Abstract: Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.

Abstract: A precipitation hardenable aluminum alloy is disclosed along with a precipitation hardened form of the aluminum alloy and a method of manufacturing an aluminum alloy article from the precipitation hardenable aluminum alloy. The disclosed precipitation hardenable aluminum alloy has a composition that includes, on a weight percent (wt %) basis, 8%-13% zinc, 1.5%-5% magnesium, 0%-5% copper, 0%-2% of zirconium, chromium, or zirconium and chromium in total, and the balance aluminum with no more than 0.5% impurities. The alloy composition is adaptable to a wide range of manufacturing processes including additive manufacturing. The composition of the aluminum alloy also enables the dispersion of strengthening precipitate phases selected from an ?-phase precipitate, a ?-phase precipitate, and a T-phase precipitate, while being free of a S-phase precipitate, when precipitation hardened.

Abstract: A rolling-element bearing cage or a rolling-element bearing cage segment includes a first side ring or a first side ring segment formed from aluminum alloy AA2618, a second side ring or a second side ring segment formed from aluminum alloy AA2618, and at least one bridge formed from aluminum alloy AA2618, the at least one bridge connecting the first side ring to the second side ring or connecting the first side ring segment to the second side ring segment.

Abstract: A porous aluminum sintered material is provided. The porous aluminum sintered material includes aluminum substrates sintered each other, wherein pillar-shaped protrusions projecting toward an outside are formed on outer surfaces of the aluminum substrates, the porous aluminum sintered material has junctions in which the aluminum substrates are bonded each other through the pillar-shaped protrusions, the junctions include a Ti—Al compound, and a eutectic alloy phase including Al and Si is provided on surface layers of the junctions.

Abstract: The present invention relates to a method of manufacturing a high purity copper (Cu) powder material useable in fabricating a sputtering target material for electronic industrial applications, for example a penetrator liner. The foregoing method has a configuration of using an apparatus composed of a raw material feeder, a plasma torch and a reactor to prepare a metal powder, and includes steps of passing a Cu powder having an average particle diameter of 30 to 450 ?m through the thermal plasma torch at an introduction rate of 2 to 30 kg/hr, to thereby fabricate a Cu powder having an average particle diameter of 5 to 300 ?m.

Abstract: The disclosure relates to the manufacture of metal articles, more specifically the manufacture of metal articles by additive manufacturing techniques, and in particular to the manufacture of metal articles by an additive manufacturing technique that may involve the selective melting or sintering of a metal powder. Examples of such techniques may include selective laser melting (SLM), selective laser sintering (SLS) and techniques that use an electron beam rather than a laser. Exemplary embodiments include a method of manufacture of an article including selective melting and/or sintering of a powder including an alloy containing aluminium, wherein the alloy contains bismuth.

Abstract: A high-strength magnesium alloy member is suitable for products in which at least one of bending stress and twisting stress primarily acts. The member has required elongation and 0.2% proof stress, whereby strength and formability are superior, and has higher strength and large compressive residual stress in the vicinity of the surface of a wire rod. In the magnesium alloy member formed as a wire rod in which at least one of bending stress and twisting stress primarily acts, the wire rod includes a surface portion having the highest hardness of 170 HV or more in the vicinity of the surface and an inner portion having a 0.2% proof stress of 550 MPa or more and an elongation of 5% or more, and the wire rod has the highest compressive residue stress in the vicinity of the surface of 50 MPa or more.

Abstract: The invention is a process for manufacturing a nano aluminum/alumina metal matrix composite and composition produced therefrom. The process is characterized by providing an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5 m2/g, hot working the aluminum powder, and forming a superfine grained matrix aluminum alloy. Simultaneously there is formed in situ a substantially uniform distribution of nano particles of alumina. The alloy has a substantially linear property/temperature profile, such that physical properties such as strength are substantially maintained even at temperatures of 250° C. and above.

Abstract: A powder metal mixture is disclosed that provides improved mechanical properties for parts made from powder metal, such as cam caps. The powder metal mixture, upon sintering, forms an S phase intermetallic in the Al—Cu—Mg alloy system. The S phase is present in a concentration that results in an enhanced response to cold work strengthening of the powder metal part. Further, by minor adjustments to certain alloy elements, such as tin, the tensile properties of the resultant part may be adjusted.

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

Abstract: A magnesium-based alloy powder is made of a magnesium-based alloy that contains 0.2 mass % to 5 mass % of calcium, wherein the magnesium-based alloy powder has an average particle diameter of 100 ?m to 1,500 ?m, wherein the magnesium-based alloy powder has a particle average aspect ratio of 0.5 to 1, wherein the magnesium-based alloy powder has an apparent density of 0.2 g/cm3 to 1.2 g/cm3, and wherein the mean value of hardness variation index values obtained by dividing the difference of the maximum value and the minimum value of micro Vickers hardnesses taken at 10 measurement points in a particle cross section by the maximum value is 0.3 or less.

Abstract: A colored metal composite including a metal matrix; and colored particles distributed throughout the metal matrix AND/OR a method including providing metal powder as a first phase of a composite; providing colored particles to form a second phase of the composite; mixing the metal powder and colored particles; and sintering the metal powder around the colored particles to form a metal matrix that has colored particles distributed throughout.

Abstract: A method for producing high strength aluminum alloy powder containing L12 intermetallic dispersoids uses high pressure gas atomization to effect cooling rates in excess of 103° C./second.

Abstract: Embodiments of a magnesium (Mg) alloy and method for producing the same are disclosed. One such embodiment, among others, is a method for producing a magnesium (Mg) alloy, comprising the steps of: (a) producing a Mg powder aggregate by mixing Mg powder and at least one strengthening agent, the strengthening agent selected from: a carbon, a metal, and a combination thereof; (b) agglomerating the aggregate; and (c) sintering the agglomerated aggregate to produce the Mg alloy. Preferably, although not necessarily, steps (a) and (b) are performed using a ball mill. Moreover, the strengthening agent may be, for example but not limited to, carbon nanotubes, copper, tin, titanium, or silicon carbide. The resulting Mg alloy comprises nano-scale crystalline and/or micro-scale crystalline lattice structures and a yield strength that is at least as high as steel, exhibiting a yield strength that is about 320 MPa to 500 MPa.

Abstract: An aluminum alloy powder metal is disclosed. A sintered part made from the aluminum alloy powder has a thermal conductivity comparable to or exceeding parts made from wrought aluminum materials.

Abstract: The present invention relates to a process for producing components consisting of magnesium or magnesium alloy by sintering. This process makes it possible, for the first time, to produce components consisting of magnesium or magnesium alloy which provide outstanding elasticity together with a sufficient strength. Materials of this type can be used as biocompatible endosseous implant materials.

Abstract: A composite article (1; 10; 40) comprises a plurality of inclusions (5) of a magnetocalorically active material embedded in a matrix (4) of a magnetocalorically passive material. The inclusions (5) and the matrix (4) have a microstructure characteristic of a compacted powder.

Abstract: A sintered porous metal body, which has a sintered structure having a volumetric porosity of 10 to 90%, wherein there are at least one powder particles selected from the group consisting of dielectric material powders and semiconductor material powders that absorb energy of electromagnetic wave having a frequency of 300 MHz to 300 GHz among the metal crystalline particles constituting the sintered body, wherein the particles are substantially homogeneously dispersed in the sintered body, and wherein the metal particles are sintered to bond each other to be united to constitute pores. The invention discloses a method of manufacturing the sintered porous metal body.

Abstract: A powder metal composite is disclosed. The powder metal composite includes a substantially-continuous, cellular nanomatrix comprising a nanomatrix material. The composite also includes a plurality of dispersed first particles each comprising a first particle core material that comprises Mg, Al, Zn or Mn, or a combination thereof, dispersed in the nanomatrix; a plurality of dispersed second particles intermixed with the dispersed first particles, each comprising a second particle core material that comprises a carbon nanoparticle; and a solid-state bond layer extending throughout the nanomatrix between the dispersed first and second particles. The nanomatrix powder metal composites are uniquely lightweight, high-strength materials that also provide uniquely selectable and controllable corrosion properties, including very rapid corrosion rates, useful for making a wide variety of degradable or disposable articles, including various downhole tools and components.

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

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

Abstract: A powder metal compact is disclosed. The powder compact includes a substantially elongated cellular nanomatrix comprising a nanomatrix material. The powder compact also includes a plurality of substantially elongated dispersed particles comprising a particle core material that comprises Mg, Al, Zn or Mn, or a combination thereof, dispersed in the cellular nanomatrix. The powder compact further includes a bond layer extending throughout the cellular nanomatrix between the dispersed particles, wherein the cellular nanomatrix and the dispersed particles are substantially elongated in a predetermined direction.

Abstract: The heat conductivity of an aluminum composite material containing a fibrous carbon material is enhanced. In order to realize this, a spark plasma sintered body having a fibrous carbon material compounded in a metal matrix powder of aluminum or the like is fabricated. At the time of fabrication, an aluminum powder serving as a matrix mother material is compounded with an Al alloy powder such as an Al-12Si powder having a melting point lower than the sintering temperature of the mother material. During the process of sintering the aluminum powder, the Al alloy powder is melted, whereby the heat conductivity between the aluminum powder particles and between the aluminum powder particle and the fibrous carbon material is improved.

Abstract: The present invention provides an electrode material for aluminum electrolytic capacitors that has a high porosity and a high capacitance, and that does not require etching. Specifically, the invention provides an electrode material for aluminum electrolytic capacitors that contains a sintered body of at least one of aluminum and aluminum alloys, the sintered body having a porosity of 35 to 55%.

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: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.

Abstract: A method and apparatus for producing high strength aluminum alloys from a powder containing Ll2 intermetallic dispersoids. The powder is degassed, sealed under vacuum in a container, consolidated by vacuum hot pressing, extruded into a rolling preform and rolled into a usable part.

Abstract: A method for producing a high strength aluminum alloy tubing containing L12 dispersoids from an aluminum alloy powder containing the L12 dispersoids. The powder is consolidated into a billet having a density of about 100 percent. The tube is formed by at least one of direct extrusion, Mannesmann process, pilgering, and rolling.

Abstract: The present invention relates to a process for producing components consisting of magnesium or magnesium alloy by sintering. This process makes it possible, for the first time, to produce components consisting of magnesium or magnesium alloy which provide outstanding elasticity together with a sufficient strength. Materials of this type can be used as biocompatible endosseous implant materials.

Abstract: A discontinuously reinforced metal matrix composite wherein the reinforcing material is a particulate binary intermetallic compound is described along with methods for preparing the same. The binary intermetallic compound includes the same type of metal as is the principal matrix metal in combination with one other metal. The particle size of the particulate binary intermetallic compound may be less than about 20 ?m and may be between about 1 ?m and about 10 ?m. The intermetallic particles may be present in the discontinuously reinforced metal matrix composites in an amount ranging from about 10% to about 70% by volume. The discontinuous reinforced metal matrix composites of the invention may be used in structures requiring greater strength and stiffness than can be provided by matrix metal alone. The materials of the invention may be used for vehicle parts, structural materials, and the like.

Abstract: An efficient oxygen scavenging composition for use in film forming polymers is disclosed wherein the oxygen scavenging composition comprises an oxidizable metal particle, such as elemental iron; a water hydrolysable Lewis acid, such as aluminum chloride; and an acidifying electrolyte such as sodium or potassium bisulfate.

Abstract: The present invention includes consolidated hard materials, methods for producing them, and industrial drilling and cutting applications for them. A consolidated hard material may be produced using hard particles such as B4C or carbides or borides of W, Ti, Mo, Nb, V, Hf, Ta, Zr, and Cr in combination with an iron-based, nickel-based, nickel and iron-based, iron and cobalt-based, aluminum-based, copper-based, magnesium-based, or titanium-based alloy for the binder material. Commercially pure elements such as aluminum, copper, magnesium, titanium, iron, or nickel may also be used for the binder material. The mixture of the hard particles and the binder material may be consolidated at a temperature below the liquidus temperature of the binder material using a technique such as rapid omnidirectional compaction (ROC), the CERACON® process, or hot isostatic pressing (HIP). After sintering, the consolidated hard material may be treated to alter its material properties.

Abstract: The present invention includes consolidated hard materials, methods for producing them, and industrial drilling and cutting applications for them. A consolidated hard material may be produced using hard particles such as B4C or carbides or borides of W, Ti, Mo, Nb, V, Hf, Ta, Zr, and Cr in combination with an iron-based, nickel-based, nickel and iron-based, iron and cobalt-based, aluminum-based, copper-based, magnesium-based, or titanium-based alloy for the binder material. Commercially pure elements such as aluminum, copper, magnesium, titanium, iron, or nickel may also be used for the binder material. The mixture of the hard particles and the binder material may be consolidated at a temperature below the liquidus temperature of the binder material using a technique such as rapid omnidirectional compaction (ROC), the CERACON™ process, or hot ecstatic pressing (HIP). After sintering, the consolidated hard material may be treated to alter its material properties.

Abstract: Certain preferred embodiments of the present invention relate to compositions for the production of sintered molded parts, components/parts produced therefrom, and methods for preparing such compositions. In accordance with certain embodiments, compositions for production of sintered molded parts comprise a metal-based, a ceramic-based, and/or a polymer-based powder, and a compaction aid, having 25 to 60 weight percent of a polyglycol, based on the total weight of the compaction aid, and 40 to 75 weight percent of a montan wax, based on the total weight of the compaction aid. The compaction aid may be present in an amount from about 0.1 to 5 weight percent, preferably 0.5 to 1.5 weight percent, based on the total weight of the composition. The composition may also include a lubricant such as, for example, MoS2, WS2, BN, MnS, and/or carbon.

Abstract: A composite element comprises:(a) a metal or metal alloy component having an elastic modulus that decreases with increasing temperature in a temperature range; and (b) sufficient amount of a shape memory alloy component having an elastic modulus that shows an increase in elastic modulus with increasing temperature in the said temperature range, such that the elastic modulus of the composite element does not fall substantially as the temperature is increased across the said temperature range. An article comprising such a composite element is suitable for use in high temperature applications, including motor vehicle components.

Abstract: The present invention is a process for producing a radiator member for electronic appliances, and is characterized in that, in a process for producing a radiator member for electronic appliances, the radiator member comprising a composite material in which SiC particles are dispersed in a matrix metal whose major component is Al, it comprises a filling step of filling an SiC powder into a mold, a pre-heating step of pre-heating the mold after the filling step to a pre-heating temperature which falls in a range of from a melting point or more of said matrix metal to less than a reaction initiation temperature at which a molten metal of the matrix metal and SiC particles in the SiC powder start to react, and a pouring step of pouring the molten matrix metal whose molten-metal temperature falls in a range of from the melting point or more of the matrix metal to less than the reaction initiation temperature, into the mold after the pre-heating step, and impregnating the SiC powder with the molten metal by pressur

Abstract: A hydrogen storage material includes a nano size material that can be formed in a multi-layered core/shell structure and/or in a nanotabular (or platelet) form.

Abstract: A three-phase nanocomposite that comprises about 0.5 to 10 vol % nano-scale aluminum oxide particles and about 1 to 45% high modulus ceramic particles and an aluminum alloy matrix. The nano phase is to enhance nanocomposite strength and the modulus phase is to enhance the specific modulus of the resulting nanocomposite.

Abstract: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.

Abstract: A method of production of large Ingots of neutron attenuating composites using a vacuum-bellows system allows for large cross-sectional shapes to be extruded and rolled. This method uses a vacuum-bellows technology which allows the manufacturing of large 8–16 inch diameter ingots (50–450 lbs. each). A variety of primary metal matrix materials can be used in this technology. High specific strength and stiffness can be achieved because the technology allows for final densities of 99% and higher. The vacuum-bellows technology allows metals and ceramics to blend and mesh together at compression pressures of 800 tons with elevated temperatures. The controlled compression movement allows for any oxide layer, on the metal, to be broken up and consolidated with the chosen ceramic particulate.

Abstract: A composite of M/AlMgB14 or M alloy/AlMgB14 is synthesized, where M=Al, Ti, W, or Cu. Small particles and/or fibers of AlMgB14 are distributed throughout a metal matrix to strengthen the resulting composite.

Abstract: A magnesium base composite material is provided such that compound particles generated by a solid-phase reaction with magnesium are uniformly dispersed in a magnesium alloy body. The compound particles dispersed in the body comprise magnesium silicide (Mg2Si) and magnesium oxide (MgO) so that the magnesium base composite material may have excellent strength, hardness and abrasion resistance and tempered opponent aggression.

Abstract: A discontinuously reinforced metal composite, having a metal matrix and a plurality of intermetallic particles comprising at least two different metals, the intermetallic particles having a size ranging from 1 ?m to about 10 ?m and being dispersed within the metal matrix in an amount of at least 20% by volume, wherein the intermetallic particles are particles having at least one same metal as the metal in the metal matrix.

Abstract: High theoretical density, metal-based materials containing graphite or hexagonal boron nitride have low coefficients of friction and wear rates are useful for bearings, bushings and other articles subject to bearing loads.

Abstract: A sinter metal part with a homogeneous distribution of non-homogeneously melting components, essentially comprising non-homogeneously melting non ferrous metal powder mixtures, produced in the following manner: continuous isostatic pressure sintering of the starting material to obtain densities which substantially correspond to the density of a high-temperature isostatically pressed solid having the same composition, using die in conditions avoiding the occurrence of a liquid phase in powder at temperatures of up to 70% of the metal melting point, preferably up to 60% of the metal melting point, forming a sinter profile substantially possessing a final contour.

Abstract: A bond coat composition for use in thermal barrier coatings comprises a NiAl—CoCrAlY matrix containing particles of AlN dispersed therein. The bond coat composition is prepared by croymilling NiAl and CoCrAlY in liquid nitrogen.

Abstract: The present invention pertains to an AlRu sputtering target characterized in that it is a sintered body composed of an AlRu intermetallic compound of 95 vol. % or more, and an object thereof is to enable the stable and low-cost manufacture of an AlRu sputtering target having an even texture and capable of significantly reducing oxygen, and to prevent or suppress the generation of particles and improve the yield ratio of deposition goods.

Abstract: There are disclosed a method for producing a composite material composed of a dispersing agent and a matrix, and a composite material produced by the method. The matrix is formed by the steps of coating a metal-coated dispersing agent to form a metal-coated layer on the surface of the dispersing agent, filling the metal-coated dispersing agent in a jig prepared in a fixed shape, and then causing the reaction of the metal-coated layer with a molten Al by impregnating the metal-coated dispersing agent with the molten Al filled in the jig.

Abstract: Targets for the fabrication of quasicrystalline films are prepared from powders of the elemental constituents of the objective quasicrystalline material that have been pressed into a required target shape. The temperature of target fabrication is maintained sufficiently low that quasicrystalline alloy formation does not occur during target fabrication. Due to the high thermal shock resistance of each of the individual constituents and due to the dispersed form of the powders comprising the target, the target demonstrates very high resistance to thermal shock.

Abstract: Objects comprising carbide particulate having pressure consolidated nanocrystalline coating material are formed. Oxides of the coating material, in particulate form, may become dispersed in the pressure consolidated object, thereby increasing its strength.