Abstract: An apparatus and method are provided for manufacturing an orthopedic prosthesis by resistance welding a porous metal layer of the orthopedic prosthesis onto an underlying metal substrate of the orthopedic prosthesis. The resistance welding process involves directing an electrical current through the porous layer and the substrate, which dissipates as heat to cause softening and/or melting of the materials, especially along the interface between the porous layer and the substrate. The softened and/or melted materials undergo metallurgical bonding at points of contact between the porous layer and the substrate to fixedly secure the porous layer onto the substrate.

Abstract: To provide a storage battery electrode including an active material layer with high density that contains a smaller percentage of conductive additive. To provide a storage battery having a higher capacity per unit volume of an electrode with the use of the electrode for a storage battery. A slurry that contains an active material and graphene oxide is applied to a current collector and dried to form an active material layer over the current collector, the active material layer over the current collector is rolled up together with a spacer, and a rolled electrode which includes the spacer are immersed in a reducing solution so that graphene oxide is reduced.

Abstract: A product may include a storage vessel that may define a first port opening into the storage vessel, and that may define a second port opening into the storage vessel. A first fill conduit may be connected to the storage vessel at the first port. A second fill conduit may be connected to the storage vessel at the second port. A control mechanism may be connected with the first and second fill conduits. A supply conduit may be connected to the control mechanism. The control mechanism may provide a flow path from the supply conduit to at least one of the first or second fill conduits to fill the storage vessel.

Abstract: The design and method of fabrication of a three-dimensional, porous flow structure for use in a high differential pressure electrochemical cell is described. The flow structure is formed by compacting a highly porous metallic substrate and laminating at least one micro-porous material layer onto the compacted substrate. The flow structure provides void volume greater than about 55% and yield strength greater than about 12,000 psi. In one embodiment, the flow structure comprises a porosity gradient towards the electrolyte membrane, which helps in redistributing mechanical load from the electrolyte membrane throughout the structural elements of the open, porous flow structure, while simultaneously maintaining sufficient fluid permeability and electrical conductivity through the flow structure.

Abstract: A cladding method for a valve seat in a cylinder head blank includes a combustion chamber, an intake port or an exhaust port communicating with the combustion chamber, and an annular countersunk groove formed in an opening end of the port on the combustion chamber side, the method being for forming a cladding layer by irradiating metal powder supplied in the countersunk groove with a laser beam. A gas flow regulating wall is provided, which projects from the countersunk groove to an inner side of the countersunk groove and to the combustion chamber side, gas is sprayed during irradiating with the laser beam, and the gas is flown by the gas flow regulating wall from the inner side to an outer side of the countersunk groove.

Abstract: A syntactic metal foam composite that is substantially fully dense except for syntactic porosity is formed from a mixture of ceramic microballoons and matrix forming metal. The ceramic microballoons have a uniaxial crush strength and a much higher omniaxial crush strength. The mixture is continuously constrained while it is consolidated. The constraining force is less than the omniaxial crush strength. The substantially fully dense syntactic metal foam composite is then constrained and deformation worked at a substantially constant volume. This deformation causes at least work hardening and grain refinement in the matrix metal. The resulting deformed syntactic metal foam composite has an energy absorption capacity that is at least 1.5 to 2 or 3 times or more the energy absorption capacity of the precursor substantially fully dense syntactic metal foam composite.

Abstract: A material and method are disclosed such that the material can be used to form functional metal pieces by producing an easily sintered layered body of dried metal paste. On a microstructural level, when dried, the metal paste creates a matrix of porous metal scaffold particles with infiltrant metal particles, which are positioned interstitially in the porous scaffold's interstitial voids. For this material to realize mechanical and processing benefits, the infiltrant particles are chosen such that they pack in the porous scaffold piece in a manner which does not significantly degrade the packing of the scaffold particles and so that they can also infiltrate the porous scaffold on heating. The method of using this paste provides a technique with high rate and resolution of metal part production due to a hybrid deposition/removal process.

Abstract: A foam for use in a lost-foam casting process utilized in the manufacture of a component for a gas turbine engine, the foam having a void fraction less than or equal to ninety five percent, is disclosed. The foam may include a first layer comprising polymer foam having an open-cell structure and a void fraction greater than ninety five percent. A second layer, comprising adhesive, may be adhered to the first layer. A third layer comprising particulate material may be adhered to the second layer.

Abstract: Prosthetic element for bone extremities such as fingers or toes, or teeth, comprising a trabecular part (20, 40, 120) and two end parts or stumps (12, 34, 112; 15, 39, 115).

Abstract: The invention relates to a method for manufacturing an electrode for an electrochemical energy store, including the following steps: a) providing a base body; b) applying an active material matrix to the base body, the active material matrix including at least one binding agent, if necessary, an active material (1), and a pore forming agent (3), the pore forming agent (3) being soluble in a solvent, in which additional components of the active material matrix are insoluble or are soluble only under certain conditions; c) if necessary, drying the active material matrix; d) rinsing out the pore forming agent (3) by treating the active material matrix with the solvent and e) if necessary, introducing an active material into the produced pores of the active material matrix. Using such a method, a high cycle stability of the electrode may be implemented in a particularly simple and cost-effective way. The invention also relates to a method for manufacturing an electrochemical energy store.

Abstract: A powder metal compact is disclosed. The powder metal compact includes a cellular nanomatrix comprising a nanomatrix material. The powder metal compact also includes a plurality of dispersed particles comprising a particle core material that comprises an Al—Cu—Mg, Al—Mn, Al—Si, Al—Mg, Al—Mg—Si, Al—Zn, Al—Zn—Cu, Al—Zn—Mg, Al—Zn—Cr, Al—Zn—Zr, or Al—Sn—Li alloy, or a combination thereof, dispersed in the cellular nanomatrix.

Abstract: The invention relates to a bone substitute (1) comprising A) a container (2) made of a porous casing (4) which is at least partly provided with openings; and B) a plurality of filler elements (5) which are not connected to one another and which are enclosed in the container (2); wherein C) the filler elements (5) consist of interconnected particles with an average diameter Dp; and D) the openings of the casing (4) are interconnected pores or channels with an average diameter of DM.

Abstract: A screen element for a fuel system includes a first screen and a second screen. The first screen defines a first aperture and the second screen defines a second aperture. The first aperture and the second aperture are arranged out of circumferential alignment with one another such that a torturous flow path is defined through the apertures for capturing particles smaller than the apertures in a collection cavity defined between the screens.

Abstract: A porous medical implant and a method of making same is described. The medical implant comprises a porous surface formed by application of pulsed electrical energy ins such a way as to cause a localized heating in the surface of the material comprising portions of the implant. The method comprises a pulsed current sintering technique.

Abstract: The invention relates to a process for fabrication of an electrode film in an all-solid-state battery comprising successive steps to: a) Procure a substrate, preferably a conducting substrate, b) Deposit an electrode film on said substrate by electrophoresis, from a suspension containing particles of electrode materials, c) Dry the film obtained in the previous step, d) Thermal consolidation of the electrode film obtained in the previous step by sintering, sintering being done at a temperature TR that preferably does not exceed 0.7 times the melting temperature (expressed in ° C.), even more preferably does not exceed 0.5 times the melting temperature (expressed in ° C.), and much more preferably does not exceed 0.3 times the melting temperature (expressed in ° C.) of the electrode material that melts at the lowest temperature.

Abstract: A powder-metallurgical body and a method for producing such a body. The powder-metallurgical body is formed with a seating base for seating a sealing element to produce a seal with respect to fluids, such as liquids and/or gases. The body is redensified in a low-lying depth region of the seating base.

Abstract: Embodiments of the present invention relate to a hydrogen generating fuel comprising grains comprising a promoter and AlH3, each grain having a size between 1 and 10 ?m. In some embodiments, the grains can be pressed into a porous pellet.

Abstract: This method for producing porous sintered aluminum includes: mixing aluminum powder with a sintering aid powder containing a sintering aid element to obtain a raw aluminum mixed powder; forming the raw aluminum mixed powder into a formed object prior to sintering having pores; and heating the formed object prior to sintering in a non-oxidizing atmosphere to produce porous sintered aluminum, wherein the sintering aid element is titanium, and when a temperature at which the raw aluminum mixed powder starts to melt is expressed as Tm (° C.), then a temperature T (° C.) of the heating fulfills Tm-10 (° C.)?T?685 (° C.).

Abstract: A method of producing a 3-dimensional (“3-D”) product from metals in the gaseous state includes the steps of providing a substrate of 3-D shape; providing a flow of a gaseous chemical compound(s) around the 3-D substrate, wherein the gaseous chemical compound(s) comprises a metal carbonyl gas; selectively heating the 3-D substrate to decompose the metal carbonyl gasses, wherein metal separated as a result of the decomposition is deposited on the 3-D substrate; selectively controlling the flow rate of one or more metal carbonyl gasses and the temporal and spatial temperature distribution throughout the 3-D substrate to achieve a desired thickness distribution of the metal or metals on the 3-D substrate; and removing the 3-D substrate to produce a resulting 3-D metal product with an complex geometry.

Abstract: To provide a storage battery electrode including an active material layer with high density that contains a smaller percentage of conductive additive. To provide a storage battery having a higher capacity per unit volume of an electrode with the use of the electrode for a storage battery. A slurry that contains an active material and graphene oxide is applied to a current collector and dried to form an active material layer over the current collector, the active material layer over the current collector is rolled up together with a spacer, and a rolled electrode which includes the spacer are immersed in a reducing solution so that graphene oxide is reduced.

Abstract: A lithium accumulator with a housing includes at least one cell with two electrodes provided with current collectors and separated by a separator. Each electrode, free of organic binders, is pressed down onto both sides of the current collector made of a perforated metal strip in the form of metal network, expanded metal or perforated metallic foil. The minimum thickness of the electrodes is three times the thickness of the perforated metal strip.

Abstract: A printable refractory material is provided having a liquid and powder component configured for use in a 3-D powder printer, where the material forms hydraulic bonds when the liquid and powder components are combined. Methods of printing the refractory material and forming castings therefrom are also provided.

Abstract: A method of manufacturing a hydrogen storage device includes the steps: (1) mix metal powder, backbone binder and wetting agent to make a canister shell feedstock; (2) mix metal powder, salts, backbone binder and wetting agent to make a porous structure feedstock; (3) feed the canister shell feedstock in an injection molding machine to form a green part of canister shell; (4) feed the porous structure feedstock in the green part of canister shell to form a green part of porous structure integral with the green part of canister shell by injection molding; (5) dissolve the salts out of the green part of porous structure to form pores; (6) remove the wetting agent from the green parts of canister shell and porous structure; (7) remove the backbone binder from the green parts of canister shell and porous structure to form the hydrogen storage device.

Abstract: High strength implantable devices having complex surfaces are injection molded from powder metal wherein the surface is defined by a monolithic insert made by additive manufacturing. The insert defines the surface texture of the device and may also include a portion to form an ingrowth texture and a portion to form a substrate interface texture. The tensile bond strength of the texture is 20 Mega Pascal or greater.

Abstract: A method of making a fluidic device is provided. The method includes locating a meltable sheet material on a face of an extruded body including extended cells therein. At least some of the cells are interconnected by melting the sheet material such that the melted sheet material flows into the at least some of the cells to form a fluidic passage through the body defined within the at least some of the cells. The fluidic passageway may have a longitudinally serpentine path back and forth along the at least some of the cells.

Abstract: A method for producing and reactivating a solid oxide cell stack structure by providing a catalyst precursor in at least one of the electrode layers by impregnation and subsequent drying after the stack has been assembled and initiated. The method includes impregnating a catalyst precursor into a cathode of a solid oxide cell stack which already contains an active material (an anode reduction) for example, in the form of Ni/YSZ anodes. Due to a significantly improved performance and an unexpected voltage improvement this solid oxide cell stack structure is particularly suitable for use in solid oxide fuel cell (SOFC) and solid oxide electrolysing cell (SOEC) applications.

Abstract: Systems and methods for fabricating multi-functional articles comprised of additively formed gradient materials are provided. The fabrication of multi-functional articles using the additive deposition of gradient alloys represents a paradigm shift from the traditional way that metal alloys and metal/metal alloy parts are fabricated. Since a gradient alloy that transitions from one metal to a different metal cannot be fabricated through any conventional metallurgy techniques, the technique presents many applications. Moreover, the embodiments described identify a broad range of properties and applications.

Abstract: The invention relates to a method for producing bioactive implant surfaces consisting of metallic or ceramic materials, to be used for implants such as artificial joints or very small implants such as so-called stents. The invention also relates to implants produced according to this method and methods of using the implants.

Abstract: A gas filtration apparatus and method comprises a housing with an inlet for gas to enter and an outlet for the gas to exit. The housing contains a filter comprised of sintered metal fibers having an active filtration area through which the gas flows to remove suspended particles from the gas. The filter is substantially uniform in thickness and porosity through the active filtration area. The filter media being sealed to a metal structure in the housing with the metal structure having an opening to permit gas to flow through. A method of making a vapor/gas mixture includes the steps of producing a vapor in a gas to form the vapor/gas mixture passing the vapor/gas mixture through an opening in a housing containing a filter comprised of sintered metal fibers through which the vapor/gas mixture flows.

Abstract: Prosthetic element for bone extremities such as fingers or toes, or teeth, comprising a trabecular part (20, 40, 120) and two end parts or stumps (12, 34, 112; 15, 39, 115).

Abstract: A cooled article and a method of forming a cooled article are disclosed. The cooled article includes a component, a porous material incorporated into the component, and a cooling medium within the porous material. Another cooled article is formed by a process includes the steps of forming a porous material from a pre-sintered preform, providing a component, and incorporating the porous material into the component. The porous material is in fluid communication with a cooling medium. The method of forming a cooled article includes providing a metal felt material infused with braze filler material, pre-sintering the metal felt material to form a porous material, providing a component, and incorporating the porous material into the component.

Abstract: A partly oxidized substrate is disclosed. According to one aspect, the substrate is formed by subjecting a substrate made of a porous metal or metal alloy including particles of at least one metal or metal alloy bound by sintering. The substrate includes a first main surface and a second main surface. The porosity of the substrate gradually changes from the first main surface to the second main surface. The substrate is partially oxidized by an oxidizing gas such as oxygen and/or air. A method for preparing the substrate and high temperature electrolyzer (THE) cell including the substrate are also disclosed.

Abstract: First, an ionic liquid is placed on a glass slide, which is then installed in an evaporation apparatus, and a metal (for example, indium) is mounted as a target material at a position facing the ionic liquid, followed by sputter deposition of the metal. After sputtering, the ionic liquid containing nanoparticles dispersed therein is recovered. The nanoparticles are solid nanoparticles. Next, the ionic liquid containing the solid nanoparticles dispersed therein is placed in a test tube and then oxidized by heating in air at 250° C. for 1 hour. As a result, hollow nanoparticles having cavities formed in core portions of the solid nanoparticles are produced.

Abstract: A method for manufacturing a high ductility Ti-, Ti-alloy or NiTi-foam, meaning a compression strain higher than 10%, includes: preparing a powder suspension of a Ti-, NiTi- or Ti-alloy powder, bringing the said powder suspension into a desired form by gelcasting to form a green artifact. The method also includes a calcination step wherein the green artifact is calcined, and sintering the artifact. The calcination step includes a slow heating step wherein said green artifact is heated at a rate lower or equal to 20° C./hour to a temperature between 400° C. and 600° C. and the Ti-, NiTi- or Ti-alloy powder has a particle size less than 100 ?m. A high ductility Ti-, Ti-alloy or NiTi foam, with a compression higher than 10%, with a theoretical density less than 30%, pore size (cell size) between 50 to 1000 ?m can be obtained with such a method.

Abstract: The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

Abstract: An orthopaedic prosthesis and a method for rapidly manufacturing the same are provided. The orthopaedic prosthesis includes a solid bearing layer, a porous bone-ingrowth layer, and an interdigitating layer therebetween. A laser sintering technique is performed to manufacture the orthopaedic prosthesis.

Abstract: This method for producing porous sintered aluminum Includes: mixing aluminum powder with a sintering aid powder containing titanium to obtain a raw aluminum mixed powder; mixing the raw aluminum mixed powder with a water-soluble resin binder, water, and a plasticizer containing at least one selected from polyhydric alcohols, ethers, and esters to obtain a viscous composition; drying the viscous composition in a state where air bubbles are mixed therein to obtain a formed object prior to sintering; and heating the formed object prior to sintering in a non-oxidizing atmosphere, wherein when a temperature at which the raw aluminum mixed powder starts to melt is expressed as Tm (° C.), a temperature T (° C.) of the heating fulfills Tm?10 (° C.)?T?685 (° C.

Abstract: A bone screw is described which includes a one-piece threaded screw body composed at least partially of a rigid foam. The screw body is headless and includes a bore extending therethrough to define a cannula and thereby providing the screw body with an annular shape defining a radial wall thickness. At least a central portion of the screw body is formed of the rigid foam which defines a matrix having a plurality of inter-connected pores therein. The inter-connected pores are disposed throughout the complete radial wall thickness of the screw body from an outer surface of the screw body to an inner surface thereof within the cannula, such as to permit bone in-growth through the complete radial wall thickness of the annular screw body. The inter-connected pores and the cannula thereby respectively allow bone in-growth through the complete radial wall thickness and the full axial length of the screw body.

Abstract: Using metal foams for the electrode of secondary lithium battery, preparing method thereof, and secondary lithium battery including the metal foam. A metal foam is used in an electrode of secondary lithium battery where the surface and the inner pore walls are coated with the active materials, a method of manufacturing such metal foam, and secondary lithium battery including the metal foam.

Abstract: The present invention relates to a process for producing porous metallic materials comprising the steps of: (a) miming metallic particles with a carbonate additive and a binder, wherein the quantity of carbonate additive in the mixture is in the range of 40 to 90 vol % and compressing the mixture beyond the yield strength of the metallic particles; (b) heating the mixture to a first temperature sufficient to evaporate the binder; (c) heating and maintaining the temperature of the mixture to a second temperature sufficient to sinter the metallic particles but insufficient to decompose or melt the carbonate additive; (d) removing the carbonate additive from the sintered porous metallic material; and optionally (e) heating and maintaining the temperature of the porous metallic material to a third temperature greater than the second temperature so as to enhance the sintering. The present invention also relates to metallic materials produced by such a process.

Abstract: A method of manufacturing an orthopedic implant is provided. The method includes creating a 3D model of an orthopedic implant having a solid portion and a porous portion and selectively adjusting a physical property of at least one of porosity of the porous portion, lattice thickness of the porous portion, beam profile of the porous portion, and topography of the 3D model. The entire implant is then additively manufactured based on the 3D model.

Abstract: One aspect relates to a medical implant, for example, implantable stimulation electrode, having a tight substrate and a porous contact region. One aspect also relates to a lead of a cardiac pacemaker having an implantable stimulation electrode and to a method for manufacturing a medical implant, for example, an implantable stimulation electrode. A medical implant according to one aspect is characterized in that the implant includes a sintered body with graduated porosity.

Abstract: The present disclosure provides methods to improve the properties of a porous structure formed by a rapid manufacturing technique. Embodiments of the present disclosure increase the bonding between the micro-particles 5 on the surface of the porous structure and the porous structure itself without substantially reduce the surface area of the micro-particles. In one aspect, embodiments of the present disclosure improves the bonding while preserving or increasing the friction of the structure against adjacent materials.

Abstract: The present invention relates to a porous amorphous alloy artificial joint and a manufacturing method thereof The porous amorphous alloy artificial joint is formed of at least one of amorphous alloy compounds represented by Formula 1 to Formula 4 as described in the present specification.

Abstract: The process comprises the steps of: mixing a load of oxide ceramic material particles (10) with a load of space holder particles (20), defined by graphite and/or amorphous carbon; compacting the mixture formed by ceramic material particles (10) and space holder particles (20), to form a compact body (E); and sintering said compact body (E), so that the ceramic material particles (10) form sintering contacts with each other, whereas the carbon of the space holder particles (20) is removed by the reaction with the oxygen in the sintering medium, to form open secondary pores (II), by eliminating the space holder particles (20). The metallurgic composition comprises the mixture of the ceramic material particles (10) with the space holder particles (20).

Abstract: [Object] The present invention provides a porous sintered body which has a uniform porosity, a high level of freedom in forming, allowing to be formed into varieties of shapes and various levels of porosity, and to be formed to an extremely high level of porosity. [Means for Solution] There is provided a porous sintered body 1 which is obtained by sintering a powder 4, and includes hollow cores 5 following a vanished shape of an interlaced or otherwise structured fibriform vanisher material 2; sintered walls 6 obtained by sintering the powder held around the cores and extending longitudinally of the cores; and voids 7 between the sintered walls.

Abstract: It is an objective of the present invention to provide an aluminum porous body which is formed of a pure aluminum and/or aluminum alloy base material and has excellent sinterability and high dimensional accuracy without employing metal stamping. There is provided an aluminum porous body having a relative density of from 5 to 80% with respect to the theoretical density of pure aluminum, in which the aluminum porous body contains 50 mass % or more of aluminum (Al) and from 0.001 to 5 mass % of at least one selected from chlorine (Cl), sodium (Na), potassium (K), fluorine (F), and barium (Ba). It is preferred that the aluminum porous body further contains from 0.1 to 20 mass % of at least one selected from carbon (C), silicon carbide (SiC), iron (II) oxide (FeO), iron (III) oxide (Fe2O3), and iron (II,III) oxide (Fe3O4).

Abstract: Methods for manufacturing an endovascular stent having channel(s) formed therein for containing a therapeutic material. A molding and sintering process forms a thin-walled tubular component having a tubular core structure encapsulated therein. Portions of the thin-walled tubular component are removed to form at least a portion of the endovascular stent in a pattern corresponding to that of the tubular core structure such that the tubular core structure or corresponding channel(s) left thereby are captured within a wall of the formed stent. The tubular core structure is removed to leave a corresponding channel(s) in its stead. A plurality of holes is formed in the stent wall for filling the stent channel(s) with the therapeutic material and for eluting the therapeutic material therefrom.

Abstract: A method for manufacturing porous aluminum, comprising steps of: press-molding a powder mixture of aluminum powder and supporting powder under pressure of not lower than 200 MPa, the aluminum powder having a volume ratio of 5 to 30% with respect to a total volume of the powder mixture; sintering a press-molded body with heat treatment in an inert atmosphere within a temperature range of not lower than a melting point of the aluminum powder and lower than 700° C.; and removing the supporting powder from a sintered body. With this method, the porous aluminum having a high porosity and a uniform pore diameter, which is suitable for a current collector in a lithium-ion secondary battery and for a variety of filters, is readily manufactured.

Abstract: A method for manufacturing a three-dimensional biomedical device for fitting in a bone defect having an osteoinductive first area with a controlled porosity and a second area, which is produced by laser technology from an absorbent and from a first powder including one of ceramics, metals, metal alloys, bioactive glasses, lead zirconate titanate and biocompatible polymers, or mixtures thereof, wherein the ratio of the porosities from the second area to the first area is equal or less than one, preferably from 0.001 to 0.9, wherein a virtual object is designed with a computer-aid designed software, and the device is manufactured by laser technology including layering a powder onto a plate (7) so that a layer of a predetermined thickness is formed; the laser beam (8) selectively processes the powder to produce a processed layer, and, thus, layer after layer, the layers are joined together until the biomedical device is formed.