Abstract: Some examples include methods of operating an additive manufacturing machine including generating thermal energy with a thermic source including a warming source and a fusing source, each of the warming and fusing sources having a major axis longitudinally extending in a y-axial direction above a build zone, the build zone to contain a build material and a fusing agent, moving the thermic source in a x-axial direction orthogonal to the y-axial direction over the build zone at a constant velocity, delivering a first substantially uniform heat flux from the warming source and a second substantially uniform heat flux from the fusing source to cause portions of the build material that the fusing agent is disposed on to form a layer of a three dimensional object, and continuously generating thermic energy from the thermic source during a build process of the three dimensional object.

Abstract: An additive manufacturing method may involve: Providing a first material in powder form and a second material as a consumable electrode; forming the first material into a first layer on a base; placing an end of the second material in close proximity to a portion of the first layer; operating a power supply connected to the base and the second material to provide electrical energy sufficient to initiate a chemical reaction between the first and second materials and form a reaction product; feeding additional amounts of the second material while moving the end of the second material along a desired pattern adjacent the first layer, additional reaction products forming additional portions of the article; providing additional quantities of the first material over the first layer to form a subsequent layer; and operating the power supply to form additional portions of the article in the subsequent layer.

Abstract: An additive manufacturing system includes a platen having a top surface, a support structure, a powder dispenser coupled to the support structure and positioned above the platen and configured to deliver a powder in a linear region that extends along a first axis, a gas dispenser coupled to the support structure in a fixed position relative to the powder dispenser and having an outlet to deliver a gas across the outermost layer of feed material, an energy source configured to selectively fused the layer of powder, and an actuator coupled to the support to move the support with the powder dispenser and the gas dispenser together along a second axis perpendicular to the first axis and parallel to the top surface such that the linear region and the outlet sweep along the second axis to deposit the powder in a swath over the platen and deliver the gas.

Abstract: A build plate system includes a body defining at least one cavity. An insert is sized and shaped to fit within the at least one cavity such that the at least one cavity orients the insert for forming at least a portion of a screw shaft thereon by a manufacturing method using an additive manufacturing apparatus. In some embodiments, systems, spinal constructs, surgical instruments and methods are disclosed.

Abstract: A powder module for an apparatus for additive manufacturing of three-dimensional objects, comprising a powder chamber limiting a powder room that can be filled with powdered construction material and a carrying device arranged in the powder room and limiting the powder room at the bottom, wherein between at least one powder chamber wall limiting the powder room and the carrying device a gap extending at least partially along the powder chamber wall limiting the powder room is formed, through which powdered construction material from the powder room can enter a powder module section lying below the carrying device, wherein the gap opens out into a receiving section of a receiving element arranged or formed on the powder chamber, wherein the receiving section is formed as or comprises an especially ring-shaped circumferential flow channel structure provided for receiving construction material from the gap.

Abstract: An additive manufacturing system includes a platen having a top surface to support an object being manufactured, a feed material dispenser to deliver a plurality of successive layers of feed material over the platen, an energy source positioned above the platen to fuse at least a portion of an outermost layer of feed material, and a coolant fluid dispenser to deliver a coolant fluid onto the outermost layer of feed material after at least a portion of the outermost layer has been fused.

Abstract: A method of selecting a scanning sequence of a laser beam in a selective laser solidification process, in which one or more objects are formed layer-by-layer by repeatedly depositing a layer of powder on a powder bed and scanning the laser beam over the deposited powder to selectively solidify at least part of the powder layers, includes determining an order in which areas should be scanned by: projecting a debris fallout zone that would be created when solidifying each area based on a gas flow direction of a gas flow passed over the powder bed; determining whether one or more other areas to be solidified fall within the debris fallout zone; and selecting to solidify the one or more other areas that fall within the debris fallout zone before solidifying the area from which the debris fallout zone has been projected.

Abstract: The present disclosure describes three-dimensional (3D) printing apparatuses and systems for producing 3D objects. Described herein are printing apparatuses and systems that are configured to facilitate control of debris within an enclosure where one or more printing operations are performed. Printing apparatuses and systems of the present disclosure may each have one or more components, such as, for example, component(s) that are configured to facilitate gas flow trajectories (e.g., turbulent movement) within an enclosure in which a 3D object is printed.

Abstract: A method for forming a three-dimensional article through successive fusion of parts of a powder bed, which parts corresponds to successive cross sections of the three-dimensional article, said method comprising the steps of: providing a model of said three dimensional article, providing a first powder layer on a work table, directing a first energy beam from a first energy beam source over said work table causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, directing a second energy beam from a second energy beam source over said work table causing said first powder layer to fuse in second selected locations according to said model to form the first cross section of said three-dimensional article, wherein said first and second locations of said first powder layer are at least partially overlapping each other.

Abstract: acting on a powder layer in a working zone, containing a device for layering said powder, said device including: means for storing powder, means for distributing powder that travel over the working zone to distribute powder in a layer having a final thickness for additive manufacturing, feeding means that transfer powder from storage means to distributing means, metering means that control the quantity of powder transferred from storage means to distributing means, said machine being wherein: storage means are positioned higher than the working zone, feeding means utilize gravity, feeding means and the metering means move with the distributing means, the machine has two separate working zones and two separate working trays that move independently of one another, each of the working trays is associated with only one working zone, and the layering device is common to both working zones.

Abstract: A laser sintering powder to be sintered by irradiation with a laser light is provided. The sintering powder includes a plurality of metal particles and a binder which binds the metal particles to one another. The binder is sublimated by the irradiation with the laser light. The average particle diameter of the metal particles is 5 ?m or more and 10 ?m or less, and the average particle diameter of the laser sintering powder is 30 ?m or more and 50 ?m or less. Further, after a powder layer is formed using the laser sintering powder, this powder layer may be compressed in the thickness direction before or after irradiation with the laser light.

Abstract: Improved devices and methods for additive manufacturing of implant components are disclosed, including improvements relating to utilizing support structures, aligning implant designs within the manufacturing apparatus, and making patient-adapted implants.

Abstract: A method for forming a three-dimensional article comprising applying a first powder layer on a work table; directing a first energy causing said first powder layer to fuse in first selected locations to form a first cross section where said first energy beam is fusing a first region with parallel scan lines in a first direction and a second region with parallel scan lines in a second direction; fusing at least one of the scan lines in said first region in said first direction immediately before fusing at least one of said scan lines in said second region in said second direction; applying a second powder layer and directing the energy beam causing said second powder layer to fuse in second selected locations where the energy beam is fusing said first region with parallel scan lines in a third direction and said second region in a fourth direction.

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: 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 for manufacturing a fluid-leading component includes positioning a base element machined by a material-removing method with a planar upper face in a mounting support. The method at least includes the initial application of a layer section with predetermined dimensions of a particulate material in a predetermined region on the planar upper face of the base element; the heating of the layer section by a heat source in such a manner that the particles of the material within predetermined dimensions bond; and the application thereto and heating of at least one further layer section with predetermined dimensions of a particulate material in a predetermined region. In this way it is possible, in the generative manufacturing method, to obviate the need to provide support structures that subsequently have to be removed, and the base element is a functional part of the component to be manufactured.

Abstract: A method for preparing an implant having a porous metal component. A loose powder mixture including a biocompatible metal powder and a spacing agent is prepared and compressed onto a metal base. After being compressed, the spacing agent is removed, thereby forming a compact including a porous metal structure pressed on the metal base. The compact is sintered, forming a subassembly, which is aligned with a metal substrate portion of an implant. A metallurgical bonding process, such as diffusion bonding, is performed at the interface of the subassembly and the metal substrate to form an implant having a porous metal component.

Abstract: A method for increasing the resolution when forming a three-dimensional article through successive fusion of parts of a powder bed, said method comprising providing a vacuum chamber, providing an electron gun, providing a first powder layer on a work table inside said vacuum chamber, directing an electron beam from said electron gun over said work table causing the powder layer to fuse in selected locations to form a first cross section of said three-dimensional article, providing a second powder layer on said work table, directing the electron beam over said work table causing said second powder layer to fuse in selected locations to form a second cross section of said three-dimensional article, reducing the pressure in the vacuum chamber from a first pressure level to a second pressure level between the providing of said first powder layer and said second powder layer.

Abstract: A method of selectively combining particulate material, comprising: (i) providing a layer of particulate material to a part bed; (ii) providing radiation to sinter a portion of the material of the layer; (iii) providing a further layer of particulate material overlying the prior layer of particulate material including the previously sintered portion of material; (iv) providing radiation to sinter a further portion of the material within the overlying further layer and to sinter said further portion with the previously sintered portion of material in the prior layer; (v) successively repeating blocks (iii) and (iv) to form a three-dimensional object; and wherein at least some of the layers of particulate material are pre-heated with a heater prior to sintering a portion of the material of the respective layer, the heater being configured to move relative to, and proximate, the particulate material.

Abstract: A component is manufactured from a powdered material such as a titanium alloy, by performing a first hot isostatic pressing HIP operation on the powdered material 14 while the powdered material is in contact with a molding surface 8 of a rigid, usable molding tool 2. The first HIP operation creates a non-porous shaped surface 16 on a partially consolidated component 14, but avoids bonding or reaction between the partially consolidated component 14 and the molding tool 2. After separation of the partially consolidated component 14 from the molding tool 2, the partially consolidated component 14 is subjected to a second HIP operation in which the powdered material is fully consolidated.

Abstract: A bearing material and a method for the manufacture of a bearing having a lining of the bearing material is described, the bearing material comprising: in wt %: 4-12 tin; 0.1-2 nickel; 1-6 bismuth; 0.01-less than 0.10 alumina; balance copper apart from incidental impurities.

Abstract: Disclosed is a method for monitoring a generative production process in real time, wherein a component is at least optically detected and the installation space is thermally detected when applying a layer, as well as a device for carrying out said method.

Abstract: A layered manufacturing method for forming a desired three-dimensional object by using a powder as a raw material. The method forms a desired solid body, which is employed in a layered manufacturing device, including a stage member having stage surface; a transparent member having an optical window to cover the stage surface to form an enclosed region together with the stage surface; and an exhaust system for exhausting gasses in the enclosed region. The optical window is positioned at a vertical upper direction when the enclosed region is formed.

Abstract: The present invention provides a metal-graphite composite material favorable to two-dimensional diffusion of heat and having a high thermal conductivity in two axial directions, and a production method therefor. The metal-graphite composite material of the present invention includes: 20 to 80% by volume of a scaly graphite powder; and a matrix selected from the group consisting of copper, aluminum and alloys thereof, wherein the scaly graphite powder in which a normal vector to a scaly surface thereof is tilted at 20° or higher with respect to a normal vector to a readily heat-conducting surface of the metal-graphite composite material is 15% or less relative to a whole amount of the scaly graphite powder, and the metal-graphite composite material has a relative density of 95% or higher.

Abstract: An apparatus for the layer-by-layer production of three-dimensional objects having a material application unit containing a doctor blade with an edge closest to the construction field having a non-continuous straight line. In one embodiment the blade may vibrate. A process for layer-by-layer production, wherein the construction field is completely coated with applied powder prior to irradiation is also provided. Three dimensional articles made according to the invention are also provided.

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 method for providing a porous metal implant. A mixture of biocompatible metal, a spacing agent, and a binder is provided. The mixture is formed into a shape and the spacing agent is removed to form a plurality of pores in the implant. A shaped porous metal is also provided.

Abstract: A method for preparing metal-matrix composites including cold-process isostatic compaction of previously mixed powders and hot-process uniaxial pressing of the resulting compact is disclosed. The method enables metal-matrix composites with improved properties to be obtained. A device for implementing isostatic compaction comprising a latex sheath into which the mixture of powders is poured, a perforated cylindrical container in which the latex sheath is arranged, and means for sealed insulation of the mixture of powders contained in the sheath is also disclosed.

Abstract: A method of improving the thermoelectric figure of merit (ZT) of a high-efficiency thermoelectric material is disclosed. The method includes the addition of fullerene (C60) clusters between the crystal grains of the material. It has been found that the lattice thermal conductivity (?L) of a thermoelectric material decreases with increasing fullerene concentration, due to enhanced phonon-large defect scattering. The resulting power factor (S2/?) decrease of the material is offset by the lattice thermal conductivity reduction, leading to enhanced ZT values at temperatures of between 350 degrees K and 700 degrees K.

Abstract: A ferrous sintered multilayer roll-formed bushing having a ferrous sintered sliding material layer which is sinter-bonded to a back metal steel, wherein the ferrous sintered sliding material layer is produced in such a manner that a Fe—C—Cu—Sn based sintered sliding material mixed powder containing at least carbon of 0.40 to 15 wt %, Cu of 13 to 40 wt % and Sn of 0.5 to 10 wt % is preliminarily sinter-bonded to said back metal steel and then finally sinter-bonded by a liquid-phase sintering at high temperatures higher than 1000° C. after bending into a roll.

Abstract: There is provided a method for manufacturing a three-dimensional shaped object. The method of the present invention comprises the steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing sintering of the powder of the predetermined portion or melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, and then irradiating another predetermined portion of the new powder layer with the light beam, the steps (i) and (ii) being repeatedly performed in a chamber; wherein a localized gas flow is provided in the chamber, and at least a part of a fume generated by the irradiation of the light beam is entrained by the localized gas flow.

Abstract: A sliding material has a sintered layer formed atop a backing plate. The sintered layer contains 5-15 mass % of Bi nonuniformly distributed in a Cu—Sn alloy matrix consisting essentially of 8-12 mass % of Sn and a remainder of Cu. The sliding material can be manufactured by nonuniformly mixing Cu—Sn alloy powder and Bi powder, dispersing the mixed powder on a backing plate, and sintering the mixed powder to form a sintered layer on the backing plate. The sliding material does not undergo seizing and does not have separation of the sintered layer from the backing plate even when used in severe conditions such as in hydraulic equipment or construction equipment.

Abstract: Earth-boring tools for drilling subterranean formations include a particle-matrix composite material comprising a plurality of silicon carbide particles dispersed throughout a matrix material, such as, for example, an aluminum or aluminum-based alloy. In some embodiments, the silicon carbide particles comprise an ABC—SiC material. Methods of manufacturing such tools include providing a plurality of silicon carbide particles within a matrix material. Optionally, the silicon carbide particles may comprise ABC—SiC material, and the ABC—SiC material may be toughened to increase a fracture toughness exhibited by the ABC—SiC material. In some methods, at least one of an infiltration process and a powder compaction and consolidation process may be employed.

Abstract: A first green or brown object is sintered while being supported by a second green or brown object in a furnace, and a body of an earth-boring tool is formed from the first object. An object is sectioned to form first and second structures, and the first structure is sintered within a furnace while it is supported by (e.g., resting on) the second structure. A layer of powder material is provided on a green or brown object, another green or brown object is rested on the powder material over the first green or brown object, and the first and second green or brown objects are sintered with the powder material therebetween. Intermediate structures formed during fabrication of a body of an earth-boring tool include a layer of powder between a green or brown tool body precursor and a green or brown structure supporting the green or brown tool body.

Abstract: Methods and powder blends are provided for fabricating a metal part. One method includes the first steps of spreading a layer of a powder blend on a platform, the powder blend including a titanium base metal or alloy, and an alloying metal having a lower melting temperature than that of the base metal or alloy. Next, an energy beam is directed onto selected areas of the powder blend layer to thereby melt the alloying metal. Then, the alloying metal is re-solidified by withdrawing the energy beam from the powder blend layer. Then, a preform part is built up by iteratively performing the spreading, melting, and re-solidifying steps on additional adjacently formed layers. A metal liquid phase sintering process is performed at a temperature sufficient to melt the alloying metal but not the base metal or alloy.

Abstract: A cerium oxide powder for one-component CMP slurry, which has a specific surface area of 5 m2/g or more, and a ratio of volume fraction of pores with a diameter of 3 nm or more to that of pores with a diameter less than 3 nm of 8:2˜2:8, is disclosed. A method for preparing the same, a one-component CMP slurry comprising the same as an abrasive material, and a method of shallow trench isolation using the one-component CMP slurry are also disclosed. The CMP slurry causes no precipitation of the cerium oxide powder even if it is provided as a one-component CMP slurry, because the CMP slurry uses, as an abrasive material, cerium oxide powder that is obtained via a low-temperature calcination step, optionally a pulverization step, and a high-temperature calcination step and has a high pore fraction and low strength.

Abstract: A method of forming an oxide layer on a powder metal part includes subjecting the powder metal part to a steam oxidation process. An oxide layer is formed on the powder metal part. The oxide layer has a thickness greater than 7 microns.

Abstract: Hardmetal compositions each including hard particles having a first material and a binder matrix having a second, different material comprising rhenium or a Ni-based superalloy. A two-step sintering process may be used to fabricate such hardmetals at relatively low sintering temperatures in the solid-state phase to produce substantially fully-densified hardmetals.

Abstract: A ferrite magnet obtained by adding a ferrite having a hexagonal W-type magnetoplumbite structure to a ferrite having a hexagonal M-type magnetoplumbite structure, in which a portion of Sr, Ba, Pb or Ca is replaced with at least one element that is selected from the group consisting of the rare-earth elements (including Y) and Bi and that always includes La, during the fine pulverization process thereof. By adding a small amount of the element such as Co, Ni, Mn or Zn to the ferrite already having the hexagonal M-type magnetoplumbite structure during the fine pulverization process thereof, the magnetic properties can be improved.

Abstract: There is provided a method for producing oxide dispersion strengthened ferritic steel tube by fabricating a raw tube by mixed sintering of a metal powder and an oxide powder and producing a tube of the desired shape by repeating cold rolling and heat treatment for a total of three times or more. The method comprises performing each of the intermediate heat treatments during the cold rolling by a two-step heat treatment consisting of a first step heat treatment of 1100° C. or lower and a second step heat treatment of 1100 to 1250° C. and higher than the first step temperature, and performing the final heat treatment at 1100° C. or higher.

Abstract: The invention relates to a method for producing a sintered part comprised of a powdery material, especially comprised of a sintered metallurgical powder. According to the inventive method, a green compact which forms an elementary shape of the part is firstly compression molded from the powder. The desired final shape of the part is produced by subjecting partial areas of the elementary shape on the green compact to a successive non-cutting shaping. Afterwards, said final shape is finished by sintering.

Abstract: A rotary chip-removing tool includes a rotary tool body and a tool tip fastened on a front end thereof. The tool tip is formed of an injection molded body which has an integral cutting edge at its front end, and a coupling structure at its rear end. The coupling structure can be in the form of a threaded hole, or a rearward projection, for coupling the tool tip against the tool body. The tool tip is formed of first and second materials. The first material forms at least part of the cutting edge, and the second material forms the coupling structure. The first material is more brittle than the second material, and the second material is tougher than the first material.

Abstract: A composite strip of compacted powders, which has a three layers structure, is continuously obtained by means of a rolling machine for powder compacting. The composite strip is sintered at a temperature of 460° C. to 550° C. to form a sintered composite strip. The sintered composite strip is continuously bonded by rolling to a steel strip. The bonded composite strip is optionally subjected to a heat treatment of heating at a temperature of 250° C. to 400° C. followed by heating to a temperature of 400° C. to 510° C., holding the strip under the temperature for not less than 30 seconds, and rapidly cooling down to 300° C. at a cooling rate of not lower than 50° C./minute, whereby obtaining a multi-layered composite material consisting of the steel strip, a sintered bonding layer, a sintered sliding layer and a sintered sacrificial layer.

Abstract: An inclined function material is formed with an iron layer on a surface of a carbon material. This material can be used in a carbon base member and does not limit the choice of desired characteristics in a carbon base member. The process by which the carbon base member is formed also ensures the iron layer is integrated firmly with the surface of the carbon material. A suitable amount of an iron powder having a particle diameter of 5 to 15 &mgr;m is placed directly on the surface of a carbon material, which is sintered in advance under suitable conditions, and stuck to the surface uniformly and flatly. The iron powder and the carbon material are sintered at 1000° C. to 1300° C. and preferably 1050 to 1150° C. for 1 to 2 hours and preferably about 1.5 hours to form a carbon base member in which the iron layer is formed on one surface of the carbon base member.

Abstract: A method of producing a gear from a metallurgical powder includes molding at least a portion of the powder to provide a gear preform. The gear preform is sintered and hot formed, and subsequently may be carburized. The gear preform is resintered and cooled at a cooling rate suitable to provide a bainitic microstructure in at least a surface region of the preform. The gear teeth of the preform may be shaved to, for example, adjust dimensions, and enhance dimensional uniformity.

Abstract: Blank for a gun barrel, consisting of a steel bar, which bar, in one or more hot working steps, has been repeatedly wrung about its own longitudinal axis.

Abstract: In a preliminary molding step 1, a metallic powder mixture 7 obtained by blending an iron-based metal powder 7a with graphite 7b such that the graphite is present in an amount of preferably not less than 0.1% by weight, more preferably not less than 0.3% by weight, is compacted into a preform 8 having a density of not less than 7.3 g/cm3. In a provisional sintering step 2, the preform 8 is provisionally sintered at a predetermined temperature to form a metallic powder-molded body 9 having a structure in which the graphite remains along a grain boundary of the metal powder. In a re-compaction step 3, the metallic powder-molded body 9 is re-compacted into a re-compacted body 10. In a re-sintering step 4, the re-compacted body 10 is re-sintered to obtain a sintered body 11. In a heat treatment step 5, the sintered body 11 is heat-treated to obtain a heat-treated sintered body 11.

Abstract: A method of manufacturing screws which can form screws each having a desired hollow axial bore easily and having excellent machinability is provided. The method comprises the steps of (A) producing a green body containing metal powder by means of extrusion molding; (B) debinding the green body to obtain a brown body; and (C) sintering the brown body to obtain a sintered compact, wherein at least one machine working including a thread cutting process is carried out at anytime after the completion of the step (A). The step (C) of this method may include a pre-sintering step for obtaining a pre-sintered compact and a secondary sintering process, and the machining process including a thread cutting process is carried out onto the pre-sintered compact after the completion of the pre-sintering step.

Abstract: A method for producing a material includes providing a metallurgical powder including iron, 1.0 to 3.5 weight percent copper, and 0.3 to 0.8 weight percent carbon. At least a portion of the powder is compressed at 20 tsi to 70 tsi to provide a compact, and subsequently the compact is heated at high temperature and then cooled at a cooling rate no greater than 60° F. per minute to increase the surface hardness of the compact to no greater than RC 25. The density of at least a region of the sintered compact is increased, by a mechanical working step or otherwise, to at least 7.6 grams/cc. The sintered compact is then re-heated to high temperature and cooled at a cooling rate of at least 120° F./min. so as to increase the surface hardness of the compact to greater than RC 25, and preferably at least RC 30. Material made by the method of the invention also is disclosed.

Abstract: The invention concerns a process for the production of a porous lithium cobaltite electrode plate with a large inner surface and low polarization resistance. Lithium carbonate powder and cobalt metal powder are uniformly mixed together and then films are produced from the mixture and plates from the films, which plates are sintered and then placed in an air stream for several hours at a temperature between 400° C. and 488° C. until the conversion of said plates to lithium cobaltite electrode plates with an extremely large inner surface has taken place.