoded on computer storage media, for recycling magnetic material to restore or improve the magnetic performance. One of the methods includes demagnetizing magnetic material from a waste magnet assembly by cyclic heating and cooling of the magnetic material, fragmenting adhesives attached to the magnetic material, cracking coating layers of the magnetic material, and subjecting the magnetic material to at least one of: a) a mechanical treatment or b) a chemical treatment, to remove the coating layers and prepare the magnetic material without impurities, fragmenting the demagnetized magnetic material to form a powder, and mixing the powder with a rare earth material R and an elemental additive A to produce a homogeneous powder, wherein the rare earth material R comprises at least one of: Nd or Pr, and the elemental additive A comprises at least one of: Nd, Pr, Dy, Co, Cu, and Fe.

Abstract: The present invention relates to a method of making cutting tools comprising a substrate having a hard phase and a binder phase, the method comprising forming green powder compacts using powder metallurgical techniques, charging the green powder compacts, placed on one or several trays, in a furnace and sintering the green powder compacts wherein the furnace comprises an insulation package, at least three individually controlled heating elements located inside the insulation package including a vertical heating element, an upper horizontal heating element arranged in an upper part of the furnace, and a lower horizontal heating element arranged in a lower part of the furnace, wherein operating the at least three heating elements such that an average controlled cooling rate from a sintering temperature down to at least a solidification temperature of the binder phase is 0.1-4.0° C./min, and a sintering furnace operable to obtain a controlled cooling rate.

Abstract: Provided are methods for processing a green body that includes compacted metal powder, comprising impacting the green body with a particulate material for a time and under conditions effective to displace a portion of the metal powder from the green body. The present methods can be used to prepare green bodies that have “roughened” surfaces and that can be used to make orthopedic implants displaying low movement relative to bone when installed in situ, which corresponds to higher stability upon implantation and decreases the time required for biological fixation of the implant. Also provided are implants comprising a metallic matrix, and methods comprising surgically installing an implant prepared from a “surface roughened” green body in accordance with the present invention.

Abstract: A composite metal surface that looks metallic, but permits effective transmission of an electromagnetic field. The composite metal surface can be integrated into various electronic equipment, such as telephones, remote controls, battery doors, keyboards, mice, game controllers, cameras, laptops, inductive power supplies, and essentially any other electronic equipment. The composite metal surface can also be integrated into non-electrically conductive heat sinks, high permeability shielding, and polished metal non-electrically conductive surfaces.

Abstract: A composite material for a medical implant includes a matrix of magnesium or magnesium alloy, and a catalyst which is dispersed within the matrix. The catalyst has the capacity to reduce an amount of hydrogen gas released from the matrix when the matrix is being degraded inside the patient.

Abstract: Forming a wear- and corrosion-resistant coating on an industrial component such as a chemical processing or nuclear power valve component by applying a cobalt-based dilution buffer layer to an iron-based substrate by slurry coating, and then applying by welding a cobalt-based build-up layer over the cobalt-based dilution buffer layer. An industrial component having a dilution buffer layer and a welding build-up layer thereover.

Abstract: Compositions and methods for making a three dimensional structure comprising: designing a three-dimensional structure; melting the three-dimensional structure from two or more layers of a metal powder with a high energy electron or laser beam is described herein. The position where the metal is melted into the structure is formed along a layer of metal powder, wherein the location and intensity of the beam that strikes the metal layer is based on the three-dimensional structure and is controlled and directed by a processor. The instant invention comprises a novel dry state sonication step for removing metal powder that is not melted from the three dimensional structure.

Abstract: A method of manufacturing three-dimensional objects by laser sintering is provided, the object is formed by solidifying powder material layer by layer at locations in each layer corresponding to the object by means of laser radiation, wherein an IR-radiation image in an applied powder layer is detected, characterized in that defects and/or geometrical irregularities in the applied powder layer are determined on the basis of the IR-radiation image.

Abstract: A metal powder reconditioning apparatus and method recondition contaminated residual powder from an additive manufacturing device. The apparatus and method include a reducing chamber that receives contaminated residual powder resulting from an additive manufacturing process and remove oxygen from the contaminated residual powder to produce reconditioned powder. The reconditioned powder may be reused in the additive manufacturing process, or may be stored in a non-oxidizing atmosphere for later reuse.

Abstract: A method of making a sintered article in which a solid object is embedded includes forming a green body of compressed particles with the solid body is partially embedded. The green body includes an opening across which the solid body extends. The green body is sintered to form a sintered body and the opening permits deformation of the solid body in response to stress applied during the sintering process. A sintered article in which a solid body is at least partially embedded includes an opening. The solid body extends across the opening so that the solid body can deform within the opening. The opening in the solid body prevents distortion of the sintered body from a planar configuration during sintering, even when the green body is relatively thin.

Abstract: A method is provided that includes depositing metal powder over a seed crystal having a predetermined primary orientation, scanning an initial pattern into the metal powder to melt or sinter the deposited metal powder, and re-scanning the initial pattern to re-melt the scanned metal powder and form an initial layer having the predetermined primary orientation. The method further includes depositing additional metal powder over the initial layer, scanning an additional pattern into the additional metal powder to melt or sinter at least a portion of the additional metal powder, re-scanning the additional pattern to re-melt a portion of the initial layer and the scanned deposited additional metal powder to form a successive layer having the predetermined primary orientation, and repeating the steps of depositing additional metal powder, scanning the additional pattern, and re-scanning the additional pattern, until a final shape of the component is achieved.

Abstract: The present invention is related to a method for manufacturing Ru powder and a target which are frequently used in a seed layer for forming a magnetic layer. When producing Ru powder and a target by using a conventional wet method, it takes terribly much time to produce powder and to perform dissolution of a waste target and it also required much expensive cost. Further, since large quantity of chemical products were used, an environmental pollution problem such as disposal of waste water was generated. Thus, the present invention is devised to solve such a drawback. In order to improve this problem, the present invention is characterized in that it simply removes surface pollutants and foreign substances on a surface of a waste Ru target by using a chemical method or a mechanical method, Ru is produced by using plasma, refined High purity Ru powder is produced through a heat process and pulverization, and a Ru target of high density by sintering is acquired.

Abstract: A sputtering target for producing a metallic glass membrane characterized in comprising a structure obtained by sintering atomized powder having a composition of a ternary compound system or greater with at least one or more metal elements selected from Pd, Zr, Fe, Co, Cu and Ni as its main component (component of greatest atomic %), and being an average grain size of 50 ?m or less. The prepared metallic glass membrane can be used as a substitute for conventional high-cost bulk metallic glass obtained by quenching of molten metal. This sputtering target for producing the metallic glass membrane is also free from problems such as defects in the metallic glass membrane and unevenness of composition, has a uniform structure, can be produced efficiently and at low cost, and does not generate many nodules or particles. Further provided is a method for manufacturing such a sputtering target for forming the metallic glass membrane.

Abstract: The present invention concerns a filtering medium, a method for the production thereof, the use of said filtering medium and a method for reducing the content of multiple contaminants simultaneously in fluids by means of said filtering medium, wherein said filtering medium consists of or comprises at least one of the following: a mixture (A) containing a major part of an iron-based powder and a minor part of a silver powder, an iron-silver powder alloy (B), and an iron-based porous and permeable composite containing silver (C).

Abstract: The present invention provides an improved metal separator for a fuel cell and a method for preparing same. More particularly, the invention provides a metal separator for a fuel cell, whereby the separator has a surface structure that imparts reduced contact resistance, improved corrosion resistance, and stable electrical conductivity. The invention further provides a surface treatment method for making the metal separator of the invention. The inventive method comprises sintering Fe—Cr—B—V-based powder on the surface of a metal foam to form an alloy layer; and forming a nitride layer of a (Cr—V—B)N-based material while supplying nitrogen gas on the surface of the alloy layer.

Abstract: In various embodiments, a precursor powder is pressed into an intermediate volume and chemically reduced, via sintering, to form a metallic shaped article.

Abstract: An integrated composite structure with a graded coefficient of thermal expansion (CTE) is formed by selecting a plurality of layers of materials with a graded CTE and using build-up (bottom-up) fabrication approaches such as metal deposition or powder metallurgy to produce a CTE-graded layered composite preform, which is then consolidated and heat treated to create the CTE graded integrated composite billet or near net shape. The integrated composite billet or near net shape is then processed to produce a first surface for attachment of a first structural member having a first CTE and to produce a second surface of for attachment of a second structural member having a second CTE.

Abstract: An iron-based powder composition for metal injection molding having an average particle size of 20-60 ?m, and having 99% of the particles less than 120 ?m wherein the iron-based powder composition includes, by weight percent of the iron-based powder composition: Mo: 0.3-1.6, P: 0.1-0.6, optionally Cu: up to 3.0, optionally Si: up to 0.6, optionally Cr: up to 5, optionally, unavoidable impurities: up to 1.0, whereof carbon is less than 0.1, the balance being iron, and wherein the sum of Mo and 8*P content is within the range of 2-4.7.

Abstract: A collimator for x-ray, gamma, or particle radiation has a plurality of collimator elements made of a tungsten-containing material to reduce scattered radiation. At least one collimator element consists of a tungsten alloy having a tungsten content of 72 to 98 wt.-%, which contains 1 to 14 wt.-% of at least one metal of the group Mo, Ta, Nb and 1 to 14 wt.-% of at least one metal of the group Fe, Ni, Co, Cu. The collimator also has very homogeneous absorption behavior at very thin wall thicknesses of the collimator elements.

Abstract: A method of pressure forming a brown part from metal and/or ceramic particle feedstocks includes: introducing into a mold cavity or extruder a first feedstock and one or more additional feedstocks or a green or brown state insert made from a feedstock, wherein the different feedstocks correspond to the different portions of the part; pressurizing the mold cavity or extruder to produce a preform having a plurality of portions corresponding to the first and one or more additional feedstocks, and debinding the preform. Micro voids and interstitial paths from the interior of the preform part to the exterior allow the escape of decomposing or subliming backbone component substantially without creating macro voids due to internal pressure. The large brown preform may then be sintered and subsequently thermomechanically processed to produce a net wrought microstructure and properties that are substantially free the interstitial spaces.

Abstract: A component, in particular an engine component, which has at least one mark with a predetermined three-dimensional shape for determining a stress in the component and where the component is constructed by a generative manufacturing method, is disclosed.

Abstract: The invention concerns a process for the polishing of metallic dental prostheses, such as frames. In order to reproducibly obtain a defined surface roughness with no need for additional finishing, it is proposed for the dental prosthesis to be polished by means of plasma polishing.

Abstract: There is provided a metal powder for use in a selective laser sintering method for producing a three-dimensional shaped object, wherein the metal powder comprises a powder mixture of a precipitation-hardening metal composition. In particular, the metal powder of the present invention is configured to have a Fe-based component powder and a Ni-based component powder which are individually included in the powder mixture wherein a powder made of an alloy of Fe-based and Ni-based components is not included as a main powder in the powder mixture.

Abstract: A process for making a diffusion hardened medical implant having a porous surface is disclosed. The medical implant is made by a hot isostatic pressing process which simultaneously forms that porous surface and the diffusion hardened surface.

Abstract: A system for forming a bulk material having insulated boundaries from a metal material and a source of an insulating material is provided. The system includes a heating device, a deposition device, a coating device, and a support configured to support the bulk material. The heating device heats the metal material to form particles having a softened or molten state and the coating device coats the metal material with the insulating material from the source and the deposition device deposits particles of the metal material in the softened or molten state on the support to form the bulk material having insulated boundaries.

Abstract: A method of making a nanoparticle reinforced metal matrix component is provided. The method involves solid state processing nanoparticles into a metal matrix material at solid state processing conditions to form a master alloy. At least a portion of the master alloy is added to a mass of metal melt to produce the nanoparticle reinforced metal matrix component.

Abstract: Provided are a powder for a magnet, which provides a rare-earth magnet having excellent magnet properties and which has excellent formability, a method for producing the powder for a magnet, a powder compact, a rare-earth-iron-based alloy material, and a rare-earth-iron-nitrogen-based alloy material which are used as materials for the magnet, and methods for producing the powder compact and these alloy materials. Magnetic particles 1 constituting the powder for a magnet each have a texture in which grains of a phase 3 of a hydride of a rare-earth element are dispersed in a phase 2 of an iron-containing material, such as Fe. The uniform presence of the phase 2 of the iron-containing material in each magnetic particle 1 results in the powder having excellent formability, thereby providing a powder compact 4 having a high relative density.

Abstract: An ultrasonic welding tool fabricated of powder metal material includes a body and a welding tip extending axially from the body to a working end. The powder metal material can be ferrous-based and admixed with additives, such as alumina, carbide, ferro-molybdenum, ferro-nickel, chrome or tribaloy. An exposed surface of the welding tip can comprise Fe3O4 oxides. The tool is compacted to the desired shape and sintered. The body can include a different second material compacted separately from the welding tip and then joined to the tip and sintered.

Abstract: A method for manufacturing a plate-type heat pipe includes providing a mold including a first cavity and a plurality of second cavities and depositing cores into the mold. Each core has a first portion in the first cavity and a second portion in a corresponding second cavity. First and second metal powder are filled into the mold. The cores are then removed from the mold to form a green piece by the first and second metal powder, which has first and second chambers therein. The green piece is sintered, whereby the first metal powder forms an outer wall of the heat pipe and the second metal powder forms a wick structure. The heat pipe has a heat absorbing portion having the first chambers and fins having the second chambers communicating with the first chambers.

Abstract: A method of manufacturing powder metal plates comprising feeding a predetermined mass of metal powder onto a moving tape (101), restricting the metal powder by surrounding the metal powder with vibrating boundary walls (201, 202) extending parallel to the direction of movement of the tape, rolling the metal powder at an ambient temperature to form a green compact strip (GS), continuously sintering the green compact strip in a furnace (400), forming the green compact strip to a net shape part (NS) while in the furnace, and cooling the net shape part in a non-oxidizing environment (404) at a temperature in excess of 1000 degrees Celsius.

Abstract: A molding is produced with a disk-shaped or plate-shaped basic body having a large number of knob-like and/or web-like elevations which merge into the basic body with inclined side surfaces. The molding is produced by pressing and sintering powdery raw materials close to the final shape. First, the boundary surfaces of the basic body are pressed to final shape as far as the transition regions of the elevations and the elevations are pressed to an oversize. The projection height of the elevations from the basic body is greater than the projection height in the finally pressed state. Their side surfaces form an angle of inclination in the range from 90°-150° with the respectively adjacent boundary surface of the basic body. Then the elevations are pressed to near final shape while the angle of inclination is enlarged to a greater value.