Abstract: An apparatus and a method for powder bed fusion additive manufacturing involve a multiple-chamber design achieving a high efficiency and throughput. The multiple-chamber design features concurrent printing of one or more print jobs inside one or more build chambers, side removals of printed objects from build chambers allowing quick exchanges of powdered materials, and capabilities of elevated process temperature controls of build chambers and post processing heat treatments of printed objects. The multiple-chamber design also includes a height-adjustable optical assembly in combination with a fixed build platform method suitable for large and heavy printed objects. A side removal mechanism of the build chambers of the apparatus improves handling and efficiency for printing large and heavy objects. Use of a wide range of sensors in the apparatus and by the method allows various feedback to improve quality, manufacturing throughput, and energy efficiency.

Abstract: The disclosure relates to processing machines and methods for producing three-dimensional components by irradiating powder with a processing beam, the machines including a container with a moveable support for the powder, as well as an irradiating device with a scanner device for aligning the processing beam on a processing field at an opening of the container. The irradiating device includes a heating device that includes a heating radiation source for generating a heating beam for heating the powder from above and including a beam shaping optical unit configured to convert a first beam profile of the heating beam into a second beam profile, e.g., a ring-shaped beam profile, of the heating beam.

Abstract: An additively manufactured (AM) structure includes a removal plane extending therein defining an object thereabove. The AM structure also includes at least one datum structure coupled relative to the AM structure. Each datum structure includes a vertical reference plane for guiding a cutting element to remove the object from a remaining portion of the AM structure through the removal plane. The vertical reference plane is horizontally coplanar with the removal plane of the AM structure. The datum structures allow for accurate object cuts regardless of whether an AM build platform is horizontal or non-planar.

Abstract: A device for manufacturing a layered object includes a container, a vibration unit, and an energy beam irradiation unit. The container includes a stage, a wall surrounding the stage, and a lid. The vibration unit vibrates raw material powder to planarize a face of the raw material powder supplied into the container. The energy beam irradiation unit irradiates part of the raw material powder with an energy beam to form part of the layered object. The lid presses the raw material powder when the vibration unit vibrates the raw material powder. A space is formed between the wall and the lid in the container when the lid is in contact with the raw material powder. The raw material powder is allowed to flow into the space.

Abstract: Provided is a method for preparing nickel-aluminum alloy powder at low temperature, which is simple and economical and is capable of solving the reactor corrosion problem. The method for preparing nickel-aluminum alloy powder at low temperature includes: preparing a powder mixture by mixing nickel powder and aluminum powder in a reactor and adding aluminum chloride into the reactor (S1); vacuumizing the inside of the reactor and sealing the reactor (S2); and preparing nickel-aluminum alloy powder by heat-treating the powder mixture in the sealed reactor at low temperature (S3).

Abstract: This disclosure deals with a class of metal alloys with advanced property combinations applicable to metallic sheet production. More specifically, the present application identifies the formation of metal alloys of relatively high strength and ductility and the use of one or more cycles of elevated temperature treatment and cold deformation to produce metallic sheet at reduced thickness with relatively high strength and ductility.

Abstract: A method of processing a superalloy powder includes mechanically alloying nitrogen with superalloy powder particles having at least one nitride-forming element such that each superalloy powder particle includes a microstructure having nitrogen dispersed throughout the microstructure. The powder may then be formed into an article having nitride regions dispersed throughout.

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

Abstract: A micro-structured article is disclosed comprising a free-standing network of interconnected traces surrounding randomly-shaped cells wherein the interconnected traces comprise at least partially-joined nanoparticles. In a preferred embodiment, the nanoparticles comprise a conductive metal. The article is preferably formed by coating a nanoparticle-containing emulsion onto a substrate and drying the emulsion. The nanoparticles self-assemble into the network pattern which is subsequently removed from the substrate. A preferred method of removing the network from the substrate comprises the steps of electroplating the traces and subsequently exposing the traces to acid to release the network from the substrate.

Abstract: A camshaft adjusting device (19) having a camshaft adjuster (4), including a stator (36), a rotor (38) which can be rotated relative to the stator (36) about a rotational axis (74), and a hub (52) which is arranged on the rotor (38) or on the stator (36) and has a receiving cup (62), and having a camshaft (12) which is received in the receiving cup (62). It is provided here that the camshaft (12) is fixed radially in the receiving cup (62) via at least three spacer elements (64). A camshaft adjusting device (19) of this type can be produced simply and inexpensively.

Abstract: Hardened amalgams formed from copper mixed with liquid gallium or liquid gallium-indium alloys are used to fabricate sputter targets comprised of copper, gallium and indium (CIG) and targets of selenides of copper, gallium and indium (CIGS). Amalgam hardening occurs by formation of intermetallic compounds at or near ambient temperature as a result of reaction between liquid metals and solid metals in powder form.

Abstract: The present invention is directed to methods of preparing a bonded metallurgical powder composition comprising melting a binding agent and blending the melted binding agent with a metallurgical powder mixture, in the substantial absence of solvent, for a time sufficient to form the bonded metallurgical powder composition. Bonded metallurgical powder compositions prepared using these methods are also described, as well as compacted powder metallurgical parts prepared using them.

Abstract: An apparatus for manufacturing an article from powder material includes a canister, a sorter, a plurality of hoppers and at least one valve. The canister has a predetermined internal shape to define the shape of the powder metal article. The sorter sorts the powder material by the size of the powder particles, the shape of the powder particles and/or the flow characteristics of the powder particles. The hoppers contain powder material with different sizes of powder particles, different shapes of powder particles and/or powder particles with different flow characteristics. The hoppers are arranged to supply the sorted powder material to the canister. The at least one valve controls the proportions of the different powder materials supplied from the one or more of the different hoppers into the canister to control the packing density of the powder material in the canister at all positions in the canister.

Abstract: There is provided a soft magnetic core including: a composite metal powder in which surfaces of iron (Fe) particles are coated with an insulating layer; a body part formed by compressing the composite metal powder; and an alloying element diffused from a surface of the body part to an inside thereof.

Abstract: A configuration for molding of a blend of metal powder around a core, which includes a mold delimiting a cavity, and which includes an elastically deformable portion on which the core is pressed, so as to adapt dimensions of the cavity to dimensions of the core. The elastically deformable portion includes an elastically deformable metal blade on one face of which the core is pressed directly.

Abstract: The present invention relates to a method for preparing a foam material, comprising the steps: a) providing a powder material, comprising at least one metal powder and optionally at least one ceramic powder; b) providing a perform comprising a particulate material; c) mixing the powder material in the preform; and d) removing the particulate material by exposing the mixture obtained in step c) to the solvent, wherein the particulate material is soluble in the solvent and to a foam material obtainable by said method.

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: One aspect relates to a method for producing an alloy characterized by grinding tantalum to form a tantalum powder and grinding tungsten to form a tungsten powder; mixing the tantalum powder and the tungsten powder to form a blended powder. The weight fraction of tungsten powder in the blended powder is larger than in the desired alloy. A blended body is produced from the blended powder by a powder metallurgical route. A pre-alloy is produced by a first melting of the blended body and at least a fraction of at least one further metal by a melt metallurgical route. The alloy is produced by a second melting of the pre-alloy and the remaining fraction of at least one metal by a melt metallurgical route.

Abstract: A method of forming micrometric or millimetric sized granules by the agglomeration of nanometric sized particles, comprising the addition of a set of nanometric sized particles into a container having an inside wall surface with a circular or approximately circular section and setting the set of particles in motion along said inside wall surface by rotating the container about a rotation axis passing through said container. The setting in motion of the particles is done in a dry state and the container is rotated continuously at constant speed for several consecutive hours.

Abstract: The invention relates to a self-hardening material for layerwise construction of three-dimensional components, whereby the material comprises at least one particulate material and a separately applied bonding agent for bonding the particulate material, and has a setting time which is at least several times as long as the application time of a particulate layer.

Abstract: The present invention provides a method of making a substantially phase pure compound including a cation and an anion. The compound is made by mixing in a ball-milling device a first amount of the anion with a first amount of the cation that is less than the stoichiometric amount of the cation, so that substantially all of the first amount of the cation is consumed. The compound is further made by mixing in a ball-milling device a second amount of the cation that is less than the stoichiometric amount of the cation with the mixture remaining in the device. The mixing is continued until substantially all of the second amount of the cation and any unreacted portion of anion X are consumed to afford the substantially phase pure compound.

Abstract: In one aspect, the present invention provides a method of forming a film of nanocomposites of carbon nanotubes (CNTs) and platinum (Pt) nanoparticles. In one embodiment, the method includes the steps of (a) providing a first solution that contains a plurality of CNTs, (b) providing a second solution that contains a plurality of Pt nanoparticles, (c) combining the first solution and the second solution to form a third solution, and (d) filtering the third solution through a nanoporous membrane using vacuum filtration to obtain a film of nanocomposites of CNTs and Pt nanoparticles.

Abstract: The present invention provides novel cathodes having a reduced resistivity and other improved electrical properties. Furthermore, this invention also presents methods of manufacturing novel electrochemical cells and novel cathodes.

Abstract: A composite particle comprises a core, a shielding layer deposited on the core, and further comprising an interlayer region formed at an interface of the shielding layer and the core, the interlayer region having a reactivity less than that of the core, and the shielding layer having a reactivity less than that of the interlayer region, a metallic layer not identical to the shielding layer and deposited on the shielding layer, the metallic layer having a reactivity less than that of the core, and optionally, an adhesion metal layer deposited on the metallic layer.

Abstract: Method of manufacturing a three-dimensional object of a building material by an additive layer-wise building method, wherein based on material parameters of the building material and predetermined characteristics of the object to be manufactured, an internal structure of the object having a grid structure calculated, and the three-dimensional object is manufactured with this internal structure by the additive layer-wise building method, so that it comprises the predetermined characteristics.

Abstract: A modeling apparatus includes a box holding mechanism, a box, a supply mechanism, and an elevation mechanism. The box includes a main body and a stage movably provided to the main body. The box is capable of accommodating powder and detachably provided to the box holding mechanism. The supply mechanism is configured to selectively supply liquid that bonds the powder together to a modeling enabled area inside the box. The elevation mechanism is configured to cause the stage to ascend and descend in the main body relative to the main body.

Abstract: One aspect is a method for producing an alloy, whereby the alloy consists of a first metal, a second metal, a third metal, and a fourth metal, and the first metal, the second metal, the third metal, and the fourth metal are selected from the group consisting of the metals, niobium, zirconium, tantalum tungsten. The method includes the steps of grinding the first metal to form a first metal powder and grinding the second metal to form a second metal powder; mixing the first metal powder and the second metal powder to form a first blended powder; generating a first blended body from the blended powder by a powder metallurgical route; and generating the alloy by melting the first blended body and the remaining metals by a melt metallurgical route.

Abstract: Material processing systems are disclosed. Some systems include methods of eliminating or reducing defects in elongate workpieces that can undergo large deformations during processing. Some systems include apparatus configured to facilitate such large deformations while maintaining internal stresses (e.g., tensile stresses) below a threshold stress. Some disclosed systems pertain to powder extrusion techniques. Continuous and batch processing systems are disclosed.

Abstract: A synchronizer sleeve for use in a transmission and method of making is disclosed herein. The synchronizer sleeve having: a plurality of gear teeth integrally formed on the inner diameter of the ring member, wherein the distal ends of the plurality of gear teeth extend from the inner diameter and comprise a portion of at least one of a pair of sides; wherein each of the distal ends of the plurality of gear teeth have a top portion, a bottom portion and a pair of opposing sides extending between the top portion and the bottom portion and each distal end is separated from each other by a recess located between each one of the pair of opposing sides; wherein no recess is formed adjacent to the top portion of the plurality of gear teeth; and wherein no secondary processing steps are required to reshape the synchronizer sleeve.

Abstract: A direct metal laser sintered material including a substrate formed from a laser sintering process, the substrate having at least one surface, and a cladding material brazed onto at least a portion of the surface.

Abstract: A composite wood product and its method of manufacture. The wood product comprises aligned, substantially straight wood strands cut from veneer, disposed side by side lengthwise in substantially parallel relationship with adhesive bonding together the strands. The product is produced in a billet having a width in the range of about 3 ft. to 12 ft. and with a thickness in the range of about 1.1 inches to 2 inches. The strand ends are distributed in a specific pattern that approximates maximizing the minimum distance between strand ends. The wide sides of the billet are coated with a dark colored resin. The billet may be sawn lengthwise into sizes used for joists and rafters. Such a sawn product (e.g. 1.5? by 9.25?) has the wide sides a dark resin color and the narrow sawn sides mostly wood colored. The strands are parallel to its length.

Abstract: A multilayered structure may include a doped buffer layer on a transparent conductive oxide layer.

Abstract: A powder metallurgical article and process are disclosed. The article is a repaired or enlarged powder metallurgical article. The repaired or enlarged powder metallurgical article includes a formed article including a first alloy and a material including a second alloy. The material is welded to the formed article to form the repaired or enlarged powder metallurgical article. The repaired or enlarged powder metallurgical article includes a substantially uniform grain structure.

Abstract: A formed article comprising a nanostructured ferritic alloy is provided. Advantageously, the article is not formed via extrusion, and thus, cost savings are provided. Methods are also provided for forming the article, and the articles so produced, exhibit sufficient continuous cycle fatigue crack growth resistance and hold time fatigue crack growth resistance to be utilized as turbomachinery components, and in particular, large, hot section components of a gas or steam turbine engines. In other embodiments, a turbomachinery component comprising an NFA is provided, and in some such embodiments, the turbomachinery component may be extruded.

Abstract: This invention discloses novel nanocomposite material structures which are strong, highly conductive, and fatigue-resistant. It also discloses novel fabrication techniques to obtain such structures. The new nanocomposite materials comprise a high-conductivity base metal, such as copper, incorporating high-conductivity dispersoid particles that simultaneously minimize field enhancements, maintain good thermal conductivity, and enhance mechanical strength. The use of metal nanoparticles with electrical conductivity comparable to that of the base automatically removes the regions of higher RF field and enhanced current density. Additionally, conductive nanoparticles will reduce the surface's sensitivity to arc or sputtering damage. If the surface is sputtered away to uncover the nanoparticles, their properties will not be dramatically different from the base surface.

Abstract: Process for producing a low volatility metal flake pigment composition, which comprises milling metal powder in a non-aqueous, non-hydrocarbon, low volatility milling fluid.

Abstract: In various embodiments, large-area sputtering targets are formed by providing a plurality of sputtering targets each comprising a backing plate and a refractory metal layer disposed thereon, and spray depositing a refractory metal powder on an interface between the sputtering targets, the refractory metal powder consisting essentially of the same metal as each refractory metal layer, thereby joining the refractory metal layers of the sputtering targets.

Abstract: A Cu—Ga alloy includes a plurality of phases, and not less than 40 wt % and not more than 60 wt % of gallium (Ga) and a balance consisting of copper and an inevitable impurity. The plurality of phases include a segregation phase including not less than 80 wt % of gallium (Ga), and a rate of a volume of the segregation phase to a total volume of the Cu—Ga alloy is not more than 1%. The plurality of phases include particles including not less than 40 wt % and not more than 60 wt % of gallium (Ga), the particles include a diameter of not less than 0.1 ?m and not more than 30 ?m, and a rate of a volume of the particles to the total volume of the Cu—Ga alloy is not less than 90%.

Abstract: A method of manufacturing improved thin-film solar cells entirely by sputtering includes a high efficiency back contact/reflecting multi-layer containing at least one barrier layer consisting of a transition metal nitride. A copper indium gallium diselenide (Cu(InXGa1-x)Se2) absorber layer (X ranging from 1 to approximately 0.7) is co-sputtered from specially prepared electrically conductive targets using dual cylindrical rotary magnetron technology. The band gap of the absorber layer can be graded by varying the gallium content, and by replacing the gallium partially or totally with aluminum. Alternately the absorber layer is reactively sputtered from metal alloy targets in the presence of hydrogen selenide gas. RF sputtering is used to deposit a non-cadmium containing window layer of ZnS. The top transparent electrode is reactively sputtered aluminum doped ZnO. A unique modular vacuum roll-to-roll sputtering machine is described.

Abstract: Refractory metal products, such as tantalum, can be rejuvenated after metal consumption in selected zones by filling the zones with powder and simultaneously applying focused radiant energy to the powder.

Abstract: A composition, a medical implant constructed from the composition, and a method of making the composition are described. The composition comprises a porous-coated substrate, the porous coating comprising a reticulated particle coating, the coating being formed by fusing the reticulated particle to the surface, preferably by sintering.

Abstract: A method for forming a compact from a powder wherein a forming portion 1A in a mold body 2 is filled with a raw powder and upper and lower punches 3,4 are fitted into the forming portion 1A to form the compact. Prior to filling the forming portion 1A with the raw powder M, a solution L with a lubricant being uniformly dissolved in a solvent is applied to a peripheral portion of the forming portion 1A, and then the solution is evaporated, thus forming a crystallized layer B thereon. Thus, the reduction of a force for ejecting the compact is realized, while improving the density of the compact, realizing the stable and successive production of the compact.

Abstract: A formed article for making alloying additions to metal melts includes particles of at least one master alloy and a binder material binding the particles of the master alloy in the formed article. The binder material changes form and frees the master alloy particles when the formed article is heated to a predetermined temperature, preferably a temperature greater than 500° F. A method for making an alloy also is provided. The method includes preparing a melt comprising a predetermined quantity of a master alloy wherein the master alloy is added to the melt or the melt starting materials in the form of particles of the master alloy bound into at least one formed article by a binder material that decomposes at a predetermined temperature, preferably a temperature greater than 500° F., and releases the particles of master alloy.

Abstract: The present invention relates to a metal powder mixture that is suitable for producing sintered bodies. The powder mixture is suitable as a binder for hard metals and contains: a) at least one prealloyed powder selected from the group of iron/nickel, iron/cobalt, iron/nickel/cobalt and nickel/cobalt; b) at least one element powder selected from the group of iron, nickel and cobalt or a prealloyed powder selected from the group consisting of iron/nickel, iron/cobalt, iron/nickel/cobalt and nickel/cobalt which is different from component a). The invention also relates to a cemented hard material which uses the inventive powder mixture and a hard material powder, wherein the overall composition of the components a) and b) together contains not more than 90% by weight of cobalt and not more than 70% by weight of nickel and the iron content.

Abstract: The present invention provides a method and an apparatus for producing radially oriented ring magnet. The problem it solved is to uniformly orient the magnet powder in the process of producing, and also to get relatively large oriented magnetic field strength, so as to increase the performance and uniformity of the radial ring. The method of forming a radially oriented ring magnet, is to position magnetic powder into a ring mold, using an oriented magnetic field to orient the magnetic powder in the ring mold along the radius or diameter direction, wherein the oriented magnetic field is distributed discretely 360° around the ring mold, and during the forming process the oriented magnetic field and the magnetic powder have relative rotation.

Abstract: The invention relates to a method for producing a penetrator (10) from a tungsten heavy metal with a high fraction of tungsten and an outer sheath (7), which consists of a material that is more ductile in relation to the penetrator core (6). To produce a penetrator (10) of this type in a cost-effective manner, according to the invention a twin-hopper filling device, which corresponds to the dimensions of the penetrator core (6), is introduced concentrically into a compression mould (1) that corresponds to the outer dimensions of the penetrator (10). The inner pipe (3) is filled with a first tungsten powder blend with a high fraction of tungsten for producing the penetrator core (6), whilst the annular gap between the outer wall of the inner pipe and the inner wall of the compression mould (1) is filled with a second tungsten powder blend with a lower fraction of tungsten, (approximately between 85% and 91%), than the first powder blend.

Abstract: In one aspect of the invention, a cartridge assembly is adapted for connection to a frame of a high pressure, high temperature press having a front end with a back up intermediate and coaxial with an anvil and a piston. The back up has an anterior end proximate the anvil and posterior end proximate the piston. The cartridge assembly has a hydraulic system adapted to apply axial pressure to the back-up through the piston to axially move the front end with respect to a cartridge body. The assembly also has a centralizing assembly with a rod rigidly attached to the cartridge body at a first end and a second end adapted to slide within a peripheral bore formed in the front end.

Abstract: A powder metallurgy method includes the steps of forming a member, such as a work piece or an aerospace component, from a titanium alloy powder. The average size of a carbide phase in the titanium alloy powder is controlled in order to control an average size of a carbide phase in the member. In one example, an amount of carbon within the titanium alloy and size of the carbide phase are selected to provide a desirable balance of good hot workability, resisting formation of an alpha-titanium phase within the member and a desired level of fatigue performance.

Abstract: A selective inhibition of sintering (SIS) technique may be used to fabricate a three-dimensional (3-D) dense metal object from a binderless metal powder. Layers of metal powder are provided on a build tank. For each layer, regions of the layer are sinter-inhibited, e.g., by depositing a sinter-inhibiting material such as a ceramic slurry, a metal salt, or oxidizing metal particles in the powder using chemicals or a concentrated heat source. Each layer may be compacted before the next layer is provided. A final compact may then be sintered. Unwanted sintered sections may be removed from the compact at boundaries formed by the sinter-inhibited (unsintered) regions, and the object extracted.

Abstract: The present invention relates to a method for readily producing an anode for rechargeable batteries having conflicting properties in good balance, including the corrosion resistance and the activities such as the initial activity and the high rate discharge performance, and having excellent recyclability. The method includes the steps of mixing and molding anode materials containing an electrically conductive material and at least two kinds of AB5 type hydrogen storage alloys, wherein said alloys have substantially single phase structures and the same composition, wherein each of the alloys have an average crystal long axis diameter of 30 to 350 ?m, and wherein the alloys have different ratios (D1/D2) of the average crystal long axis diameter (D1) to the average short axis diameter (D2).