Abstract: A method for producing a solid-state cell which makes it possible to produce a highly reliable solid-state cell that suppresses a decrease in the thickness of the solid electrolyte layer and a short circuit between the positive and negative electrodes, and which is highly flexible in the size and shape of the solid electrolyte layer and electrodes. The method comprising: a structure preparing step for preparing a first structure, a second structure, or a third structure, a solid electrolyte material powder layer, and a positive electrode material powder layer are stacked, in this sequence; an insulating member disposing step for disposing a heat-resistant insulating member which is in contact with an outer periphery of the structure in the stacking direction of the structure and surrounds the outer periphery; and a heat-compressing step for heat-compressing the structure and heat-resistant insulating member, in the stacking direction of the structure.

Abstract: A method of forming an article includes forming a layer of a mixture of at least two distinct metal powders selected such that when combined they are chemically in the proportions of a superalloy containing a gamma prime phase, and fusing the powders locally without diffusion to define the shape of a part of the article such that the materials of the distinct metal powders remain substantially chemically segregated forming regions of different chemical composition. The method further includes repeating the forming and fusing until the derived article is formed, and heat treating the finished article such that at least one of the distinct separate materials diffuses to form a gamma prime phase containing superalloy with the other.

Abstract: A composite material comprising a plurality of hard particles surrounded by a matrix material comprising a plurality of nanoparticles. Earth boring tools including the composite material and methods of forming the composite material are also disclosed. A polycrystalline material having a catalyst material including nanoparticles in interstitial spaces between inter-bonded crystals of the polycrystalline material and methods of forming the polycrystalline material are also disclosed.

Abstract: A process for manufacturing a disk shaped component comprising fabricating a disk shaped component using a composite material having at least a first material and a second material, wherein the first material is disposed at and proximate to a center portion of the disk shaped component and the second material is disposed at and proximate to a rim of the disk shaped component, wherein the first material comprises a first coefficient of thermal expansion, a first stress value and a first oxidation resistance, and the second material comprises a second coefficient of thermal expansion, a second stress value and a second oxidation resistance, wherein the first coefficient of thermal expansion is greater than the second coefficient of thermal expansion, the first stress value is greater than the second stress value and the first oxidation resistance is less than the second oxidation resistance.

Abstract: A method of fabricating an object is disclosed. A first layer of powder is deposited onto a substrate in a configuration defining a first cross-section of the object, and is consolidated by laser irradiation. To fabricate the object, further layers of powder are deposited onto the sintered first layer of powder to define further cross-sections of the object. The further layers are consolidated. A heat source is applied to the substrate to mitigate distortion of the substrate during fabrication of the object.

Abstract: A surface treatment method of a subject body is comprised steps of: packing and pressurizing powder including an electrically conductive material in a mold so as to obtain a plurality of compressed powder bodies; joining the plurality of compressed powder bodies together by arranging the plurality of compressed powder bodies to be mutually in close contact and applying isostatic pressure on the arranged compressed powder bodies; sintering the joined compressed powder bodies so as to obtain a sintered body; and carrying out a discharge surface treatment by bringing the sintered body close to a subject body and generating electric discharge.

Abstract: A method of producing three-dimensional bodies which wholly or for selected parts consist of amorphous metal. A metal powder layer (4) is applied to a heat-conducting base (1, 13), and a limited area of the layer is melted by a radiation gun (5) and the area is cooled so that the melted area solidifies into amorphous metal. The melting process is successively repeated on new limited areas of the powder layer until a continuous layer of amorphous metal is formed. A new powder layer is applied and the method is repeated, the new layer being fused to underlying amorphous metal for successive construction of the three-dimensional body. The heat-conducting base can be a worktable or a body of amorphous metal or crystalline metal to which amorphous metal is added.

Abstract: Three dimensionally large metallic structures comprised of submicron grain sizes are produced by a process which includes directing a supersonic powder jet against a substrate such that the powder adheres to the substrate and to itself to form a dense cohesive deposit. The powder jet may be comprised of refractory metal powders. The powder may be deposited by a supersonic jet and may be extruded by Equi channel angular extrusion.

Abstract: An article includes a working portion including cemented carbide, and a heat sink portion in thermal communication with the working portion. The heat sink portion includes a heat sink material having a thermal conductivity greater than a thermal conductivity of the cemented carbide. Also disclosed are methods of making an article including a working portion comprising cemented carbide, and a heat sink portion in thermal communication with the working portion and including a heat sink material having a thermal conductivity that is greater than a thermal conductivity of the cemented carbide. The heat sink portion conducts heat from the working portion.

Abstract: A probe for friction stir welding MMCs, ferrous alloys, non-ferrous alloys, and superalloys, as well as non-ferrous alloys, the probe including a shank, a shoulder, and a pin disposed through the shoulder and into the shank, wherein the pin and the shoulder at least include a coating comprised of a superabrasive material, the pin and shoulder being designed to reduce stress risers, disposing a collar around a portion of the shoulder and the shank to thereby prevent movement of the shoulder relative to the shank, and incorporating thermal management by providing a thermal flow barrier between the shoulder and the shank, and between the collar and the tool.

Abstract: A powdered metal assembly includes a mechanical part, a powdered metal part and a fastener configured to join the mechanical part and the powdered metal part. In another aspect of the disclosure, a method for manufacturing a powdered metal assembly may include the steps of positioning the mechanical part in a forming apparatus, providing a powdered metal into the forming apparatus, compressing the powdered metal to form and bond a powdered metal part to the mechanical part to form the powdered metal assembly, and removing the powdered metal assembly from the forming apparatus.

Abstract: A rotor comprising bonded magnet portions mainly composed of magnet powder and a binder, which are embedded in a soft magnetic portion mainly composed of soft magnetic powder and a binder, the rotor being produced by a compression-molding method, and the magnetic pole surfaces of the bonded magnet portions being embedded in the soft magnetic portion.

Abstract: In a process for manufacturing composite sintered machine components, the composite sintered machine component has an approximately cylindrical inner member and an approximately disk-shaped outer member, the inner member has pillars arranged in a circumferential direction at equal intervals and a center shaft hole surrounded by the pillars, and the outer member has holes corresponding to the pillars of the inner member and a center shaft hole corresponding to the center shaft hole of the inner member and connected to the holes. The process comprises compacting the inner member and the outer member individually using an iron-based alloy powder or an iron-based mixed powder so as to obtain compacts of the inner member and the outer member, tightly fitting the pillars of the inner member into the holes of the outer member, and sintering the inner member and the outer member while maintaining the above condition so as to bond them together.

Abstract: A friction stir tool has an axis of rotation and a welding tip that is made of powdered metal material.

Abstract: The invention relates to a method for making a metal part that comprises a reinforcement (15) made of ceramic fibres. The method comprises the following steps: forming at least one annular-shaped insert (15) by assembling a bundle of metal-coated fibres; placing the insert into a hollow metal mould (10) such that the insert is spaced between the walls (10a, 10b) of the mould; filling the mould with a metal powder; generating vacuum in the mould and closing the same; hot isostatic compressing the assembly at a temperature and under a pressure sufficient for binding the powder particles between them and for binding the insert fibres between them; removing the mould and optionally machining to the desired shape.

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

Abstract: A forged composite gear and a method of making a forged composite powder metal gear. The forged composite gear includes a plurality of teeth extending from a core, a first section having a first powder metal material, a second section having a second powder metal material and a variable boundary profile. The variable boundary profile is formed between the first section and the second section, whereby said variable boundary profile exhibits greater tooth wear resistance on the teeth and greater impact resistance in the core.

Abstract: A method of making an article having at least one re-entrance surface includes the steps of (a) forming a layer of metal powder on a base, (b) selectively laser fusing portions of the layer, and (c) repeating steps (a) and (b) to form the article, each step (a) being performed on the preceding layer characterised in that prior to performing step (a) in a layer which will initiate the formation of a re-entrant feature reversibly bonding at least some of the unfused underlying powder such that it is stable under the application of the laser.

Abstract: The invention concerns an apparatus (1) for producing a three-dimensional object (6) layer by layer using a powdery material which can be solidified by irradiating it with an energy beam (4), said apparatus (1) comprising an electron gun (3) for generating said energy beam (4) and a working area (5) onto which the powdery material is distributed and over which the energy beam (4) sweeps during irradiation. The invention is characterized in that the apparatus (1) is provided with a system (12, 14, 16, 18) for feeding controlled amounts of a reactive gas into the apparatus (1) such as to contact the reactive gas with material positioned on the working area (5), said reactive gas being capable of, at least when having been exposed to the energy beam (4), reacting chemically and/or physically with the material positioned on the working area (5). The invention also concerns a method for operating an apparatus of the above type.

Abstract: Hard phase particles including Co alloy particles, carbide alloy particles, and silicide particles are dispersed substantially uniformly throughout a matrix composed of Cu self-fluxing alloy of a cladded portion. The cladded portion contains 6 to 15% by weight of Co, 3 to 8% by weight of one of Cr and Mo, 0.3 to 1% by weight of W, 0.5 to 1.8% by weight of Fe, 8 to 15% by weight of Ni, 0.08 to 0.2% by weight of C, 1.5 to 4% by weight of Si, 0.5 to 0.8% by weight of Al, and 0.1 to 0.3% by weight of P, and inevitable impurities and Cu as a balance. The hard phase particles have an average particle diameter of 8 to 20 ?m and a particle size distribution width of 0.1 to 100 ?m, and to occupy 10 to 20% in an arbitrary cross section of the cladded portion.

Abstract: Method for forming a unitary component from a plurality of powder metallurgy compacts. The method in some embodiments includes fluidizing first and second surfaces, wherein a first powder metallurgy compact defines the first surface and a second powder metallurgy compact defines the second surface. The method also includes joining the fluidizing first and second surfaces to form a bonded structure and thermally treating the bonded structure to fuse the first and second compacts into a unitary component.

Abstract: A process for joining two or more powder injection molded parts by preparing at least two green parts from a feedstock including a binder and an injection powder. Placing the two or more green part into intimate contact, and maintaining the two green parts in intimate contact at a position with a linkage between the at least two green parts to produce an interconnected green assembly. Placing the assembly under shape retaining conditions, melting the binder of the interconnected green assembly under shape retaining conditions to produce a seamless body.

Abstract: A method for manufacturing a shaft member having a sintered part bonded thereto is simple and provides an increased process yield and a high accuracy in position and angle of the sintered part. A green compact is prepared by subjecting a metal or alloy powder to a compression molding. A projection formed on an outer peripheral surface of the shaft member is embedded into the green compact, while chipping partially the green compact with the projection, to combine the green compact with the shaft member. Then, a sintering is carried out.

Abstract: Disclosed is a three layer process for making contact points to a high transition temperature superconductor (HTSC), particularly to (Bi,Pb)2Sr2Ca2Cu3O19+x with and without silver in the superconductor. The contact structure is a three layer configuration with a perforated silver foil (3) sandwiched between two metal spray gun deposited silver layers (2,5) and subsequent heat treatment in air. The contact has been made on tubes and rods (1). The silver contacts are capable of carrying a continuous current of 200 Amps without adding any substantial heat load to the cryogen used to cool the HTSC. The contact resistance at 4.2 K is in the range of 1.5×10 (hoch?8) to 8.5? 10 (hoch?8)OHM in zero applied filed.

Abstract: A matrix drill bit and method of manufacturing a matrix bit body from a composite of matrix materials is disclosed. Two or more different types of matrix materials may be used to form a composite matrix bit body. A first matrix material may be selected to provide optimum fracture resistance (toughness) and optimum erosion, abrasion and wear resistance for portions of a matrix bit body such as cutter sockets, cutting structures, blades, junk slots and other portions of the bit body associated with engaging and removing formation materials. A second matrix material may be selected to provide desired infiltration of hot, liquid binder material with the first matrix material to form a solid, coherent, composite matrix bit body.

Abstract: The invention relates to a process for the production of a dental prosthetic item (10) by means of local sintering, in which the dental prosthetic item (10) is produced layer-wise by energy input, by means of an energy transferring beam (7), into a layer of powder (6) of a sinterable material. One or more parameters of the sintering process are modified during production such that the material (6) is regionally sintered to various degrees to produce denser material in the marginal region (14) of a sintered layer of said dental prosthetic item (10) than is produced in the inner region (15) of said sintered layer. The invention furthermore relates to a dental prosthetic item (10) of a material subjected to local sintering, which material is sintered in a marginal region (14) of the dental prosthetic item (10) to a greater density than in an inner region (15).

Abstract: Methods of forming bit bodies for earth-boring bits include assembling green components, brown components, or fully sintered components, and sintering the assembled components. Other methods include isostatically pressing a powder to form a green body substantially composed of a particle-matrix composite material, and sintering the green body to provide a bit body having a desired final density. Methods of forming earth-boring bits include providing a bit body substantially formed of a particle-matrix composite material and attaching a shank to the body. The body is provided by pressing a powder to form a green body and sintering the green body. Earth-boring bits include a unitary structure substantially formed of a particle-matrix composite material. The unitary structure includes a first region configured to carry cutters and a second region that includes a threaded pin. Earth-boring bits include a shank attached directly to a body substantially formed of a particle-matrix composite material.

Abstract: The invention relates to a method of producing a steel moulding using a sinter powder with a base of iron containing at least one non-ferrous metal selected from a group comprising Mn, Cr, Si, Mo, Co, V, B, Be, Ni and Al, the rest being Fe and unavoidable impurities resulting from the manufacturing process, comprising the steps of preparing the sinter powder, compacting the sinter powder to produce a green compact in a mould, sintering the green compact under a reducing atmosphere and then cooling and hardening, characterised in that the total proportion of non-ferrous metals in the sinter powder is selected from a range with a lower limit of 1% by weight and an upper limit of 60% by weight, and the sinter powder is sintered to an at least approximately completely austenitic structure, and hardening takes place by subjecting the steel moulding to mechanical load so that the austenitic structure is transformed at least partially to a martensitic structure.

Abstract: A composite material includes a structural material and a shape-memory alloy embedded in the structural material. The shape-memory alloy changes crystallographic phase from austenite to martensite in response to a predefined critical macroscopic average strain of the composite material. In a second embodiment, the composite material includes a plurality of particles of a ferromagnetic shape-memory alloy embedded in the structural material. The ferromagnetic shape-memory alloy changes crystallographic phase from austenite to martensite and changes magnetic phase in response to the predefined critical macroscopic average strain of the composite material.

Abstract: The present invention provides a continuous powder extrusion method for making an article having a profile including an outer shape and optionally including one or more inner hollows. One or more bulk material powders and one or more binders are provided, and the bulk material powders and the binders are mixed to form a mixture. A die is provided, the die optionally including a mandrel having one or more shapes. The mixture is extruded through the die and the optional mandrel to produce a green form. The green form is debound to produce a brown form and the brown form is sintered to produce a densified form. The densified form is optionally processed using thermal, mechanical, and/or thermomechanical processing to produce a wrought form. The densified or wrought form is optionally cut to a length and/or finished using traditional metal finishing processes.

Abstract: In order to create titanium components with a titanium composite insert, a method is provided whereby an initial pre form 1 has a groove 2 formed in it. An encapsulating member 4 is then provided about the groove 2 in order to create a cavity 5 which is filled with titanium alloy powder 6. This titanium alloy powder 6 is densified and then accurately machined in order to create a groove insert form 7 which can accommodate a titanium composite material pre form insert 8 and further titanium alloy powder 9 such that through a high temperature isostatic pressing (HIP) process, the insert 8 is embedded. The original component form 1 can then be machined in order to create the final component elements such as aerofoils 13.

Abstract: A process for the production of a ball screw, which has at least one element produced powder metallurgically, is suggested, with which the at least one element is produced from a plurality of parts, wherein at least one first precursor body with a first joining area and one second precursor body with a second joining area are produced and the first precursor body and the second precursor body have been or are brought into contact via the first joining area and the second joining area prior to the sintering and/or during the sintering.

Abstract: An R-T-B based sintered magnet includes both a light rare-earth element RL (which is at least one of Nd and Pr) and a heavy rare-earth element RH (which is at least one of Dy and Tb) and Nd2Fe14B type crystals as a main phase. The magnet has a first region, which includes either the heavy rare-earth element RH in a relatively low concentration or no heavy rare-earth elements RH at all, and a second region, which includes the heavy rare-earth element RH in a relatively high concentration. The first and second regions are combined together by going through a sintering process.

Abstract: A method of preparing a titanium-based metal matrix composite component. The method includes combining a titanium alloy-based matrix and a titanium-based ceramic reinforcement to form one or more mixtures, placing the mixture or mixtures into a mold, compacting the mixture or mixtures by shock loading, and sintering the compacted mixture or mixtures. In one form, the various mixtures may include differing levels of reinforcement concentration. In this way, different portions of a component produced by the present method may be made up of different mixtures from other portions of the manufactured component, thereby facilitating tailored mechanical or related structural properties.

Abstract: In a method for forming a dental part, a laser beam is guided over a powder layer of biocompatible material. The laser is guided by a computer controlled laser scanning system based on data representing the shape of the cross-section through the shaped body. The powder is substantially melted by the laser beam to form a layer in the shaped body, to build the shaped body entirely from layers of laser-melted material.

Abstract: A modular fuel nozzle configuration is defined which permits lower-cost manufacturing operations such as injection moulding to be employed. Also described is a method of making such a component.

Abstract: A method of forming a hollow part from a mixture is disclosed. The method may include rotationally molding the mixture into a green part. Additionally, the method may include debinding the green part into a brown part. The method may also include sintering the brown part into the hollow part.

Abstract: One embodiment includes providing a first layer including a first powder material and a second layer including a second powder material over the first layer, and compacting the first powder material and the second powder material using at least a first magnetic field.

Abstract: Methods of forming earth-boring rotary drill bits by forming and joining two less than fully sintered components, by forming and joining a first fully sintered component with a first shrink rate and forming a second less than fully sintered component with a second sinter-shrink rate greater that that of the first shrink rate of the first fully sintered component, by forming and joining a first less than fully sintered component with a first sinter-shrink rate and by forming and joining at least a second less than fully sintered component with a second sinter-shrink rate less than the first sinter-shrink rate.

Abstract: A macroscopic composite sintered powder metal article including a first region including cemented hard particles, for example, cemented carbide. The article includes a second region including one of a metal and a metallic alloy selected from the group consisting of a steel, nickel, a nickel alloy, titanium, a titanium alloy, molybdenum, a molybdenum alloy, cobalt, a cobalt alloy, tungsten, and a tungsten alloy. The first region is metallurgically bonded to the second region, and the second region has a thickness of greater than 100 microns. A method of making a macroscopic composite sintered powder metal article is also disclosed, herein. The method includes co-press and sintering a first metal powder including hard particles and a powder binder and a second metal powder including the metal or metal alloy.

Abstract: The present invention provides a method for manufacturing a biomedical porous article wherein communicability between the pores in the porous article is ensured and a desired porosity can be easily obtained, the method comprising a plate-like thread cluster formation step in which a plate-like thread cluster is obtained by dispersing many metallic threads made of a biomedical metallic material along a flat surface and entangling them; a compressing step of compressing the plate-like thread cluster into a desired thickness; and a sintering step of sintering the plate-like thread cluster.

Abstract: Methodology for constructing composite particles from ingredients comprising two or more particulate components. The resultant particles are usefully incorporated into powder coating compositions. The approach also finds utility in other applications, including but not limited to the food, drug, and cosmetics industry. Fluidized particles are subjected to an intense, but relatively brief heating event. This causes associated particles to fusingly assemble into fused composite clusters.

Abstract: A method for fabricating a unitary component for a combustor is disclosed, said method comprising the steps of determining three-dimensional information of the unitary component, converting the three-dimensional information into a plurality of slices that each define a cross-sectional layer of the unitary component, and successively forming each layer of the unitary component by fusing a metallic powder using laser energy. A fuel nozzle component is disclosed, comprising a body having a unitary construction wherein the body is made by using a rapid manufacturing process.

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

Abstract: A compositionally graded gas turbine disk is made by placing a cylindrically symmetric slip case concentrically into an interior of a cylindrically symmetric outer container. A first nickel-base superalloy powder is loaded into a radially inner first portion of the interior and a second nickel-base superalloy powder is loaded into a radially outer second portion of the interior. The slip case is removed so that the first nickel-base superalloy powder and the second nickel-base superalloy powder contact in the transition region and form a non-compacted powder mass. The non-compacted powder mass is processed into a gas turbine disk, typically by compacting the non-compacted powder mass to form a compacted powder mass, and thereafter heat treating the compacted powder mass.

Abstract: A method of making an article having at least one re-entrance surface includes the steps of (a) forming a layer of metal powder on a base, (b) selectively laser fusing portions of the layer, and (c) repeating steps (a) and (b) to form the article, each step (a) being performed on the preceding layer characterised in that prior to performing step (a) in a layer which will initiate the formation of a re-entrant feature reversibly bonding at least some of the unfused underlying powder such that it is stable under the application of the laser

Abstract: Embodiments of the present invention include methods of producing a composite article. A method comprises introducing a first powdered metal grade from a feed shoe into a first portion of a cavity in a die and a second powdered metal grade from the feed shoe into a second portion of the cavity, wherein the first powder metal grade differs from the second powdered metal grade in chemical composition or particle size. Further methods are also provided. Embodiments of the present invention also comprise composite inserts for material removal operations. The composite inserts may comprise a first region and a second region, wherein the first region comprises a first composite material and the second region comprises a second composite material.

Abstract: A method is provided for producing a sealing segment for use in compressor and turbine components, by powder injection molding, the method comprising the following steps: a) preparing a first homogeneous mixture of a metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binding agent; b) producing a first molded article by injection molding the first mixture; c) preparing a second homogeneous mixture of a metal powder or a mixture of metal powders or a ceramic powder or a mixture of ceramic powders and at least one binding agent, the second mixture being selected to exhibit a lower abrasion resistance than the first mixture following a subsequent joint sintering process; d) producing a second molded article as a rub strip by injection molding the second mixture; and e) joining the first and second molded articles to produce the sealing segment.

Abstract: Diffusion bonded brake rotor and hub formed by powder metallurgy including metals such as titanium powder.

Abstract: Vehicular brake rotor formed by powder metallurgy including metals such as titanium powder.