Способ изготовления трёхслойного листового металлополимерного материала

Изобретение относится к технологии получения композиционных металлополимерных антифрикционных материалов с помощью энергии взрывчатых веществ и может быть использовано в промышленности для изготовления пар трения. Предложен способ изготовления трёхслойного листового металлополимерного материала, при котором для взрывного прессования используют спрессованные давлением два листа - один из металлополимерной смеси и второй - полимерный, размещают между пуансонами в виде одинаковых стальных пластин прессуемые листы с размещением между ними стального слоя, производят прессование взрывом полученной сборки с использованием скользящей ударной волны при заданных параметрах, после отделения спрессованных взрывом металлополимерного и полимерного листов от пуансонов и стального слоя между ними размещают металлическую сетку из коррозионностойкой стали и осуществляют термообработку между тепловыми губками указанной сборки под давлением. Изобретение обеспечивает получение листового коррозионностойкого, ...

СПОСОБ ИЗГОТОВЛЕНИЯ СУВЕНИРНЫХ БИМЕТАЛЛИЧЕСКИХ ИЗДЕЛИЙ

Изобретение относится к порошковой металлургии, в частности к получению сувенирных биметаллических изделий. Может использоваться для получения сувенирных монет, медалей с эффектом разноцветности. Рельефную часть нижнего пуансона выставляют на 2-3 мм над матрицей пресс-формы, наносят на нее пастообразную смесь порошка на основе меди. Затем опускают нижний пуансон на глубину 15 мм с образованием рабочей полости, засыпают порошок железа и производят полуавтоматическое прессование. Полученную заготовку спекают в защитном газе, после чего осуществляют чеканку и финишную отделку. Обеспечивается возможность изготовления биметаллических изделий полуавтоматическим прессованием. 1 з.п. ф-лы, 2 ил.

АППАРАТ И СПОСОБ ДЛЯ СВЯЗЫВАНИЯ ПОЗИЦИИ В НАБОРЕ ДАННЫХ КОНСТРУКЦИИ С ПОЗИЦИЕЙ В СЕКЦИИ ПОСТРОЕНИЯ АППАРАТА

Заявленная группа изобретений относится к получению трехмерного изделия, состоящего из основного элемента и послойно изготовленного на нем из порошкообразного материала дополнительного элемента. Устройство содержит секцию построения для размещения в ней основного элемента, содержащего ограничивающую поверхность, облучающий модуль для формирования пучка излучения с возможностью сканирования по заданному полю, измерительный модуль для измерения зависимой от времени интенсивности электромагнитного излучения в позиции пятна пучка излучения, контроллер, выполненный с возможностью связывания измеренной интенсивности электромагнитного излучения с информацией о текущей позиции пучка излучения, определения позиции ограничивающей поверхности по отношению к полю сканирования на основании изменения измеренной интенсивности электромагнитного излучения во времени и на основании информации о позиции, связывания позиции в наборе данных конструкции трехмерного изделия с позицией в секции построения и связывания ...

АДДИТИВНОЕ ИЗГОТОВЛЕНИЕ ДЕТАЛИ ТУРБИНЫ С ИСПОЛЬЗОВАНИЕМ НЕСКОЛЬКИХ МАТЕРИАЛОВ

... 1. Способ изготовления детали, включающий этапы, на которыхнаносят множество смежных порошковых слоев из соответствующих различных материалов на рабочую поверхность по формам соответствующих областей, которые представляют соответствующий конечный материал в заданной плоскости сечения многокомпонентной детали, при этомперекрывают по меньшей мере два смежных порошковых слоя с образованием зоны постепенного перехода материала между указанными по меньшей мере двумя смежными порошковыми слоями,воздействуют первым лазерным излучением с первой интенсивностью на первый порошковый слой и вторым лазерным излучением со второй интенсивностью, отличной от первой интенсивности, на второй порошковый слой, иповторяют этапы от указанного этапа нанесения, для последующих плоскостей сечения детали, с тем чтобы изготовить деталь.2. Способ по п. 1, в котором первый порошковый слой содержит металл, второй порошковый слой содержит керамику, создающую тепловой барьер, при этом лазерное излучение с первой энергией ...

СПОСОБ УПЛОТНЕНИЯ ТВЕРДЫХ ПОРОШКОВ С ЖЕСТКИМ ПОКРЫТИЕМ

Изобретение относится к порошковой металлургии, в частности к получению изделий из порошков с покрытием. На частицы сердцевины, состоящие из по меньшей мере одного соединения, выбранного из нитридов металла и металлоида, карбидов металла и металлоида, карбонитридов металла и металлоида, боридов металла и металлоида, оксидов металла и металлоида, сульфидов металла и металлоида и силицидов металла и металлоида, и алмаза, наносят промежуточный слой из соединения, отличного по составу от материала частиц сердцевины. Соединение промежуточного слоя способно связываться с материалом частиц и с металлом, выбранным из группы: железо, кобальт, никель, медь, титан, алюминий, магний, литий, бериллий, серебро, золото, платина и их смеси. На промежуточный слой наносят наружный слой из металла, выбранного из группы: железо, кобальт, никель и их смеси, с образованием компонентных частиц. Полученные частицы формуют и проводят жидкофазное спекание при температуре, достаточной для превращения в жидкое состояние ...

МЕЛКОЗЕРНИСТЫЙ ПОЛИКРИСТАЛЛИЧЕСКИЙ АБРАЗИВНЫЙ МАТЕРИАЛ

... 1. Абразивный элемент из поликристаллического алмаза, содержащий мелкозернистый поликристаллический алмазный материал и вторую фазу, включающую катализатор-растворитель для алмазного материала, причем поликристаллический алмазный материал имеет среднее значение длины свободного пробега для катализатора-растворителя менее 0,60 мкм и среднеквадратическую погрешность менее 0,90. ! 2. Абразивный элемент по п.1, в котором среднеквадратическая погрешность средней длины свободного пробега для катализатора-растворителя составляет менее 0,85. ! 3. Абразивный элемент по п.1, в котором поликристаллический алмазный материал имеет средний размер зерен от примерно 0,1 до примерно 10,5 мкм. ! 4. Абразивный элемент по п.3, в котором поликристаллический алмазный материал имеет средний размер зерен от примерно 0,1 до примерно 6,5 мкм. ! 5. Абразивный элемент по п.4, в котором поликристаллический алмазный материал имеет средний размер зерен от примерно 0,1 до примерно 2,0 мкм. ! 6. Абразивный элемент по одному ...

ЭЛЕКТРОДНЫЙ МАТЕРИАЛ И ЕГО ПРИМЕНЕНИЕ ДЛЯ ПОЛУЧЕНИЯ ИНЕРТНОГО АНОДА

СПОСОБЫ, СИСТЕМЫ И УСТРОЙСТВО ДЛЯ ЦИКЛОТРОННОГО ПОЛУЧЕНИЯ ТЕХНЕЦИЯ-99M

СПОСОБ УПЛОТНЕНИЯ ТВЕРДЫХ ПОРОШКОВ С ЖЕСТКИМ ПОКРЫТИЕМ

... 1. Способ формирования изделия, при этом вышеупомянутый способ включает:приготовление множества частиц сердцевины, содержащих один материал частиц сердцевины или множество различных материалов частиц сердцевины, при этом вышеупомянутый материал частиц сердцевины выбран из группы, состоящей из нитридов металла и металлоида, карбидов металла и металлоида, карбонитридов металла и металлоида, боридов металла и металлоида, оксидов металла и металлоида, сульфидов металла и металлоида и силицидов металла и металлоида, и алмаза;создание промежуточного слоя на большинстве вышеупомянутых частиц сердцевины, при этом вышеупомянутый промежуточный слой включает второе соединение, отличное по составу от вышеупомянутого материала частицы сердцевины, и имеет более высокую относительную вязкость при разрушении, при этом второе соединение способно связываться с вышеупомянутым материалом частицы сердцевины и способно связываться с металлом, выбранным из группы, состоящей из железа, кобальта, никеля, меди, ...

Vorrichtung zur generativen Herstellung eines Bauteils

Die Erfindung betrifft eine Vorrichtung (10) zur generativen Herstellung eines Bauteils (12), umfassend mindestens einen Beschichter (14) zum Erzeugen einer Pulverschicht (16) auf einer Bauplattform (18), mindestens eine Strahlungsquelle (20), insbesondere einen Laser, zum Erzeugen eines Hochenergiestrahls (24), mittels welchem die Pulverschicht (16) in einer Baufläche (22) lokal zu einer Bauteilschicht (30) verschmelzbar und/oder versinterbar ist, mindestens eine Ablenkeinrichtung (26), mittels welcher der Hochenergiestrahl (24) auf unterschiedliche Bereiche der Pulverschicht (16) ablenkbar und auf die Baufläche (22) fokussierbar ist, mindestens ein Messsystem (28), mittels welchem eine Querschnittsgeometrie des Hochenergiestrahls (24) auf der Pulverschicht (16) und/oder der Bauteilschicht (30) ermittelbar ist, und mindestens eine Ausgleichseinrichtung (32). Die Ausgleichseinrichtung (32) ist dazu ausgebildet, anhand der Querschnittsgeometrie des Hochenergiestrahls (24) eine Fokusfläche ...

Verfahren zum Herstellen einer Elektrode zur Oberflächenbehandlung mittels Entladung und Verfahren zum Herstellen eines Filmkörpers

Ein Verfahren zum Herstellen einer Elektrode (1) zur Oberflächenbehandlung mittels Entladung umfasst: einen ersten Legeschritt des Legens von Pulverpartikeln (21) derart, dass eine erste Pulverschicht (11) gebildet wird; und einen ersten Bindeschritt des Bindens einiger der Pulverpartikel (21) in der ersten Pulverschicht (11) aneinander. Das Verfahren umfasst ferner: einen zweiten Legeschritt des Legens der Pulverpartikel (21) ferner auf eine Pulverschicht, in welcher einige der Pulverpartikel (21) aneinander gebunden sind, derart, dass eine zweite Pulverschicht (12) gebildet wird; und einen zweiten Bindeschritt des Bindens einiger der Pulverpartikel (21) in der zweiten Pulverschicht (12) aneinander derart, dass ein Schichtkörper (2) von granulierten Partikeln gebildet wird. Innerhalb des Schichtkörpers (2) wird ein Bereich gebildet, welcher eine von einem anderen Bereich verschiedene Porosität aufweist.

INHOMOGENOUS SINTERED BODY

Verfahren zur Herstellung von Verschleissteilen

VERFAHREN ZUR HERSTELLUNG EINES WERKSTOFFES MIT EINEM ABHAENGIGEN GRADIENTEN.

Verfahren zur Herstellung einer porigen Aluminiumschicht

Vorrichtung zur Herstellung eines Rohlings nebst Verfahren hierzu und Rohling

Die vorliegende Erfindung betrifft eine Vorrichtung, vorzugsweise Presse, umfassend eine zu befüllende Kavität, zumindest eine erste Materialzuführung eines ersten Materials und eine zweite Materialzuführung eines zweiten Materials, wobei die erste und die zweite Materialzuführung getrennt voneinander angeordnet sind, mit einer Zuführvorrichtung zum Zuführen des ersten und des zweiten Materials in die zu befüllende Kavität, wobei die Zuführvorrichtung einen Mündungsquerschnitt mit zumindest einem ersten Bereich des Mündungsquerschnitts für das erste Material und mit einem davon abgetrennten zweiten Bereich des Mündungsquerschnitts für das zweite Material aufweist zum vorzugsweise parallelen, örtlich getrennten Befüllen der Kavität. Des Weiteren sind ein Verfahren wie auch ein Rohling vorgeschlagen.

Walze und Verfahren zum Herstellen einer Walze zum Warm- oder Kaltwalzen von Metallflachprodukten

Bei der erfindungsgemäßen Herstellung einer Walze zum Walzen von Metallflachprodukten, die einen mit einer verschleißfesten Schicht beschichteten Ballenabschnitt mit daran angeformten Zapfen umfasst, wird ein Grundkörperrohling mit einem Ballenabschnitt und zwei Zapfenrohabschnitten bereitgestellt, die einen größeren Durchmesser als der Ballenabschnitt und ein Materialvolumen aufweisen, das mindestens gleich dem Volumen des der jeweiligen Stirnseite zugeordneten Zapfens der Walze ist. Dieser Ballenabschnitt wird mit einem Mantel ummantelt, der mit seinen den Zapfenrohabschnitten zugeordneten Randbereichen dicht an die ihm jeweils zugeordneten Stirnseiten der Zapfenrohabschnitte angeschlossen wird, und einen um den Ballenabschnitt umlaufenden Hohlraum umgrenzt. Der Hohlraum wird mit einem Legierungspulver gefüllt. Anschließend wird daraus durch heißisostatisches Verpressen die den Ballenabschnitt ummantelnde, stoffschlüssig mit ihm verbundene verschleißfeste Schicht gebildet. Dann werden ...

Diamond impregnated bits and method of using and manufacturing the same

A drill bit that includes a body having a lower end face for engaging a rock formation, the end face having a plurality of raised ribs extending from the face of the bit body and separated by a plurality of channels therebetween; and at least one of the plurality of ribs having a cutting portion of the at least one rib comprising a first diamond impregnated matrix material and at least a portion of a gage surface region thereof comprising a second diamond impregnated matrix material, the gage surface region backed by a third matrix material is disclosed.

WEAR-RESISTANT ARTICLES OF HARD MATERIAL

... 1404752 Coated sintered cemented carbide HOY CARBIDES Ltd 19 July 1972 [19 July 1971] 33837/71 Heading C7D A wear resistant article such as a cutting tool tip comprises a body of cobalt cemented tungsten carbide coated with an outer layer of cobalt. The cobalt layer 0.01 "thick may be applied by painting with a slurry of cobalt flake or powder in a volatile solvent and then sintering. Other coating methods such as electroless deposition, hydrogen precipitation from aqueous solution, sputtering, flame spraying or vapour phase deposition from a volatile compound. After coating the article is heated to effect diffusion.

Diamond impregnated bits

Polycrystalline diamond compact with gradient interfacial layer

The present disclosure relates to a polycrystalline diamond compact (PDC) including a gradient interfacial layer between a thermally stable diamond (TSP) table and a base, such as a substrate or an earth-boring drill bit body. The gradient interfacial layer has a gradient of coefficients of thermal expansion between that of the diamond and the base. The disclosure also relates to methods of forming a gradient interfacial layer and a PDC containing such a layer.

Additive manufacture of electrically conductive materials

ZWEISCHICHTEN-SINTERKONTAKTSTUCK FUR ELEKTRISCHE SCHALTGERATE

BONDING MATERIAL FOR THE PRODUCTION OF ELEKRI CONTACTS AND PROCEDURES FOR ITS PRODUCTION

PRODUCTION OF METAL PARTS USING SIS SINTERS (SIS - SELECTIVE INHIBITION OF SINTERING)

A method of making a cutting tool body and tool body

Es wird ein Verfahren zum Herstellen eines Zerspanungswerkzeug-Körpers (100) mit den folgenden Schritte beschrieben: Erzeugen eines Werkzeugschaft- Rohlings aus Ausgangspulver für Hartmetall, das einen ersten metallischen Binder und zumindest überwiegend durch Wolframkarbid gebildete Hartstoffpartikel aufweist; Ausbilden zumindest eines Sitzes (13) für eine Schneide (20) an einem Außenumfang des Werkzeugschaft-Rohlings an einem Schneidenbereich (12); und lotmittelfreies Einsintern einer Schneide (20) aus einem Verbundwerkstoff an dem Sitz (13). Der Verbundwerkstoff der Schneide (20) weist zumindest eine in einem zweiten metallischen Binder eingebettete Phase aus Hartstoffpartikeln in Form eines Metallkarbids oder Metallkarbonitrids auf, die zumindest 50 Gew.-% des Verbundwerkstoffes bildet. Der Anteil des zweiten metallischen Binders am Verbundwerkstoff beträgt zumindest 4 Gew.-%.

DEVICE AND PROCEDURE FOR SOLIDS CREATION AND COMPRESSION OF PULVERTEILCHEN OF MEANS HIGH SPEED AND THERMAL OF PLASTIC DEFORMATION

PROCEDURE FOR THE PRODUCTION OF FREE FORMING PRODUCTS

Molding method and apparatus, particularly applicable to metal and/or ceramics

Method and apparatus for manufacturing a molded layered product comprises: printing a first mold to define one layer of the product; filling the first mold with a cast material, thereby forming a first layer; printing a second mold on top of the first layer to define a second layer; and filling the second mold, over the first layer, with a cast material. The cast material may be a paste. The alternative mold printing and casting are continued until a molded layered product or part product is formed.

METHOD OF FORMING FREESTANDING THIN CHROMIUM COMPONENTS FOR AN ELECTROCHEMICAL CONVERTER

Cold isopressing method

METALLIC PARTS FABRICATION USING SELECTIVE INHIBITION OF SINTERING (SIS)

Layered construction of metallic materials

The present disclosure is directed at alloys and method for layer-by-layer deposition of metallic alloys on a substrate. The resulting deposition provides for relatively high hardness metallic parts with associated wear resistance. Applications for the metallic parts include pumps, valves and/or bearings.

LIQUID PHASE BONDED AMORPHOUS MATERIALS AND PROCESS FOR PREPARATION THEREOF

METHOD FOR THE MANUFACTURE OF TWO-LAYER SINTERED CONTACT PIECE

STAINLESS STEEL, A PREALLOYED POWDER OBTAINED BY ATOMIZING THE STEEL AND USE OF THE PREALLOYED POWDER

The invention relates to a stainless steel. The stainless steel consists of in weight % (wt. %): C0.32 0.50 Si0.1 1.0 Mn0.1 -0.8 Cr11 -14 Mo1.8 -2.6 V0.35 -0.70 N0.05 0.19 optional elements, balance Fe and impurities.

A APPARATUS AND PROCESS FOR SOLID-STATE DEPOSITION AND CONSOLIDATION OF HIGH VELOCITY POWDER PARTICLES USING THERMAL PLASTIC DEFORMATION

Apparatus and process for solid-state deposition and consolidation of powder particles entrained in a subsonic or sonic gas jet onto the surface of an object. Under high velocity impact and thermal plastic deformation, the powder particles adhesively bond to the substrate and cohesively bond together to form consolidated materials with metallurgical bonds.

Verfahren zur Herstellung von gesinterten Hartmetallplättchen für spanabhebende Werkzeuge.

Procédé de formation de couches poreuses minces d'aluminium sur de l'aluminium

Procédé de fabrication d'un objet par la métallurgie des poudres

Verfahren zur Herstellung eines selbstschmierenden Lagers

System having a layered structure and method of manufacturing the same.

Ein System enthält eine Schichtstruktur. Die Schichtstruktur enthält eine erste (50) und eine zweite (52) koaleszierte Schicht und eine Zwischenschicht (54), die zwischen der ersten (50) und der zweiten (52) koaleszierten Schicht angeordnet ist. Die erste und die zweite (52) koaleszierte Schicht haben ein höheres Mass an Koaleszenz als die Zwischenschicht (54).

Article and method of making an article.

Es sind ein Gegenstand und ein Verfahren zur Herstellung formgestalteter Kühllöcher in einem Gegenstand geschaffen. Das Verfahren enthält die Schritte des Auftragens eines Metalllegierungspulvers, um eine Anfangsschicht zu bilden, die wenigstens eine Öffnung enthält, des Schmelzens des Metalllegierungspulvers mit einer fokussierten Energiequelle, um die Pulverschicht in eine Metalllegierungsbahn umzuwandeln, des darauffolgenden Auftrags einer zusätzlichen Schicht des Metalllegierungspulvers, um eine Schicht zu bilden, die wenigstens eine Öffnung enthält, die der wenigstens einen Öffnung in der Anfangsschicht entspricht, des Schmelzens der zusätzlichen Schicht des Metalllegierungspulvers mit der fokussierten Energiequelle zur Erhöhung der Bahndicke und des Wiederholens der Schritte des aufeinanderfolgenden Auftrags und Aufschmelzens der zusätzlichen Schichten des Metalllegierungspulvers, bis eine Struktur, die wenigstens eine Öffnung mit einem vorbestimmten Profil enthält, erhalten wird.

Article and method of making an article.

Es sind ein Gegenstand und ein Verfahren zur Herstellung formgestalteter Kühllöcher in einem Gegenstand geschaffen. Das Verfahren enthält die Schritte des Auftragens eines Metalllegierungspulvers, um eine Anfangsschicht zu bilden, die wenigstens eine Öffnung enthält, des Schmelzens des Metalllegierungspulvers mit einer fokussierten Energiequelle, um die Pulverschicht in eine Metalllegierungsbahn umzuwandeln, des darauffolgenden Auftrags einer zusätzlichen Schicht des Metalllegierungspulvers, um eine Schicht zu bilden, die wenigstens eine Öffnung enthält, die der wenigstens einen Öffnung in der Anfangsschicht entspricht, des Schmelzens der zusätzlichen Schicht des Metalllegierungspulvers mit der fokussierten Energiequelle zur Erhöhung der Bahndicke und des Wiederholens der Schritte des aufeinanderfolgenden Auftrags und Aufschmelzens der zusätzlichen Schichten des Metalllegierungspulvers, bis eine Struktur, die wenigstens eine Öffnung mit einem vorbestimmten Profil enthält, erhalten wird.

COMPOUND ROLL

For the static cylindrical drum on the method of manufacturing the supporting metal layer

A powder metallurgy composite cam blades

METHOD FOR MANUFACTURING AN ABRADABLE LAYER

MATERIAL LAMINATES AND PROCEEDED FOR SA MANUFACTURE BY PLATING THERMOCINETIQUE

Improvements with the junction of metals

Prouits semi-finished with several subgrades of bars, with one or more layers out of materials compound and processes and devices for the manufacture of this bar by the technique of the metallurgy of the powders

자동차용 실린더 블록 제조방법

... 본 발명은 실린더 라이너와 실린더 블록을 일체화시킨 자동차용 실린더 블록 제조방법에 관한 것으로서, 본 발명의 일 실시형태에 따른 자동차용 실린더 블록 제조방법은 실린더 라이너 형상의 성형체를 준비하는 준비단계와; 준비된 성형체를 실린더 블록용 몰드의 내부에 고정시키는 고정단계와; 성형체가 고정된 실린더 블록용 몰드에 실린더 블록용 주조재 용탕을 주입하여 상기 성형체가 일체화된 실린더 블록을 주조하는 주조단계를 포함한다.

Compositions of nanoparticles with radial concentration gradients and methods of use thereof

COPPER ALLOY FOR SLIDING MEMBER

SINTERING AND BONDING METHOD OF STEEL MATERIAL AND COPPER ALLOY AND SINTERED AND BONDED ASSEMBLY

The present invention relates to a method of sintering and bonding copper alloy powder containing lead on a steel material and a sintered and bonded assembly. The sintering and bonding method of a steel material and a copper alloy and the sintered and bonded assembly prevent a lead precipitate from being formed with an area along the bonded interface between a steel material and a copper alloy when the copper alloy containing lead is sintered and bonded on the steel material. The sintering and bonding method of a steel material and a copper alloy performs sintering and bonding in two steps through the following steps: a step of forming a first copper alloy powder layer on a steel material; a step of forming a first copper alloy bonding layer by sintering and bonding the first copper alloy powder layer on the steel material; a step of forming a second copper alloy powder layer on the first copper alloy bonding layer; and a step of forming a second copper alloy bonding layer by sintering ...

One-step manufacturing method of laminated molding porous component which has curved surface

Method of isoprensagem the cold

Method for producing a sintered article rigid hard metals and the resultant article

La invención provee un método para producir un artículo rígido sinterizado de metales duros que tiene un núcleo de una composición de metal duro de unaprimera clase, y al menos una capa superficial de un metal duro de una segunda clase, que comprende las etapas de: (a) preparar una lechada que contiene unpolvo de metal duro de la segunda clase en calidad de constituyente de la lechada en partículas, y un vehículo líquido que consiste esencialmente enhidrocarburos, incluyendo dicho vehículo líquido disolventes, agentes activadores de tensión superficial, aglutinantes y agentes plastificadores; (b)aplicar dicha lechada a una superficie de compacto verde, estando dicho compacto verde formado por dicho metal duro de primera clase; (c) permitir quela lechada se seque sobre dicho compacto verde para formar un compacto verde constituido por capas; y (d) sinterizar dicho compuesto verde constituido porcapas para formar el artículo rígido deseado. Se provee además el artículo rígido sinterizado ...

طريقة method لدمج consolidating مساحيق powders خشنة متينة الغلاف

En funktionell gradientmaterialkomponent och metod för att producera en sådan komponent

PROCESS FOR PRODUCING METALLIZED ALUMINUM NITRIDE SUBSTRATE AND SUBSTRATE OBTAINED THEREBY

... [PROBLEMS] To provide a metallized aluminum nitride substrate that as a metallized aluminum nitride substrate for mounting of semiconductor elements, such as LD and LED, excels in the dimensional precision of wiring pattern and realizes high junction strength. [MEANS FOR SOLVING PROBLEMS] First, there is provided an intermediate material substrate consisting of a sintered aluminum nitride substrate having on its surface a wiring pattern constituted of a conductor layer composed of a composition comprising at least a high-melting-point metal powder, an aluminum nitride powder and an aluminum nitride sintering aid. Subsequently, the intermediate material substrate is sintered while disposing an aluminum nitride sintering product, the aluminum nitride sintering product having been sintered with the use of a sintering aid of the same type as that of the sintering aid contained in the above composition, in contact with the conductor layer on the surface of the intermediate material substrate ...

R-T-B SINTERED MAGNET AND METHOD FOR PRODUCING THE SAME

Disclosed is an R-T-B sintered magnet containing both a light rare earth element RL (at least one of Nd and Pr) and a heavy rare earth element RH (at least one of Dy and Tb), and having a main phase of Nd2Fe14B crystal. This magnet internally contains a first region wherein the concentration of the heavy rare earth element RH is zero or relatively low and a second region wherein the concentration of the heavy rare earth element RH is relatively high, and the first region and the second region are joined by sintering.

SURFACE MODIFIED POWDER METAL PARTS AND METHODS FOR MAKING SAME

A sintered metal part which has a pressed and sintered core; the part is coated with a sintered metal surface layer; the layer has a property different from that of the metal part; the interior regions of the core are free of the metal constituting the coating; and process for making the parts.

ADDITIVE LAYER MANUFACTURING

A method for the manufacture of a component of defined geometry from two or more materials using a powder bed ALM process includes providing a bed of a first powdered material, selectively fusing portions of the first powdered material to build up a first three dimensional portion of the component geometry and fusing a powder containment bund from the first material to contain unfused first powdered material. A bed of a second powdered material is deposited onto the powder containment bund and selectively fused to build up a second three dimensional portion of the component geometry. Unfused first powdered material can subsequently be removed from a first side of the bund and unfused second powder from a second side of the bund. Remaining parts of the bund which do not form part of the defined geometry of the component can be removed to provide the net shape component.

Fine Grained Polycrystalline Abrasive Material

Polycrystalline diamond abrasive elements having a fine grained microstructure are produced from fine grained diamond particles and a catalyst solvent material, at least a portion of which is in the form of nanosized particles. The abrasive elements exhibit high homogeneity and exhibit significant increases in toughness and improved wear resistance.

Method for manufacturing erosion-resistant wearing parts and a wearing part

A method of manufacturing erosion-resistant wearing parts and a wearing part are disclosed, whereby the wearing part manufactured according to the invention comprises at least one hard powder composition (A) and at least one ductile powder composition (B) that together are densified in a single pressing step into an entirely dense product. According to the method, the temperature coefficient of the hard powder composition (A) is controlled by keeping the temperature coefficient of the hard powder composition smaller than that of the encapsulating powder composition (B), whereby the hard powder composition (A), with the exception of the outer erosion-subjected surface of the wearing part, remains entirely encapsulated by powder composition (B) so effectively that the imposed eroding forces cannot essentially extrude the hard powder composition (A) out from the wearing part through its erosion-subjected outer surface.

Composite material for use in the manufacture of electrical contacts and a method for its manufacture

An electrically conductive composite material for use in the manufacture of electrical contact components, consisting of a metal strip and a contact layer made of a silver or tin contact material, which contact layer is applied at least to one side of the metal strip, whereby the contact material contains as a first additive 0.5 to 60 weight percentage of carbon powder in the form of fine particles having a diameter of Ø1=5 to 200 nm and 0.5 to 60 weight percentage of a second powdery additive in the form of fine particles having a diameter of Ø2=5 to 200 nm. Moreover a device for the gas atomization of a jet of a flowable or liquid material and a method for the manufacture of an electrically conductive composite material and its use are disclosed.

Copper alloy for sliding materials

A copper alloy having excellent sliding performance is produced without relying on lead or molybdenum. The copper alloy contains a sintered Cu5FeS4 material produced by sintering a raw material powder that comprises Cu, Fe and S and is produced by a gas atomizing method.

Titanium carbide/titanium alloy composite and process for powder metal cladding

A microcomposite material having a matrix of a titanium-base alloy, the material further including about 10-80% by weight TiC substantially uniformly dispersed in the matrix. Several methods of cladding a macrocomposite structure including pressing quantities of a matrix material and a microcomposite material composed of the matrix material and a compatible stiffener material into layers to form a multi-layered compact and sintering the multi-layered compact to form an integral metallurgical bond between the layers of the compact with diffusion but essentially no composition gradient between the layers. A multi-layered macrocomposite article composed of an alloy layer of a matrix material and a layer of a microcomposite material composed of the matrix material and a compatible stiffener material bonded together at the interface region between the layers, the interface region being essentially free of a composition gradient.

Surface modified powder metal parts and methods for making same

A sintered metal part which has a pressed and sintered core; the part is coated with a sintered metal surface layer; the layer has a property different from that of the metal part; the interior regions of the core are free of the metal constituting the coating; and process for making the parts.

Molding tool

A die comprises metal-rich sections which form an inner wall and an outer wall of the die, respectively. Gradient sections are disposed adjacent to the metal-rich sections, respectively. Further, a ceramics-rich section is disposed between the gradient sections. A punch comprises an inner ceramics-rich section, a gradient section, and an outer metal-rich section. In the die, the composition ratio of metal gradually decreases from the metal-rich sections to the ceramics-rich section. Similarly, in the punch, the composition ratio of the metal gradually decreases from the metal-rich section to the ceramics-rich section.

Direct-manufactured duct interconnects

A duct connection system has a direct-manufactured first duct structure including a first duct section. The first duct section has a passage for conveying a substance and a first interconnect component moveably and captivity coupled to the duct section. The duct connection system also has a direct-manufactured second duct structure including a second duct section. The second duct section has a passage for conveying the substance and a first interconnect component configured to enter a locked state with the first interconnect component such that a sealing force between the first and second duct structures is substantially equal to a predetermined value.

METHOD FOR MANUFACTURING A PART BY METAL INJECTION MOULDING

A method for manufacturing a part includes metal injection molding of metal powder mixed with a binder to produce individual components of the part as separately molded green compact sections which are then debindered to form brown compact sections. At least one of the brown compact sections is subjected to a pre-sintering process to undergo a first shrinkage. The pre-sintered brown compact section and a further brown compact section are joined together to form a multi-part brown compact which is subsequently subjected to a main sintering process, where the pre-sintered brown compact section undergoes less shrinkage than the further brown compact section to draw together and firmly connect the pre-sintered brown compact section and the further brown compact section. 1. A method for manufacturing a part , comprising:producing individual components of the part as separately molded green compact sections by metal injection molding of metal powder mixed with a binder, and then removing the binder from the green compact sections to form debindered brown compact sections;subjecting at least one of the brown compact sections to a pre-sintering process in which it undergoes a first shrinkage;connecting together the at least one pre-sintered brown compact section and at least one further brown compact section to form a multi-part brown compact; andsubsequently subjecting the multi-part brown compact to a main sintering process whereby the connected brown compact sections undergo shrinkage, with the at least one pre-sintered brown compact section undergoing a second shrinkage less than a shrinkage of the at least one further brown compact section to draw together and firmly connect to one another the at least one pre-sintered brown compact section and the at least one further brown compact section.2. The method in accordance with claim 1 , wherein the pre-sintered brown compact section and the further brown compact section are connected to one another before the main ...

THERMOELECTRIC ELEMENT, THERMOELECTRIC MODULE AND METHOD OF MANUFACTURING THERMOELECTRIC ELEMENT

Cracking in a thermoelectric element made of a filled-skutterudite-type alloy is suppressed. A p-type thermoelectric element includes: a p-type thermoelectric conversion layer made of an alloy having a filled-skutterudite structure containing antimony; a p-side first metal layer that contains titanium simple substances and iron simple substances, and is laminated on the p-type thermoelectric conversion layer; and a p-side second metal layer that contains titanium simple substances, and is laminated on the p-side first metal layer.

MAGNETIC SHIELDING SHEET AND METHOD OF PREPARATION THEREOF

The present disclosure relates to a magnetic shielding sheet and a method of preparation thereof. The magnetic shielding sheet includes a magnetic layer, and a protective layer disposed on at least one surface of the magnetic layer. The magnetic layer includes a metal-ceramic composite that is metal powder, on which a ceramic coating layer is formed.

MANUFACTURING METHOD FOR THREE-DIMENSIONAL FORMED OBJECT AND MANUFACTURING APPARATUS FOR THREE-DIMENSIONAL FORMED OBJECT

A manufacturing method for a three-dimensional formed object for manufacturing the three-dimensional formed object by stacking layers includes supplying a first supply object including a first material to a supporting body and sintering the first material to thereby solidify the first material to form a first layer and supplying a second supply object including a second material having a melting point or a sintering temperature lower than a sintering temperature of the first material to be superimposed on the first layer and sintering or melting the second material to thereby solidify the second material to form a second layer. 1. A manufacturing method for a three-dimensional formed object for manufacturing the three-dimensional formed object by stacking layers , the manufacturing method for the three-dimensional formed object comprising:forming a first layer by supplying a first supply object including a first material to a supporting body and sintering the first material to thereby solidify the first material; andforming a second layer by supplying a second supply object including a second material having a melting point or a sintering temperature lower than a sintering temperature of the first material to be superimposed on the first layer and sintering or melting the second material to thereby solidify the second material.2. The manufacturing method for the three-dimensional formed object according to claim 1 , further comprising stacking one or more layers by executing the supply of the second supply object and the sintering or the melting of the second material on the second layer.3. The manufacturing method for the three-dimensional formed object according to claim 2 , further comprising supplying a third supply object and forming a support layer that supports the second supply object supplied in the stacking one or more layers.4. The manufacturing method for the three-dimensional formed object according to claim 1 , wherein a melting point of the supporting ...

PRESSURE FORMING OF METAL AND CERAMIC POWDERS

A method of pressure forming a brown part from metal and/or ceramic particle feedstocks includes: introducing into a mold cavity or extruder a first feedstock and one or more additional feedstocks or a green or brown state insert made from a feedstock, wherein the different feedstocks correspond to the different portions of the part; pressurizing the mold cavity or extruder to produce a preform having a plurality of portions corresponding to the first and one or more additional feedstocks, and debinding the preform. Micro voids and interstitial paths from the interior of the preform part to the exterior allow the escape of decomposing or subliming backbone component substantially without creating macro voids due to internal pressure. The large brown preform may then be sintered and subsequently thermomechanically processed to produce a net wrought microstructure and properties that are substantially free the interstitial spaces.

METHOD FOR MANUFACTURING COBALT-BASED ALLOY STRUCTURE, AND COBALT-BASED ALLOY STRUCTURE OBTAINED THEREBY

In order to stably produce a structured article made of a metal with a complex shape, such as a turbine stator blade, while securing a sufficient mechanical strength, there is provided a method for manufacturing a cobalt-based alloy structure, the cobalt-based alloy structure including a first structure region comprising a hollow space and a second structure region filled in the hollow space. The method includes the steps of: forming the first structure region by additive manufacturing from a first cobalt-based alloy powder having a particle size distribution within a range of 5-85 μm and in D90 within a range of 40-80 μm; and forming the second structure region in the hollow space by hot isostatic pressing, the hollow space being filled with a second cobalt-based alloy powder with a particle size distribution within a range of 5-85 μm and in D90 within a range of 40-80 μm.

Haftfester Metall-Keramik-Verbund und Verfahren zu seiner Herstellung

Die Erfindung bezieht sich auf das Gebiet der Werkstoffwissenschaften und betrifft einen haftfesten Metall-Keramik-Verbund, wie er beispielsweise für Umformwerkzeuge oder Schneidwerkzeuge zur Anwendung kommen kann. Die Aufgabe der vorliegenden Erfindung besteht in der Angabe eines haftfesten Metall-Keramik-Verbundes, welcher zwischen Keramik und Metall eine feste und dauerhafte Bindung aufweist. Die Aufgabe wird gelöst durch einen haftfesten Metall-Keramik-Verbund, bestehend aus einer Metall- und einer Keramikkomponente, die stoff- oder stoff- und kraftschlüssig miteinander verbunden sind, wobei Silicium, Beryllium, Titanium, Chromium, Nickel, Mangan, Hafnium, Vanadium, Zirkonium, Aluminium und/oder deren organische Verbindungen im Bereich der Verbindungsflächen vorhanden ist und wobei die Komponenten als Grünkörper zu einem Verbund verarbeitet und gemeinsam gesintert worden sind. Die Aufgabe wird weiterhin gelöst durch ein Verfahren, bei dem mindestens je eine Metall- und Keramikkomponente ...

VERFAHREN ZUR HERSTELLUNG EINES WERKZEUGTEILS

Adaptiver Formgedächtnisverbund

Herstellen eines Refraktärmetall-Bauteils

Diamond impregnated bits

Diamond impregnated bits and method of using and maufacturing the same

Controlling the quality of ultra-hard materials

A method for controlling the consistency of the quality of ultra hard materials formed over tungsten carbide substrates formed from different batches of tungsten carbide powder by controlling the tungsten carbide particle size distribution in each batch. The deviation of particle size distribution between different batches having no more than 30Y. Such control ensures similar infiltration kinetics of cobalt into the tungsten carbide substrates.

Diamond impregnated bits and method of using and manufacturing the same

Additive manufacturing method and apparatus

Methods of manufacturing drill bits

PROCEDURE FOR THE PRODUCTION OF SAMPLES CARRYING, FORMED ARTICLES USING FRICTION ANGLE FORMING TOOL

PROCEDURE AND DEVICE FOR THE PRODUCTION OF SINTERED MOLDED ARTICLES BY PARTIAL SINTERING

FLATTEN MOLDED ARTICLES WITH AT LEAST TWO LAYERS.

HARTMETALLBAUTEIL MIT GRADIERTEM AUFBAU

Structural component comprises cemented carbide alloy containing carbonized material, mixed carbonized material or carbonitride of tungsten, titanium, tantalum, vanadium, molybdenum, zirconium, hafnium, niobium and/or chromium, additive(s) and binder (1-20 wt.%) of cobalt, nickel and/or iron. Additive suppresses crystal growth of vanadium, chromium, titanium, tantalum, niobium or their compounds. An Independent claim is included for manufacture of structural component.

TWO-LAMINATING INTERCCONTACT STUCCO FUR ELECTRICAL SWITCHINGTURNED OUT

Verfahren zur Herstellung eines Bauteils

Die Erfindung betrifft ein Verfahren zur Herstellung eines Bauteils aus Refraktärmetall oder einer Refraktärmetalllegierung mit einem Refraktärmetallgehalt > 50 At.%, das die Schritte Bereitstellen eines aus Partikeln gebildeten Pulvers und Verfestigen des Pulvers unter Einwirken eines Laser- oder Elektronenstrahls umfasst, wobei das Pulver eine laseroptisch gemessene Partikelgröße d50 von > 10 µm und eine mittels BET gemessene mittlere Oberfläche > 0,08 m2/g aufweist.

Powder metallurgy procedure, thereafter manufactured bush and thereafter manufactured piston ring

STRUCTURED THREE-DIMENSIONAL PRINTING PROCESS

Method for producing decorative metallic article with wood grain metal pattern, and decorative metallic article with wood grain metal pattern

Provided are a method for producing a decorative metallic article with a wood grain metal pattern and the decorative metallic article with the wood grain metal pattern; the decorative metallic article comprising a sintered copper part produced by sintering a plastic copper containing clay compound, and a sintered silver part produced by sintering a plastic silver containing clay compound. The method comprises: a plate forming step of forming a copper plate and a silver plate; a multi layering and adhesion step of mutually laminating the copper and silver plates one another by applying water to the surfaces of the plates, and elongating the laminated plates so that a thickness thereof decreases in 10% or more, thereby to adhesively paste together; a wood grain metal plate forming step of forming a wood grain pattern by carving the surface of the multi layered plate produced in the multi layering and adhesion step so as to expose at least a part of the plurality of plate layers, and elongating the surface of the multi layered plate to become flat; a decorative object forming step of forming a decorative object by using the prepared wood grain metal plate; a decorative object drying step of drying the decorative object; and a sinter producing step of sintering the decorative object produced in the decorative object drying step, thereby to obtain the decorative metallic article.

Copper alloy for sliding materials

A copper alloy having excellent sliding performance is produced without relying on lead or molybdenum. The copper alloy contains a sintered Cu 5 FeS 4 material produced by sintering a raw material powder that comprises Cu, Fe and S and is produced by a gas atomizing method.

METHOD FOR PRODUCING REGENERATED TARGET

A sintering method with uniaxial pressing includes: a powder filling step of disposing a spent target in an inner space of a frame jig having the inner space piercing in a uniaxial direction, and filling the inner space with a raw material powder for a target to cover an erosion part side of the spent target with the raw material powder for a target, a cushioning-material disposition step of disposing a deformable cushioning material so that the raw material powder for a target with which the inner space has been filled in the powder filling step is sandwiched between the spent target and the deformable cushioning material; and a sintering step of pressing the raw material powder for a target with which the inner space has been filled and the spent target in the uniaxial direction through the cushioning material and sintering them. 1. A method for producing a regenerated target , comprising:a powder filling step of disposing a spent target made of a metal sintered body or a composite sintered body of a metal and a metal compound in an inner space of a frame jig having the inner space piercing in a uniaxial direction, and filling the inner space with a raw material powder for a target made of a metal or made of a metal and a metal compound to cover an erosion part side of the spent target with the raw material powder for a target;a cushioning-material disposition step of disposing a deformable cushioning material made of an inorganic fiber so that the raw material powder for a target with which the inner space has been filled in the powder filling step is sandwiched between the spent target and the cushioning material; anda sintering step of pressing the raw material powder for a target with which the inner space has been filled and the spent target in the uniaxial direction through the cushioning material disposed in the cushioning-material disposition step and sintering them.2. A method for producing a regenerated target , comprising:a powder filling step of ...

METHOD OF MANUFACTURING A WELD-FREE APPARATUS FOR CONNECTION OF DISSIMILAR METALS USING FUNCTIONALLY GRADED COMPOSITIONALLY CONTROL POWDER METALLURGY AND HOT ISOSTATIC PROCESSING METHODS

A method of manufacturing a weld-free apparatus for use in the connection of dissimilar metals includes the steps of providing a mold designed to replicate a reverse of the apparatus, introducing a low alloy, ferritic steel composition atomized powder into a first portion of the mold, introducing a series of atomized powders incrementally into a second portion of the mold to form a transition region between the ferritic steel composition and an austenitic stainless steel composition, and introducing an austenitic stainless steel composition atomized powder into a third portion of the mold. The method further includes the step of consolidating and melting the atomized powders in a high temperature, high pressure inert gas atmosphere to form the apparatus. 1. A method of providing a weld-free apparatus for use in the connection of dissimilar metals , comprising the steps of:(a) providing a mold designed to replicate a reverse of the apparatus;(b) providing a first metal powder and introducing the first metal powder into a first portion of the mold;(c) providing a second metal powder and introducing the second metal powder into a second portion of the mold;(d) providing a third metal powder and introducing the third metal powder into a third portion of the mold, wherein the second metal powder forms a transition between the first metal powder and the third metal powder;(e) pulling a vacuum on the mold and sealing the mold to maintain the vacuum;(f) placing the mold into a hot isostatic pressing (HIP) furnace to consolidate and melt the first, second, and third powders; and(g) cooling the mold to room temperature and removing the apparatus from the mold.2. The method according to claim 1 , wherein the first metal powder is a low alloy ferritic steel composition atomized powder.3. The method according to claim 1 , wherein the third powder is an austenitic stainless steel composition atomized powder.4. The method according to claim 1 , wherein the mold is maintained in ...

Multilayered Metal Including Titanium, and Method for Manufacturing Method Same

A multilayer metal structure is provided that includes an inner layer of metal materials which are not titanium and outer layers on both sides of the inner layer which are formed by rolling titanium powders. A method for manufacturing the multilayer metal structure is provided that includes preparing titanium powders and metal materials which are not titanium, feeding the titanium powders and the metal materials to a vertical type rolling mill, simultaneously rolling the titanium powders and the metal materials by the rolling mill and forming the multilayer metal structure consisting of an inner layer and outer layers on both sides of the inner layer, and post-forming the multilayer metal structure to increase a packing density. 1. A multilayer metal structure comprises an inner layer of metal materials which are not titanium and outer layers on both sides of the inner layer which are formed by rolling titanium powders.2. The multilayer metal structure according to claim 1 , wherein the outer layers have a packing density of 95 vol. % or more.3. The multilayer metal structure according to claim 2 , wherein the outer layers are formed of the titanium powders having a particle size of less than 100 mesh and the inner layer is formed of the metal materials in powder having a particle size of less than 100 mesh.4. The multilayer metal structure according to claim 2 , wherein the inner layer is in the form of plate claim 2 , bar claim 2 , or shape.5. The multilayer metal structure according to claim 3 , wherein the outer and inner layers are mechanically adjoined.6. A method for manufacturing a multilayer metal structure comprises the steps of: preparing titanium powders and metal materials which are not titanium claim 3 , feeding the titanium powders and the metal materials to a vertical type rolling mill claim 3 , simultaneously rolling the titanium powders and the metal materials by the rolling mill and forming the multilayer metal structure consisting of an inner ...

HIGH PRESSURE CARBIDE COMPONENT WITH SURFACES INCORPORATING GRADIENT STRUCTURES

An anvil including a hard phase and a metal matrix in which the hard phase is dispersed, a concentration of the metal matrix phase varying according to a concentration gradient, is disclosed. The anvil may be used in a high pressure press. Methods of making an anvil including forming a hard phase dispersed in a metal matrix phase, a concentration of the metal matrix phase varying according to a concentration gradient, are also disclosed. 1. An anvil comprising:a hard phase; anda metal matrix phase in which the hard phase is dispersed, wherein a concentration of the metal matrix phase varies according to a concentration gradient.2. The anvil of claim 1 , wherein the hard phase comprises a hard material selected from the group consisting of tungsten carbide claim 1 , tantalum carbide claim 1 , titanium carbide and combinations thereof3. The anvil of claim 1 , wherein the metal matrix phase comprises a material selected from the group consisting of Co claim 1 , Fe claim 1 , Ni and combinations thereof4. The anvil of claim 1 , further comprising a working surface for applying high pressure claim 1 , wherein the concentration gradient extends from the working surface to a gradient depth within the anvil.5. The anvil of claim 4 , wherein a concentration of the metal matrix phase at the working surface is lower than a concentration of the metal matrix phase at the gradient depth within the anvil by an amount in a range of about 1 to about 2%.6. The anvil of claim 4 , wherein a concentration of the metal matrix phase at the working surface is lower than a concentration of the metal matrix phase at the gradient depth within the anvil by an amount in a range of about 2 to about 4%.7. The anvil of claim 4 , wherein a concentration of the metal matrix phase at the working surface is lower than a concentration of the metal matrix phase at the gradient depth within the anvil by an amount in a range of about 4 to about 6%.8. The anvil of claim 4 , wherein the concentration of the ...

Ceramic, graded resistivity monolith using the ceramic, and method of making

According to one embodiment, a monolithic cassette with graded electrical resistivity is presented. The monolithic cassette has a continuous grain structure between a first end and a second end; wherein electrical resistivity of the monolithic cassette is graded such that the resistance varies continuously from the first end to the second end. Methods and compositions for forming the monolithic cassette are also presented.

METHOD AND ARRANGEMENT FOR MANUFACTURING A COMPONENT WITH HOT ISOSTATIC PRESSING, A CORE, A PREFORM FOR A CLADDING, AND USE OF THE CORE

A method and an arrangement for manufacturing a component with hot isostatic pressing occurring in solid form, the component comprising a shape opening onto the outer surface. The method comprises forming a sheet metal capsule for metallic powder, and manufacturing a core by arranging around a core centre made of a first material, a form layer made of a second material, the shape of the outer surface of the form layer corresponding to the shape of the outer surface of the opening shape of the component. The core is placed in a spot, where the shape opening onto the outer surface is to be formed, and metallic powder is arranged in the sheet metal capsule, which forms the body part of the component to be manufactured. Cladding material is arranged between the outer surface of the core and the metallic powder, and hot isostatic pressing is performed to simultaneously compact the metal powder and the cladding material. 1. A method for manufacturing a component with hot isostatic pressing occurring in solid form , the component to be manufactured including a shape opening onto the outer surface of the component , which method comprises:forming a sheet metal capsule for metallic powder;manufacturing a core by arranging around a core centre made of a first material a form layer made of a second material, the shape of the outer surface of the form layer corresponding to the shape of the outer surface of the opening shape of the component;placing the core in a place, where the shape opening onto the outer surface is to be formed;arranging metallic powder into the sheet metal capsule, which metallic powder forms the body part of the component to be manufactured,characterized inarranging cladding material between the outer surface of the core and the metallic powder; and inperforming hot isostatic pressing in order to simultaneously compact the metallic powder and the cladding material.2. The method according to claim 1 , characterized in placing the core inside the sheet ...

ONE-PIECE COMPONENT AND METHOD FOR ITS PRODUCTION

A one-piece component includes a first subregion made of a base material, and a second subregion made of the base material as binder with intercalated hard material particles, the second subregion being injection-molded onto the first subregion by means of MIM injection molding, so that an integral connection is formed between the first subregion and the second subregion. Furthermore, a method for producing the one-piece component by means of MIM injection molding is described. 1. A one-piece component , comprising:a first subregion made of a base material, anda second subregion made of the base material as binder with intercalated hard material particles,the second subregion being injection-molded onto first subregion by means of MIM injection molding, so that an integral connection is formed between the first subregion and the second subregion.2. The component according to claim 1 , wherein the base material is an austenitic or ferritic steel claim 1 , which includes iron and chromium.3. The component according to claim 1 , wherein the hard material particles are oxides claim 1 , including AlO claim 1 , ZrOor YO.4. The component according to claim 1 , wherein the hard material particles are one of a) carbides claim 1 , including titanium carbide claim 1 , wolfram carbide claim 1 , niobium carbide or tantalum carbide claim 1 , or b) nitrides claim 1 , including titanium nitride.5. The component according to claim 1 , wherein the one-piece component is used as a piston claim 1 , cylinder claim 1 , valve seat or stop.6. A method for producing a one-piece component by means of MIM injection molding claim 1 , comprising:injection-molding a first subregion made of a base material, andinjection-molding a second subregion made of the base material as binder and including intercalated hard material particles, onto the first subregion, such that an integral connection is formed between the first and second subregions.7. The method according to claim 6 , wherein the base ...

MANUFACTURING METHOD OF MULTILAYER SHELL-CORE COMPOSITE STRUCTURAL COMPONENT

A manufacturing method of a multilayer shell-core composite structural component comprises the following procedures: (1) respectively preparing feeding material for injection forming of a core layer, a buffer layer and a shell layer, wherein the powders of feeding material of the core layer and the shell layer are selected from one or more of metallic powder, ceramic powder or toughening ceramic powder, and are different from each other, and the powder of feeding material of the buffer layer is gradient composite material powder; (2) layer by layer producing the blank of multilayer shell-core composite structural component by powder injection molding; (3) degreasing the blank; (4) sintering the blank to obtain the multilayer shell-core composite structural component. The multilayer shell-core composite structural component has the advantages of high surface hardness, abrasion resistance, uniform thickness of the shell layer, stable and persistent performance. 1. A method for manufacturing a multilayer shell-core composite structural component , comprising:(1) preparing feedstocks of a shell layer, a transition layer and a core layer for powder injection molding, respectively, the feedstocks being obtained by mixing a powder, a hinder and an additive comprising a surface active agent and a plasticizer; where the powder of the feedstock of the core layer is selected from one or more of a metal powder, a ceramic powder and a toughening ceramic powder; the powder of the feedstock of the shell layer is selected from one or more of a metal powder, a ceramic powder and a toughening ceramic powder; the powder of the feedstock of the core layer is different from the powder of the feedstock of the shell layer, and the powder of the feedstock of the transition layer is a powder of gradient composite material which is mixed by the powder of the feedstock of the shell layer with the powder of the feedstock of the core layer;(2) performing a powder injection molding using the ...

PRESSURE FORMING OF METAL AND CERAMIC POWDERS

A method of pressure forming a brown part from metal and/or ceramic particle feedstocks includes: introducing into a mold cavity or extruder a first feedstock and one or more additional feedstocks or a green or brown state insert made from a feedstock, wherein the different feedstocks correspond to the different portions of the part; pressurizing the mold cavity or extruder to produce a preform having a plurality of portions corresponding to the first and one or more additional feedstocks, and debinding the preform. Micro voids and interstitial paths from the interior of the preform part to the exterior allow the escape of decomposing or subliming backbone component substantially without creating macro voids due to internal pressure. The large brown preform may then be sintered and subsequently thermomechanically processed to produce a net wrought microstructure and properties that are substantially free the interstitial spaces. 1. A method of producing a consolidated preform for a part , comprising: a first portion comprising a first metal and/or ceramic powder composition dispersed in a binder;', 'one or more additional portions, at least one of which shares a boundary with the first portion, each additional portion comprising a metal and/or ceramic powder composition dispersed in a binder that is different from at least the first portion; and, 'providing a green or brown preform comprisingsintering the preform to bind the powder particles to each other to produce a consolidated, unitary preform.2. The method of further performing a densification process on the preform subsequent to sintering to densify at least a portion of the consolidated claim 1 , unitary preform.3. The method of wherein at least one additional portion comprises a core that is substantially surrounded by the composition of the first portion.4. The method of wherein the core is completely surrounded by the first portion.5. The method of wherein the core comprises a majority of the part by ...

Method for Producing Hard Tip

The object of the invention is to provide a hard tip where the nose side has wear resistance and the bonding side has toughness. The chemical composition of sintered hard alloy constituting the hard tip is such that a compounding ratio of WC to Co is substantially the same from the nose side to the bonding side, and a first bonding metal or a second bonding metal has a gradient chemical composition wherein the content of the first bonding metal or the second bonding metal is increased from the nose side to the bonding side, the first bonding metal does not form the eutectic texture with WC, and the second bonding metal has the eutectic temperature with WC over the eutectic temperature of WC—Co sintered hard alloy and the melting point over the liquid phase sintering temperature of WC—Co sintered hard alloy. 1. A method for producing a hard tip defining a nose side and a bonding side and comprising a block of a WC—Co sintered hard alloy and a nickel bonding metal , wherein a compounding ratio of WC to Co in the WC—Co sintered hard alloy is substantially the same at each layer from a nose layer of the nose side to a bonding layer of a bonding side via at least one intermediate layer , and a content of the bonding metal increases from the nose side to the bonding side , comprising:(a) feeding sintered hard alloy powder for the nose layer containing a required compounding ratio of WC to Co and a first quantity of a bonding metal into a compacting mold for the hard tip,(b) layering sintered hard alloy powder for at least one intermediate layer comprising a required compounding ratio of WC to Co and the bonding metal whose content gradually increases compared with the nose layer upon the nose layer in the compacting mold for the hard tip,(c) layering sintered hard alloy powder for the bonding layer comprising a required compounding ratio of WC to Co and a second quantity of the bonding metal upon the intermediate layer(s) in the compacting mold for the hard tip and adding ...

METHODS OF FORMING A METALLIC OR CERAMIC ARTICLE HAVING A NOVEL COMPOSITION OF FUNCTIONALLY GRADED MATERIAL AND ARTICLES CONTAINING THE SAME

There is disclosed a method of making a metallic or ceramic component, such as a cutting or forming tool, from at least two distinct powder precursors. In one embodiment, the method comprising forming a first mixture comprised of a plurality of coated particles, such as Tough-Coated Hard Powder (TCHP) composite particles created by encapsulating extremely hard core particles with very tough binder and structural materials, and at least one support powder, such as a carbide, typically WC—Co. The mixture is formed into a green body and sintered to form a functionally graded or multicomponent article. Non-limiting examples of the articles made from the disclosed methods are also disclosed and include drills, mills, cutting tools, forming tools, wires dies and mechanical components. 1. A method of making a metallic or ceramic component , said method comprising:a) providing at least one first powder, said first powder comprising a plurality of composite particles, made of a core particle material, an intermediate layer on said core particle material, and an outer layer, wherein said core particle material has a hardness higher than both the intermediate layer and the outer layer, and said intermediate layer has a fracture toughness greater than both the core particle material and the outer layer;b) providing at least one second powder comprising a carbide material;c) forming a green body comprised of said first and second powder mixtures such that the first powder mixture forms a first portion of said green body with the second powder mixture forming a second portion of said green body;d) molding, pressing or shaping said green body to form a compact; ande) sintering said compact to form an article having portions of different juxtaposed properties, said first portion of said green body forming hard wear-resistant portion of said article and said second portion of said green body forming a tough, strong load bearing portion of said article.2. The method of claim 1 , ...

ADDITIVE MANUFACTURE OF TURBINE COMPONENT WITH MULTIPLE MATERIALS

A method for additive manufacturing with multiple materials. First (), second (), and third () adjacent powder layers are delivered onto a working surface (A) in respective first (), second (), and third () area shapes of adjacent final materials () in a given section plane of a component (). The first powder may be a structural metal delivered in the sectional shape of an airfoil substrate (). The second powder may be a bond coat material delivered in a sectional shape of a bond coat () on the substrate. The third powder may be a thermal barrier ceramic delivered in a section shape of the thermal barrier coating (). A particular laser intensity (A, B) is applied to each layer to melt or to sinter the layer. Integrated interfaces () may be formed between adjacent layers by gradient material overlap and/or interleaving projections. 1. A method for making a component , comprising the steps of:delivering a plurality of adjacent powder layers of respectively different powder materials onto a working surface in respective area shapes representing respective final materials in a given section plane of a multi-material component;overlapping at least two of the adjacent powder layers to form a material gradient zone between said at least two adjacent powder layers;applying a first laser energy of a first intensity to a first of the powder layers, and a second laser energy of a second different laser intensity to a second of the powder layers; andrepeating from the delivering step for successive section planes of the component to fabricate the component.2. The method of claim 1 , wherein the first powder layer comprises a metal claim 1 , the second powder comprises a thermal barrier ceramic claim 1 , the first laser energy is directed to follow a first plurality of scan paths parallel to a non-linear perimeter of the first powder layer claim 1 , and the second laser energy is directed to follow a second plurality of scan paths parallel to a non-linear perimeter of the second ...

STATOR WINDING ASSEMBLY

In one embodiment, a stator includes a stator core and a winding assembly. The stator core has an axis and a slot extending a radial depth from a slot opening. The winding assembly is disposed in the slot, and includes a plurality of winding strands with cross-sectional shapes that vary as a function of radial location within the slot. 1. A stator comprising:a stator having an slot extending a slot depth from a slot opening; anda winding assembly disposed in the slot, the winding assembly comprising a plurality of winding strands with cross-sectional shapes that vary as a function of depth within the slot.2. The stator of claim 1 , wherein the stator has an axis claim 1 , and the slot depth is a radial depth from the slot opening.3. The stator assembly of claim 1 , wherein the winding strands have substantially the same cross-sectional area claim 1 , despite varying in cross-sectional shape.4. The stator assembly of claim 1 , wherein each winding strand has a substantially rectangular or trapezoidal cross-section though a plane normal to the axis.5. The stator assembly of claim 4 , wherein a radial depth of each winding strand decreases as a function of radial distance from the slot.6. The stator assembly of claim 1 , wherein the plurality of winding strands are arranged in a plurality of radial sections claim 1 , each radial section having a different number of winding strands per radial layer.7. The stator assembly of claim 1 , wherein each winding strand is displaced across a range of radial locations over the course of one or more full turns.8. The stator assembly of claim 1 , wherein the winding strands form twisted bundles.9. A method of forming a stator winding assembly for a stator slot claim 1 , the method comprising:additively manufacturing a plurality of winding strands with cross-sectional shape that varies as a function of depth within the slot; andadditively manufacturing an insulating gap matrix that separates separating the winding strands.10. The ...

METHOD FOR MANUFACTURING ADDITIVE MANUFACTURED OBJECT, AND MIXED MATERIAL

A method for manufacturing an additive manufactured object according embodiments includes supplying a powdered first material capable of being melted or sintered by irradiation with energy rays; supplying a powdered second material through which the energy rays are transmitted; melting or sintering the first material by irradiation with the energy rays; and solidifying the first material after melting or solidifying the first material by sintering. 1. (canceled)2. A method for manufacturing an additive manufactured object , the method comprising:supplying a powdered first material capable of being melted or sintered by irradiation with energy rays;supplying a powdered second material having absorptivity of the energy rays lower than the first material; andmelting or sintering the first material by irradiation with the energy rays, whereinthe first material and the second material are adjacent to each other.3. The method according to claim 2 , whereinthe supplying of the first material includes supplying the first material, andthe supplying of the second material includes supplying the second material to a second region adjacent to the first region.4. The method according to claim 3 , whereinthe first material includes a plurality of different first materials,the supplying of the first material includes the plurality of different first materials to the first region.5. The method according to claim 3 , wherein the first region claim 3 , and a third region being a part of the second region and being adjacent to the first region are irradiated with the energy rays claim 3 , in the melting or sintering of the first material.6. The method according to claim 2 , wherein the second material is removed claim 2 , after solidifying the first material after melting the first material claim 2 , or after sintering the first material.7. (canceled)8. A method for manufacturing an additive manufactured object claim 2 , the method comprising:supplying a powdered first material ...

SELECTIVE MATERIAL DISPENSING IN ADDITIVE MANUFACTURING

Additive manufacturing includes successively forming a plurality of layers on a support. Depositing a layer from the plurality of layers includes dispensing first particles, selectively dispensing second particles in selected regions corresponding to a surface of the object, and fusing at least a portion of the layer. The layer has the first particles throughout and the second particles in the selected regions. Alternatively or in addition, forming the plurality of layers includes depositing multiple groups of layers. Depositing a group of layers includes, for each layer in the group of layers dispensing a feed material to provide the layer, and after dispensing the feed material and before dispensing a subsequent layer fusing a selected portion of the layer. After all layers in the group of layers are dispensed, a volume of the group of layers that extends through all the layers in the group of layers is fused. 1. A method of additive manufacturing of an object , comprising: dispensing first particles on a support or an underlying layer, the first particles having a first mean diameter;', 'selectively dispensing second particles on the support or the underlying layer in selected regions corresponding to an exterior surface of the object, such that the layer has the first particles throughout and the second particles in the selected regions, the second particles having a second mean diameter at least two times smaller than the first mean diameter; and', 'fusing at least a portion of the layer., 'successively forming a plurality of layers on a support, wherein depositing a layer from the plurality of layers comprises'}2. The method of claim 1 , comprising dispensing the second particles after dispensing the first particles so that the second particles infiltrate into a layer of first particles.3. The method of claim 2 , wherein dispensing the first particles comprises pushing the first particles from a reservoir across the support or underlying layer.4. The method of ...

FUSING OF MULTIPLE LAYERS IN ADDITIVE MANUFACTURING

Additive manufacturing includes successively forming a plurality of layers on a support. Depositing a layer from the plurality of layers includes dispensing first particles, selectively dispensing second particles in selected regions corresponding to a surface of the object, and fusing at least a portion of the layer. The layer has the first particles throughout and the second particles in the selected regions. Alternatively or in addition, forming the plurality of layers includes depositing multiple groups of layers. Depositing a group of layers includes, for each layer in the group of layers dispensing a feed material to provide the layer, and after dispensing the feed material and before dispensing a subsequent layer fusing a selected portion of the layer. After all layers in the group of layers are dispensed, a volume of the group of layers that extends through all the layers in the group of layers is fused. 1. A method of additive manufacturing of an object , comprising: for each layer in the group of layers, dispensing a feed material on a support or an underlying layer to provide the layer;', 'for each layer in the group of layers, after dispensing the feed material to provide the layer and before dispensing a subsequent layer, fusing a selected portion of the layer corresponding to the object; and', 'after all layers in the group of layers are dispensed, fusing a volume of the group of layers that extends through all the layers in the group of layers., 'successively forming a plurality of a layers on a support, wherein forming the plurality of layers includes depositing multiple groups of layers, each group of layers including multiple layers, and depositing a group of layers from the plurality of layers includes'}2. The method of claim 1 , wherein the portion of the layer corresponds to an exterior surface of the object.3. The method of claim 1 , wherein regions of at least two adjacent layers in the group of layers have perimeters that are laterally offset ...

Composite Tungsten Carbide Insert With Heterogeneous Composition And Structure And Manufacturing Method Thereof

A composite tungsten carbide insert (B, I) with heterogeneous composition and structure has a working part (W) and a non-working part (N). The working part (W) is made of a tungsten carbide material consisting of tungsten carbide powder and cobalt powder or nickel. The non-working part (N) is made of a low density tungsten carbide material consisting of titanium carbide powder, tungsten carbide powder, and cobalt powder or nickel powder. During pressing, the tungsten carbide material for the working part (W) and the low density tungsten carbide material for the non-working part (N) are weighed and added to a steel die successively for molding and then sintering. The non-working part (N) which accounts for most of the overall product volume has low density and less material consumption, and can greatly reduce the raw material costs of the product, significantly improving the performance-cost ratio of the insert (B, I).

Additive Metal Manufacturing Process

Three dimensional “green” parts are formed by combining sheet layers comprising metal powder bound together by a polymer. The “green” parts are then sintered to drive off the polymer and consolidate the metal powder to produce a monolithic metal part. Particularly, the invention is directed to processes for forming and stacking the shaped sheet layers that are readily automated and preserve the high value powder metal and polymer sheet trim scrap for reuse resulting in an additive overall process with little material waste. The invention includes processes in which “green” elements formed by methods such as three dimensional printing are incorporated into the “green” stack and become an integral part of the final sintered part. It further includes processes in which “green” sheet layers are shaped by means such as hot bending or vacuum forming to provide three dimensional part features.

SINTERABLE METAL PASTE FOR USE IN ADDITIVE MANUFACTURING

A material and method are disclosed such that the material can be used to form functional metal pieces by producing an easily sintered layered body of dried metal paste. On a microstructural level, when dried, the metal paste creates a matrix of porous metal scaffold particles with infiltrant metal particles, which are positioned interstitially in the porous scaffold's interstitial voids. For this material to realize mechanical and processing benefits, the infiltrant particles are chosen such that they pack in the porous scaffold piece in a manner which does not significantly degrade the packing of the scaffold particles and so that they can also infiltrate the porous scaffold on heating. The method of using this paste provides a technique with high rate and resolution of metal part production due to a hybrid deposition/removal process. 1. A metal paste for use in the layerwise growth of metal structures , comprising:a vehicle comprising at least one solvent and at least one polymeric binder;metal scaffold particles comprising a population of large particles comprising iron at a concentration of about 70% to 100% by weight with a first D50 and a population of small particles comprising iron at a concentration of about 70% to 100% by weight with a second D50 that is smaller than the first D50; andinfiltrant particles with a D50 particle size such that the infiltrant particles primarily position in interstitial spaces between the metal scaffold particles.21. The metal paste of , wherein the population of large particles comprising iron has a lower concentration of iron than the population of small particles comprising iron.3. The metal paste of claim 1 , wherein the population of small particles comprises iron at a concentration of about 90% to 100% by weight.4. The metal paste of claim 1 , wherein the infiltrant particles comprise nickel at a concentration of 95% by weight or more.5. The metal paste of claim 1 , wherein the infiltrant particles have a D50 particle ...

SHAPE MEMORY ALLOY COATING USING ADDITIVE MANUFACTURING

A gear pump can include at least one gear having a plurality of gear teeth. At least the plurality of gear teeth can be additively manufactured and can include a substrate and a pitting resistant outer coating additively manufactured on the substrate and configured to prevent pitting due to cavitation. The substrate can include a substrate material and the pitting resistant outer coating includes a pitting resistant material different than the substrate material. The pitting resistant outer coating defines an outer surface layer of the gear teeth. 1. A gear pump , comprising: a substrate; and', 'a pitting resistant outer coating additively manufactured on the substrate and configured to prevent pitting due to cavitation,', 'wherein the substrate includes a substrate material and the pitting resistant outer coating includes a pitting resistant material different than the substrate material, wherein the pitting resistant outer coating defines an outer surface layer of the gear teeth., 'at least one gear having a plurality of gear teeth, at least the plurality of gear teeth being additively manufactured and comprising2. The gear pump of claim 1 , wherein the pitting resistant outer coating further comprises a mixture section that includes a composition having a mixture of the substrate material and the pitting resistant material additively manufactured together.3. The gear pump of claim 2 , wherein the mixture section is a gradient.4. The gear pump of claim 3 , wherein the gradient includes an increasing concentration of the pitting resistant material toward the outer surface layer from the substrate.5. The gear pump of claim 4 , wherein at least the outer surface layer defined by the pitting resistant outer coating only includes pitting resistant material.6. The gear pump of claim 5 , wherein the outer surface layer is about 20 microns thick or more.7. The gear pump of claim 6 , wherein the gradient is about 50 microns thick or more.8. The gear pump of claim 1 , ...

REDUCING STRESSES IN METAL LAYERS

A system including: a polymer substrate with a thermal conductivity of less than 0.5 W/(m-k); a spreader to form a layer of metal particulate on the polymer substrate; a mask applicator to apply a mask to a portion of the layer of metal particulate; and a pulsed irradiation light source to fuse a portion of the layer of metal particulate not covered by the mask. 1. A system comprising:a polymer substrate with a thermal conductivity of less than 0.5 W/(m-k);a spreader to form a layer of metal particulate on the polymer substrate;a mask applicator to apply a mask to a portion of the layer of metal particulate; anda pulsed irradiation light source to fuse a portion of the layer of metal particulate not covered by the mask.2. The system of claim 1 , wherein the polymer substrate has a thermal conductivity of less than 0.1 W/(m-K).3. The system of claim 1 , wherein the polymer substrate has a thermal conductivity of less than 0.07 W/(m-K).4. The system of claim 1 , wherein the polymer substrate has a thermal conductivity of less than 0.05 W/(m-K).5. The system of claim 1 , wherein the polymer substrate has a thermal conductivity lower than a thermal conductivity of the metal particulate layer.6. The system of claim 1 , wherein the mask applicator is an ink jet.7. The system of claim 1 , wherein the polymer substrate is a composite.8. A method of forming a metal object claim 1 , the method comprising:forming a layer of metal particles on a polymer substrate, wherein the polymer substrate has a lower thermal conductivity than the layer of metal particles:masking a portion of the layer of metal particles; andmelting an unmasked portion of the layer of metal particles using a pulse radiation light source.9. The method of claim 8 , further comprising: repeating forming claim 8 , masking claim 8 , and melting to build up a multiple layer solid metal object.10. The method of claim 8 , wherein masking a portion of the layer of metal particles is performed with a printhead.11. ...

GRADIENT SINTERED METAL PREFORM

A method of forming a metal component with two and three dimensional internal functionally graded alloy composition gradients includes forming the component by a powder based layer-by-layer additive manufacturing process. The areal composition distribution of each powder layer is determined by simultaneously depositing different powders and powder mixtures through a mixing valve attached to a single nozzle during powder deposition. The layers are then sintered with a directed energy source to form a forging preform. The preform is then forged to form a component. 1. A method of forming a metal component with two and three dimensional internal alloy compositional gradients comprises:forming the component by a powder-based layer-by-layer additive manufacturing process;controlling the areal composition of each powder layer by depositing different powders to different areas through a single powder deposition nozzle during powder deposition; andsintering the layer with a directed energy source to form the component.2. The method of claim 1 , wherein the directed energy source is a laser.3. The method of claim 1 , wherein the powder deposition nozzle is positioned by a computer controlled robotic support.4. The method of claim 1 , wherein the different powders are selected with the use of a mixing valve attached to two or more powder sources.5. The method of claim 4 , wherein the mixing valve is controlled by manual or electronic means.6. The method of claim 5 , wherein depositing different powders comprises simultaneously depositing two or more different powder materials.7. The method of wherein the two-dimensional composition gradients are radial composition gradients.8. The method of claim 1 , wherein the metal is a nickel based claim 1 , iron based claim 1 , cobalt based superalloy or mixtures thereof.9. The method of claim 1 , wherein the component is a forging preform.10. The method of claim 9 , and further comprising forging the preform into a turbine disk.11. The ...

Shell and Core Additive Manufacture

A process for manufacturing a part includes forming a shell by an additive manufacturing process, the shell having an interior surface that defines a cavity therein, filling the cavity with a liquid material, applying a heat transfer fluid to the shell during the filling the cavity with the liquid material, and solidifying the liquid material to form a solid core within the shell. 1. A part manufactured by a process , the process comprising:forming a metallic shell by additive manufacturing, the metallic shell having an interior surface that defines a cavity therein;filling the cavity with a molten metallic material to form a metallic core within the metallic shell; andeffecting a metallurgical bond between the metallic core and the metallic shell, such that the metallic shell composes at least a portion of an external surface of the part.2. The part of claim 1 , wherein the process further comprises solidifying the molten metallic material within the metallic shell claim 1 , and the process does not include separating substantially all of the metallic shell from the metallic core after the solidifying the molten metallic material.3. The part of claim 1 , wherein the process further comprises filling pores within a wall of the metallic shell with the molten metallic material in addition to the filling the cavity with the molten metallic material.4. The part of claim 1 , wherein the interior surface of the metallic shell is substantially impermeable to the molten metallic material.5. The part of claim 2 , wherein a material of the metallic shell is selected from the group consisting of stainless steel claim 2 , TiA16V4 claim 2 , maraging steel claim 2 , and carbide-containing alloys.6. The part of claim 1 , wherein the metallic shell further comprises a support structure disposed within the cavity.7. The part of claim 1 , wherein a material of the metallic core is selected from the group consisting of tin alloys claim 1 , bismuth alloys claim 1 , tin and bismuth ...

Systems and methods for repairing fluid handling equipment

A method includes removing a worn portion from a component of a rotary isobaric pressure exchanger (IPX). The rotary IPX is configured to exchange pressures between a first fluid and a second fluid. The method also includes repairing the component after the worn portion is removed from the component.

MANUFACTURING METHOD OF MULTILAYER SHELL-CORE COMPOSITE STRUCTURAL COMPONENT

A manufacturing method of a multilayer shell-core composite structural component comprises the following procedures: (1) respectively preparing feeding material for injection forming of a core layer, a buffer layer and a shell layer, wherein the powders of feeding material of the core layer and the shell layer are selected from one or more of metallic powder, ceramic powder or toughened ceramic powder, and are different from each other, and the powder of feeding material of the buffer layer is gradient composite material powder; (2) layer by layer producing the blank of multilayer shell-core composite structural component by powder injection molding; (3) degreasing the blank; and (4) sintering the blank to obtain the multilayer shell-core composite structural component. The multilayer shell-core composite structural component has the advantages of high surface hardness, abrasion resistance, uniform thickness of the shell layer, stable and persistent performance. 1. A method for manufacturing a ball valve body having a multilayer shell-core composite structure , comprising:preparing feedstocks of a shell layer, at least one transition layer and a liner layer respectively, each of the feedstocks being formed by mixing a main powder of one of the three layers, a binder and an additive comprising a surface active agent and a plasticizer, wherein the main powder of the at least one transition layer comprises at least one mixed powder formed by mixing the main powder of the shell layer with the main powder of the liner layer at a ratio;performing a powder injection molding with the feedstocks, to obtain a green body of the ball valve body comprising the shell layer, the at least one transition layer and the liner layer;performing debinding on the green body of the ball valve body; andsintering the green body of the ball valve body after being debound, to obtain the ball valve body;wherein the main powder of the liner layer is made of a powdered toughened ceramic material, ...

METHOD FOR PRODUCING A MACHINING SEGMENT FOR THE DRY MACHINING OF CONCRETE MATERIALS

A method for producing a machining segment for a machining tool, where the machining segment is connectable to a basic body of the machining tool by an underside of the machining segment, includes producing a green body by placing first hard material particles in depressions of a first press punch and applying a first matrix material to the first hard material particles. The green body is processed by hot pressing under temperature and pressure between the first press punch, which forms an upper side of the machining segment, and a second press punch, which forms the underside, to form the machining segment, where the upper side is opposite from the underside. 17.-. (canceled)8. A method for producing a machining segment for a machining tool , wherein the machining segment is connectable to a basic body of the machining tool by an underside of the machining segment , comprising the steps of:producing a green body by placing first hard material particles in depressions of a first press punch and applying a first matrix material to the first hard material particles; andprocessing the green body by hot pressing under temperature and pressure between the first press punch, which forms an upper side of the machining segment, and a second press punch, which forms the underside, to form the machining segment, wherein the upper side is opposite from the underside.9. The method as claimed in further comprising the step of applying a protective layer of the first matrix material into the depressions of the first press punch prior to the placing of the first hard material particles.10. The method as claimed in further comprising the step of applying a protective layer of a second matrix material into the depressions of the first press punch prior to the placing of the first hard material particles claim 8 , wherein the second matrix material is different from the first matrix material.11. The method as claimed in further comprising the step of encasing the first hard material ...

Method for Producing a Machining Segment for the Dry Machining of Concrete Materials

A method for producing a machining segment for a machining tool includes producing a green body by placing first hard material particles in respective depressions of a first press punch and applying a first matrix material to the placed first hard material particles. The green body is compacted by pressure between the first press punch, which forms an upper side of the machining segment, and a second press punch, which forms an underside of the machining segment, to form a compact body. The compact body is processed by temperature or by infiltration to produce the machining segment. 17.-. (canceled)8. A method for producing a machining segment for a machining tool , wherein the machining segment is connectable to a basic body of the machining tool by an underside of the machining segment , comprising the steps of:producing a green body by placing first hard material particles in respective depressions of a first press punch and applying a first matrix material to the placed first hard material particles;compacting the green body by pressure between the first press punch, which forms an upper side of the machining segment, wherein the upper side is opposite from the underside, and a second press punch, which forms the underside, to form a compact body; andprocessing the compact body by temperature or by infiltration to produce the machining segment.9. The method as claimed in further comprising the step of applying a layer of the first matrix material into the depressions of the first press punch prior to the placing of the first hard material particles in the depressions.10. The method as claimed in further comprising the step of applying a layer of a second matrix material into the depressions of the first press punch prior to the placing of the first hard material particles in the depressions claim 8 , wherein the second matrix material is different from the first matrix material.11. The method as claimed in further comprising the step of encasing the first hard ...

Method for Producing a Machining Segment for the Dry Machining of Concrete Materials

A method for producing a machining segment for a machining tool, where the machining segment is connectable to a basic body of the machining tool by an underside of the machining segment, includes producing a green body by placing first hard material particles in a first matrix material in a defined particle pattern. The green body is compacted by pressure between a first press punch, which forms the underside, and a second press punch, which forms an upper side of the machining segment, to form a compact body. The compact body is processed by temperature or by infiltration to produce the machining segment. The second press punch has depressions in a pressing surface where an arrangement of the depressions corresponds to the defined particle pattern of the first hard material particles. 17.-. (canceled)8. A method for producing a machining segment for a machining tool , wherein the machining segment is connectable to a basic body of the machining tool by an underside of the machining segment , comprising the steps of:producing a green body by placing first hard material particles in a first matrix material in a defined particle pattern;compacting the green body by pressure between a first press punch, which forms the underside, and a second press punch, which forms an upper side of the machining segment, to form a compact body, wherein the upper side is opposite from the underside and wherein the second press punch has depressions in a pressing surface and wherein an arrangement of the depressions corresponds to the defined particle pattern of the first hard material particles; andprocessing the compact body by temperature or by infiltration to produce the machining segment.9. The method as claimed in further comprising the step of applying an outer layer of the first matrix material to the green body after the placing of the first hard material particles.10. The method as claimed in further comprising the step of applying an outer layer of a second matrix material ...

METHODS FOR FABRICATING GRADIENT ALLOY ARTICLES WITH MULTI-FUNCTIONAL PROPERTIES

Systems and methods for fabricating multi-functional articles comprised of additively formed gradient materials are provided. The fabrication of multi-functional articles using the additive deposition of gradient alloys represents a paradigm shift from the traditional way that metal alloys and metal/metal alloy parts are fabricated. Since a gradient alloy that transitions from one metal to a different metal cannot be fabricated through any conventional metallurgy techniques, the technique presents many applications. Moreover, the embodiments described identify a broad range of properties and applications. 1. A method of fabricating a multi-functional multilayer article comprising:determining a shape for the article and defining at least two spatially separated regions on said article, said two regions to be formed of at least two distinct materials being joined by at least one compositional gradient transition region;mapping a compositional gradient pathway onto said article between said at least two regions such that the at least one compositional gradient transition region substantially excludes any undesirable compositional phases; andforming the article, wherein at least the at least one compositional gradient transition region comprises a plurality of distinct gradient layers formed by incrementally adjusting the compositional ratio between the at least two distinct materials.2. The method according to claim 1 , wherein the incremental adjustment between the at least two distinct materials comprises compositional increments between 0.1 and 50%.3. The method according to claim 1 , wherein the at least one gradient transition region comprises a direct compositional transition from one distinct material to another.4. The method according to claim 1 , wherein the at least one gradient transition region comprises a multi-stage gradient wherein the gradient region includes both incremental compositional steps and direct stepwise compositional transitions.5. The ...

Structures with Internal Microstructures to Provide Multifunctional Capabilities

A structural spacecraft component comprising internal microstructure; wherein said microstructure comprises a plurality of parallel layers and a plurality of spacers that connect adjacent parallel layers; wherein said structural spacecraft component is a product of an additive manufacturing process. 1. A structural spacecraft component comprising internal microstructure;wherein said microstructure comprises a plurality of parallel sheets and a plurality of spacers that connect adjacent parallel sheets; andwherein said structural spacecraft component is a product of an additive manufacturing process.2. A structural spacecraft component as in claim 1 , wherein said additive manufacturing process comprises 3D printing.3. A structural spacecraft component as in claim 1 , wherein said additive manufacturing process comprises fused filament fabrication.4. A structural spacecraft component as in claim 1 , wherein said additive manufacturing process comprises selective laser sintering.5. A structural spacecraft component as in claim 1 , wherein said spacecraft component comprises a plurality of materials such that material properties vary within said spacecraft component's structure.6. A structural spacecraft component as in claim 5 , wherein said plurality of materials comprises one or more of polymers claim 5 , high strength fibers claim 5 , conductors claim 5 , and high atomic weight metals.7. A structural spacecraft component as in claim 1 , wherein said spacecraft component comprises structural multilayer insulation.8. A structural spacecraft component as in claim 7 , wherein said parallel sheets comprise polymer;and wherein said plurality of spacers comprise polymer.9. A structural spacecraft component as in claim 7 , further comprising an outer layer of metal plating applied to the surfaces of said polymer sheets and polymer spacers.10. A structural spacecraft component as in claim 1 , wherein said spacecraft comprises versatile structural radiation shielding.11. A ...

Method for Manufacturing a Contact Component, and Contact Component, Vacuum Interrupter and a Switchgear

Various embodiments include a method for manufacturing a contact component for an electrical switch with a contact surface for closing in electrical contact comprising manufacturing the contact component at least partially using a powder. At least two powder types are used to create different material compositions in the contact component. Manufacturing the contact component include using an additive fabrication process based on a powder bed. The contact component includes a sequence of layers. At least two of the layers include different powder types. 1. A method for manufacturing a contact component for an electrical switch with a contact surface for closing in electrical contact , the method comprising:manufacturing the contact component is at least partially using a powder;wherein at least two powder types are used to create different material compositions in the contact component;wherein manufacturing the contact component include using an additive fabrication process based on a powder bed;the contact component includes a sequence of layers; andat least two of the layers include different powder types.2. The method as claimed in claim 1 , further comprising combining powders of different powder types by applying the powders with a plurality of dosing devices in at least one of the layers of the powder bed.3. The method as claimed in claim 2 , wherein a first one of the dosing devices comprises a sprinkling device guided at a distance above the surface of the powder bed.4. The method as claimed in claim 3 , further comprising claim 3 , after dosing by sprinkling claim 3 , smoothing a surface of the powder bed with a further dosing device including a wiper or a roller.5. The method as claimed in claim 3 , further comprising claim 3 , after dosing the first powder type claim 3 , dosing a second powder of a second powder type is dosed by a second dosing device.6. The method as claimed in claim 1 , wherein the powder is dosed only in a partial area of the powder bed ...

Functionally Graded Metal-Metal Composite Structures

Methods and devices are disclosed for creating a multiple alloy composite structure by forming a three-dimensional arrangement of a first alloy composition in which the three-dimensional arrangement has a substantially open and continuous porosity. The three-dimensional arrangement of the first alloy composition is infused with at least a second alloy composition, where the second alloy composition comprises a shape memory alloy. The three-dimensional arrangement is consolidated into a fully dense solid structure, and the original shape of the second alloy composition is set for reversible transformation. Strain is applied to the fully dense solid structure, which is treated with heat so that the shape memory alloy composition becomes memory activated to recover the original shape. An interwoven composite of the first alloy composition and the memory-activated second alloy composition is thereby formed in the multiple alloy composite structure. 1. A method of creating a multiple alloy composite structure , comprising:forming a three-dimensional arrangement of a first alloy composition, wherein the three-dimensional arrangement has a substantially open and continuous porosity;infusing the three-dimensional arrangement of the first alloy composition with at least a second alloy composition, wherein the second alloy composition comprises a shape memory alloy;consolidating the three-dimensional arrangement into a fully dense solid structure, wherein an original shape of the second alloy composition is set for reversible transformation.2. The method of claim 1 , further comprising:mechanically applying strain to the fully dense solid structure; andtreating the fully dense solid structure with heat such that the shape memory alloy composition becomes memory activated to recover the original shape,wherein an interwoven composite of the first alloy composition and the memory-activated second alloy composition is formed.3. The method of claim 2 , wherein forming the three- ...

METHOD OF MAKING AND USING A FUNCTIONALLY GRADIENT COMPOSITE TOOL

A method of making a composite downhole article is disclosed. The method include forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; and disposing at least one outer member on the core member, the outer member comprising a second material that is removable in the wellbore fluid at a second removal rate, wherein the removable core member has a composition gradient or a density gradient, or a combination thereof, and wherein the first removal rate is substantially greater than the second removal rate. A method of using a composite downhole article is also disclosed. The method includes forming a composite downhole article as described above; using the article to perform a first wellbore operation; exposing the article to the wellbore fluid; and selectively removing the second removable member. 1. A method of making a composite downhole article , comprising:forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; anddisposing at least one outer member on the core member, the outer member comprising a second material that is removable in the wellbore fluid at a second removal rate, wherein the removable core member has a composition gradient or a density gradient, or a combination thereof, and wherein the first removal rate is substantially greater than the second removal rate.2. The method of claim 1 , wherein at least one of forming the removable core member and disposing the outer member comprises forming an unsintered powder compact.3. The method of claim 2 , wherein forming the unsintered powder compact comprises compacting a powder comprising a plurality of metallic powder particles claim 2 , each powder particle comprising: a particle core claim 2 , the particle core comprises a core material comprising Mg claim 2 , Al claim 2 , Zn claim 2 , Fe claim 2 , or Mn claim 2 , or a combination ...

MANUFACTURING METHOD OF MULTILAYER SHELL-CORE COMPOSITE STRUCTURAL COMPONENT

A manufacturing method of a multilayer shell-core composite structural component comprises the following procedures: (1) respectively preparing feeding material for injection forming of a core layer, a buffer layer and a shell layer, wherein the powders of feeding material of the core layer and the shell layer are selected from one or more of metallic powder, ceramic powder or toughening ceramic powder, and are different from each other, and the powder of feeding material of the buffer layer is gradient composite material powder; (2) layer by layer producing the blank of multilayer shell-core composite structural component by powder injection molding; (3) degreasing the blank; (4) sintering the blank to obtain the multilayer shell-core composite structural component. The multilayer shell-core composite structural component has the advantages of high surface hardness, abrasion resistance, uniform thickness of the shell layer, stable and persistent performance. 1. A method for manufacturing a hip joint prosthesis , the prosthesis comprising a femoral ball head and an acetabulum , either of which comprises a multilayer shell-core composite structure , and a method for manufacturing the multilayer shell-core composite structure comprises:preparing feedstocks of a shell layer, a transition layer and a core layer for powder injection molding, respectively, each of the feedstocks being formed by mixing a main powder of one of the three layers, a binder and an additive comprising a surface active agent and a plasticizer, wherein the main powder of the transition layer comprises at least one mixed powder formed by mixing the main powder of the shell layer with the main powder of the core layer at a ratio;performing a powder injection molding with the feedstocks, to obtain a green body of the prosthesis comprising the shell layer, the transition layer and the core layer;performing debinding on the green body of the prosthesis; andsintering the green body of the prosthesis ...

Manufacturing method of femoral condyle prosthesis

A manufacturing method of a femoral condyle prosthesis having a multilayer shell-core composite structure comprises the following procedures: (1) respectively preparing feeding material for injection forming of a core layer, a buffer layer and a shell layer, wherein the powders of feeding material of the core layer and the shell layer are selected from one or more of metallic powder, ceramic powder or toughening ceramic powder, and are different from each other, and the powder of feeding material of the buffer layer is gradient composite material powder; (2) layer by layer producing the blank of multilayer shell-core composite structural component by powder injection molding; (3) degreasing the blank; (4) sintering the blank to obtain the multilayer shell-core composite structural component. The femoral condyle prosthesis has the advantages of high surface hardness, abrasion resistance, uniform thickness of the shell layer, stable and persistent performance.

MANUFACTURING METHOD OF MULTILAYER SHELL-CORE COMPOSITE STRUCTURAL COMPONENT

A manufacturing method of a multilayer shell-core composite structural component comprises the following procedures: (1) respectively preparing feeding material for injection forming of a core layer, a buffer layer and a shell layer, wherein the powders of feeding material of the core layer and the shell layer are selected from one or more of metallic powder, ceramic powder or toughening ceramic powder, and are different from each other, and the powder of feeding material of the buffer layer is gradient composite material powder; (2) layer by layer producing the blank of multilayer shell-core composite structural component by powder injection molding; (3) degreasing the blank; (4) sintering the blank to obtain the multilayer shell-core composite structural component. The multilayer shell-core composite structural component has the advantages of high surface hardness, abrasion resistance, uniform thickness of the shell layer, stable and persistent performance. 1. A method for manufacturing a multilayer shell-core composite structural component , comprising:preparing feedstocks of a shell layer, a transition layer and a core layer for powder injection molding, respectively, each of the feedstocks being formed by mixing a main powder of one of the three layers, a binder and an additive comprising a surface active agent and a plasticizer, wherein the main powder of the transition layer comprises at least one mixed powder formed by mixing the main powder of the shell layer with the main powder of the core layer at a ratio;performing a powder injection molding with the feedstocks, to obtain a green body of the multilayer shell-core composite structural component comprising the shell layer, the transition layer and the core layer;performing debinding on the green body of the multilayer shell-core composite structural component; andsintering the green body of the multilayer shell-core composite structural component after being debound, to obtain the multilayer shell-core ...

INDEPENDENT FABRICATION OF OBJECTS AND OBJECT SUPPORTS

Additive fabrication systems generally use support structures to expand the available range of features and geometries in fabricated objects. For example, when a vertical shelf or cantilever extends from an object, a supplemental support structure may be required to provide a surface for fabrication thereon. This process may become more difficult when, e.g., a part will be subjected to downstream processing steps such as debinding or sintering that impose different design rules. To address these challenges and provide a greater range of flexibility and processing speed, it may be useful in certain circumstances to independently fabricate the object and support structures, and then assemble these structures into a composite item for debinding and sintering. This approach also advantageously facilitates various techniques for spraying, dipping, or otherwise applying a release layer between the support structure and the part so that these separate items do not become fused together during sintering. 1. A method comprising:fabricating a support structure for an object from a first material;fabricating the object from a second material, the object including a surface positionable adjacent to and supportable by the support structure, wherein the second material includes powdered material for forming a final part and a binder system including one or more binders, wherein the one or more binders resist deformation of a net shape of the object during processing of the object into the final part;applying an interface layer to a least one of the support structure and object at a location corresponding to the surface of the object positionable adjacent to and supportable by the support structure, wherein the interface layer resists bonding of the support structure to the object during sintering; andassembling the support structure and the object together with the surface positioned adjacent to and supported by the support structure, thereby providing an assembled workpiece.2. ...

MICRO-SELECTIVE SINTERING LASER SYSTEMS AND METHODS THEREOF

A microscale selective laser sintering (μ-SLS) that improves the minimum feature-size resolution of metal additively manufactured parts by up to two orders of magnitude, while still maintaining the throughput of traditional additive manufacturing processes. The microscale selective laser sintering includes, in some embodiments, ultra-fast lasers, a micro-mirror based optical system, nanoscale powders, and a precision spreader mechanism. The micro-SLS system is capable of achieving build rates of at least 1 cm/hr while achieving a feature-size resolution of approximately 1 μm. In some embodiments, the exemplified systems and methods facilitate a direct write, microscale selective laser sintering μ-SLS system that is configured to write 3D metal structures having features sizes down to approximately 1 μm scale on rigid or flexible substrates. The exemplified systems and methods may operate on a variety of material including, for example, polymers, dielectrics, semiconductors, and metals. 1. A system for additively producing a three-dimensional workpiece , the system comprising:an electromagnetic radiation source configured to coherently and intermittently emit an electromagnetic radiation beam; anda lens assembly having a plurality of micro-mirrors, collectively, forming a matrixed mirror array, each micro-mirror being configured to selectively direct the emitted electromagnetic radiation beam to a focus point on a sintering plane comprising a layer of particles to form one or a plurality of sintered layers, wherein each sintered layer is successively produced, in a layer-by-layer manner, to form the three-dimensional workpiece.2. The system of claim 1 , wherein the plurality of micro-mirrors direct the plurality of emitted electromagnetic radiation beams onto an area spanning a maximum cross-sectional profile of the three-dimensional workpiece.3. The system of claim 1 , comprising:a slot die coater, the slot die coater being configured to dispense a solvent having ...

METHOD FOR FORMING A COMPOSITE MATERIAL, AND HEAT SINK

A method for forming a carbon-metal composite material for a heat sink, comprising the following steps: applying at least one layer comprising carbon particles and at least one layer comprising metal particles on top of one another; and fusing of the layers by irradiating the layers with laser radiation to form the carbon-metal composite material. The invention also relates to a heat sink having a shaped body that comprises a plurality of layers, each layer containing carbon particles in a metal matrix. 1. Method for forming a carbon-metal composite material for a heat sink , comprising the following steps:applying at least one layer comprising carbon particles and at least one layer comprising metal particles on top of one another; andfusing of the layers by irradiating the layers with laser radiation to form the carbon-metal composite material.2. Method according to claim 1 , in which claim 1 , in order to form a shaped body from the carbon-metal composite material claim 1 , the applying and the fusing of layers is repeated a number of times.3. Method according to claim 2 , in which claim 2 , in order to form a final layer for the shaped body claim 2 , a layer comprising metal particles is applied and fused by irradiation with laser radiation.4. Method according to claim 2 , in which at least two of the layers have carbon particles with different granulation.5. Method according to claim 1 , in which at least two layers of the carbon-metal composite material are produced having a different volume ratio of carbon particles to a metal matrix formed from metal particles.6. Method according to claim 1 , in which the metal particles are selected from the group comprising:copper, silver, gold, aluminium, tin and titanium.7. Method according to claim 1 , in which the carbon particles are selected from the group comprising:diamond, graphite and carbide.8. Method according to claim 1 , further comprising the following steps:applying at least one layer of metal particles to ...

PRINTER WITH DUAL EXTRUDERS FOR FABRICATING REMOVABLE SUPPORTS

Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, a printer is configured to further fabricate an interface layer between the object and the support structure in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. 1. A printer for three-dimensional fabrication , the printer comprising:a build plate;a first extruder coupled to a first source of a build material for fabricating an object, the build material including a powdered material for forming the object and a binder system including one or more binders that resist deformation of a net shape of the build material extruded from the first extruder during processing of the net shape into a final part;a second extruder coupled to a second source of an interface material for fabricating an interface layer, wherein the interface material resists bonding of the build material to adjacent surfaces during sintering, and wherein the interface material reduces to a powder and resists bonding of the build material to adjacent surfaces during sintering of the build material;a robotic system operable to move the first extruder and the second extruder relative to the build plate; anda processor configured by computer executable code to move the robotic system along a build path relative to the build plate while extruding from at least one of the first extruder and the second extruder to: fabricate a first object from the build material, apply an interface layer to a first surface of the first object, and fabricate a second surface of a second object from the build material at a location adjacent to the interface layer and opposing the first surface of the first object, wherein the second object is structurally independent from and mechanically related to the first object.2. The printer of ...

ADDITIVE MANUFACTURING OF FUNCTIONALLY GRADIENT DEGRADABLE TOOLS

A method of manufacturing an article comprises depositing a metallic powder on a substrate or a worktable; fusing the metallic powder according to a preset pattern; and adjusting a composition of the metallic powder or a condition to fuse the metallic powder or a combination thereof to additively form an article such that the article has a first portion and a second portion, wherein the first portion has one or more of the following properties different than those of the second portion: corrosion rate; tensile strength; compressive strength; modulus; or hardness. 1. A method of manufacturing an article , the method comprising:depositing a metallic powder on a substrate or a worktable;fusing the metallic powder according to a preset pattern; andadjusting a composition of the metallic powder or a condition to fuse the metallic powder or a combination thereof to additively form an article such that the article has a first portion and a second portion, wherein the first portion has one or more of the following properties different than those of the second portion: corrosion rate; tensile strength; compressive strength; modulus; or hardness.2. The method of claim 1 , wherein the depositing and the fusing are carried out as part of a selective laser sintering process claim 1 , a laser melting process claim 1 , or a direct metal deposition process.3. The method of claim 1 , wherein fusing the metallic powder comprises applying an energy beam from an energy source to the metallic powder.4. The method of claim 1 , wherein the metallic powder is at least partially fused before deposited on the substrate or the worktable.5. The method of claim 1 , wherein the metallic powder is fused after deposited on the substrate or the worktable.6. The method of claim 1 , wherein the metallic powder comprises an uncoated metallic matrix particle and a second particle;the metallic matrix particle comprising one or more of the following: a magnesium-based alloy; an aluminum-based alloy; or a ...

Apparatus for Producing a Blank, Also a Method for This Purpose and a Blank

The present invention relates to an apparatus, preferably a press, comprising a cavity which is to be filled and at least a first material feed, for a first material, and a second material feed, for a second material, wherein the first and the second material feeds are arranged separately from one another, having a feeding apparatus for feeding the first and the second materials into the cavity which is to be filled, wherein the feeding apparatus has a mouth-opening cross section with at least a first region of the mouth-opening cross section for the first material, and with a second, separate region of the mouth-opening cross section for the second material, for filling the cavity preferably in parallel, and at separate locations. A method and also a blank are proposed in addition. 1. A press device having a device for filling of a mold of the press device with at least two different materials , comprisinga cavity to be filled with the at least two materials anda filling unit for discharging the at least two materials for the purpose of introducing these materials into different regions of the cavity,wherein the filling unit has at least two separate chambers or at least two chamber regions of a common chamber for simultaneous feeding of the at least two materials, directly adjoining one another or in separate locations, for introduction thereof into the cavity as at least partly distinguishable layers, andcomprising a relative rotary motion between the filling unit and the cavity, preferably about a common axis, preferably about a common center axis, during a filling operation.2. The press device as claimed in claim 1 , characterized in that wherein the filling unit and the cavity and/or a base of the cavity are movable in a translational manner relative to one another during the filling operation claim 1 , and are preferably movable away from one another along the center axis.3. The press device as claimed in claim 1 , wherein a first of the chambers extends at ...

Composite system

A multiphase composite system is made by binding hard particles, such as TiC particles, of various sizes with a mixture of titanium powder and aluminum, nickel, and titanium in a master alloy or as elemental materials to produce a composite system that has advantageous energy absorbing characteristics. The multiple phases of this composite system include an aggregate phase of hard particles bound with a matrix phase. The matrix phase has at least two phases with varying amounts of aluminum, nickel, and titanium. The matrix phase forms a bond with the hard particles and has varying degrees of hard and ductile phases. The composite system may be used alone or bonded to other materials such as bodies of titanium or ceramic in the manufacture of ballistic armor tiles.

COMPOUND HIGH PRESSURE, HIGH TEMPERATURE TOOL

A tool for a high temperature, high pressure apparatus includes a working layer of a first hard metal composition of material and at least one supporting layer of a second hard metal composition of material attached to the working layer. The first hard metal composition has a mean linear intercept of less than about 0.4 μm of a binder phase. The working layer has a top and bottom surface. At least one supporting layer of a second hard metal composition of material is attached to the working layer. The at least one supporting layer includes an upper portion. An interface region is formed by the bottom surface of the working layer and the upper portion of the at least one supporting layer. The bottom surface and upper portion have a corresponding shape, wherein the bottom surface and upper portion are bonded to form the corresponding shape in the interface region. 1. A tool for a high temperature , high pressure apparatus , the tool comprising:a working layer of a first hard metal composition of material; andat least one supporting layer of a second hard metal composition of material attached to the working layer, wherein the first hard metal composition of the working layer has a mean linear intercept of less than about 0.4 μm of a binder phase.2. The tool of claim 1 , wherein the first and second hard metal composition of materials each is cemented carbide.3. The tool of claim 2 , wherein the cemented carbide is a tungsten carbide bonded with a cobalt alloy binder.4. The tool of claim 2 , wherein the cemented carbide is from the group of tungsten claim 2 , silicon claim 2 , chromium claim 2 , vanadium claim 2 , tantalum claim 2 , niobium claim 2 , titanium claim 2 , nickel claim 2 , cobalt claim 2 , iron or combinations thereof.5. The tool of claim 1 , wherein the first hard metal composition of material has a plastic deformation resistance to a pressure up to about 11 GPa.6. The tool of claim 1 , wherein the working layer has a top and bottom surface and the at ...

A seal for barrel shaped cylinder

A helical coiled seal for sealing a barrel-shaped cylinder piston-cylinder assembly, comprising: a piston-sealing C-shaped ring; a connecting C-shaped ring comprising an inward wing protruded inwardly from a section near a first end on an inner perimeter of the connecting C-shaped ring, and an outward wing protruded outwardly from a section near a second end on an outer perimeter of the connecting C-shaped ring; and a cylinder-sealing C-ring; wherein the piston-sealing C-ring is connected end-to-end to the first end of the connecting C-ring and cylinder-sealing C-ring is connected end-to-end to the second end of the connecting C-ring forming a three-ring helical structure having a contraction-dilation response time sufficiently short required for the up-down stroke speed of the cylinder piston-cylinder assembly.

Method of forming a thermal barrier coating system with engineered surface roughness

A method of manufacturing a substrate ( 16 ) with a ceramic thermal barrier coating ( 28, 32 ). The interface between layers of the coating contains an engineered surface roughness ( 12, 24 ) to enhance the mechanical integrity of the bond there between. The surface roughness is formed in a surface of a mold ( 10,20 ) and is infused by a subsequently cast layer of material ( 16, 28 ). The substrate may be partially sintered ( 76 ) prior to application of the coating layer(s) and the coated substrate and coating layer(s) may be co-sintered to form a fully coherent strain-free interlayer.

METHOD AND APPARATUS FOR FORMING LAYERS OF PARTICLES FOR USE IN ADDITIVE MANUFACTURING

A method and an apparatus for forming a particle layer are provided. The layering method includes injecting particles in an injection zone defined at a gas-liquid interface between a carrier liquid and an ambient gas, and controlling a flow of the carrier liquid along the gas-liquid interface to carry the particles downstream along a particle flow path from the injection zone to a layer formation zone. The method also includes accumulating the particles in the layer formation zone to gradually form the particle layer on the gas-liquid interface, and withdrawing the particle layer from the layer formation zone. The particle layer formed by the layering method and apparatus can be used to fabricate a three-dimensional object by additive manufacturing. 1. A method for forming a particle layer , the method comprising the steps of:injecting particles in an injection zone defined at a gas-liquid interface between a carrier liquid and an ambient gas;controlling a flow of the carrier liquid along the gas-liquid interface to carry the particles downstream along a particle flow path from the injection zone to a layer formation zone;accumulating the particles in the layer formation zone to gradually form the particle layer on the gas-liquid interface; andwithdrawing the particle layer from the layer formation zone.26-. (canceled)7. The method of claim 1 , wherein the injecting step comprises injecting the particles in the injection zone at a single injection point claim 1 , at a plurality of spaced-apart injection points in the injection zone claim 1 , or along an injection line.810-. (canceled)11. The method of claim 1 , wherein the controlling step comprises controlling the flow of the carrier liquid substantially without gravity flow.12. The method of claim 1 , wherein the controlling step comprises controlling a flow of an upper portion of the carrier liquid extending from the gas-liquid interface down to an operating depth below the gas-liquid interface.13. The method of ...

SYSTEM AND METHOD FOR ADDITIVE MANUFACTURING

A method for forming a component includes providing a first layer of a mixture of first and second powders. The method includes determining the frequency of an alternating magnetic field to induce eddy currents sufficient to bulk heat only one of the first and second powders. The alternating magnetic field is applied at the determined frequency to a portion of the first layer of the mixture using a flux concentrator. Exposure to the magnetic field changes the phase of at least a portion of the first powder to liquid. The liquid portion couples to at least some of the second powder and subsequently solidifies to provide a composite component. 2. The method of claim 1 , wherein two or more particles of the first powder combine to form a consolidated material after the two or more particles change to the liquid phase claim 1 , the consolidated material having a size de-coupling the magnetic field from the consolidated material.3. The method of claim 1 , wherein surface heating of each particle of the second powder occurs when 2δ for the respective particle of the second powder is less than a diameter of the respective particle of the second powder.4. The method of claim 1 , wherein determining the frequency of the alternating magnetic field is based on a dimension of the particles within the first powder.5. The method according to claim 4 , wherein the first powder has a first mean particle diameter and the second powder has a second mean particle diameter which is different from the first mean particle diameter.6. The method of claim 1 , wherein determining the frequency of the alternating magnetic field is based on a resistivity of particles with the first powder.7. The method according to claim 6 , wherein the first material has a first resistivity and the second material has a second resistivity different than the first resistivity.8. The method according to claim 1 , wherein the first powder includes particles from a first material and the second powder includes ...

Article and method for making an article

An article and a method for making shaped cooling holes in an article are provided. The method includes the steps of depositing a metal alloy powder to form an initial layer including at least one aperture, melting the metal alloy powder with a focused energy source to transform the powder layer to a sheet of metal alloy, sequentially depositing an additional layer of the metal alloy powder to form a layer including at least one aperture corresponding to the at least one aperture in the initial layer, melting the additional layer of the metal alloy powder with the focused energy source to increase the sheet thickness, and repeating the steps of sequentially depositing and melting the additional layers of metal alloy powder until a structure including at least one aperture having a predetermined profile is obtained. The structure is attached to a substrate to make the article.

DIRECT WRITING FOR ADDITIVE MANUFACTURING SYSTEMS

There are provided techniques for direct printing material into parts made by additive manufacturing, such as parts made by laser sintering. The direct printed material may be a metal, elastomer, ceramic, or any other material. Further, the direct printed material is typically different than the laser sintering material. Other aspects of the invention include using direct printed materials in the laser sintered parts to improve part strength, provide multi-materials, selectively provide electrical conductivity, and/or provide other desirable features to the parts. 1. A method of fabricating a three-dimensional object from digital data representing the object , the method comprising:forming a first cross-sectional layer of the object in a bed of particulate material, wherein the first cross-sectional layer is electrically insulating;forming a second cross-sectional layer of the object over portions of the first cross-sectional layer, wherein the second cross-sectional layer is electrically conductive; andforming a third cross-sectional layer of the object over portions of the second cross-sectional layer, wherein the third cross-sectional layer is electrically insulating.2. The method of claim 1 , wherein forming the first cross-sectional layer of the object comprises exposing the bed of particulate material to electromagnetic radiation for sintering and consolidating a plurality of particulates disposed in the bed of particulate material.3. The method of claim 1 , wherein forming the first cross-sectional layer of the object comprises applying a fluid binder material to the bed of particulate material for consolidating a plurality of particulates disposed in the bed of particulate material.4. The method of claim 1 , wherein the particulate material is formed from alumina claim 1 , an aluminosilicate claim 1 , an acrylic resin claim 1 , polyethylene claim 1 , polypropylene claim 1 , polyethylene oxide claim 1 , polypropylene oxide claim 1 , polyethyleneimine claim 1 ...

A MOUNTING MEDIUM FOR EMBEDDING A SAMPLE MATERIAL AND A METHOD OF MOUNTING A SAMPLE MATERIAL IN A MOUNTING MEDIUM

A method of embedding a sample material in a mounting medium with reduced cycle times and a mounting medium for embedding a sample material. 1251025. A granular mounting medium () for a sample material () CHARATERIZED IN that said granular mounting medium () includes a mixture of a granular resin and a granular metal filler and in that the weight ratio between said granular resin and said granular metal filler is 20-40% granular resin and 60-80% granular metal filler , alternatively , 28-32% granular resin and 68-72% granular metal filler , alternatively 30% granular resin and 70% granular metal filler.210. The granular mounting medium according to claim 1 , wherein said granular mounting medium is configured for at least partially embedding and fixating a sample material ().3. The granular mounting medium according to or claim 1 , wherein said granular resin is acryl.4. The granular mounting medium according to any one or more of the foregoing claims claim 1 , wherein said granular resin is epoxy or Bakelite.510. The granular mounting medium according to any one or more of the foregoing claims claim 1 , wherein said granular mounting medium is configured for fixating said sample material () by means of a sintering process.6. The granular mounting medium according to any one or more of the foregoing claims claim 1 , wherein at least 95% said granular metal filler particles has a particle size below 200 μm and maximum 5% of said granular metal filler particles has a particle size in excess of 200 μm.7. The granular mounting medium according to any one or more of the foregoing claims claim 1 , wherein said granular metal filler particles constitute filigree particles having a typical particle size which is less than the particle size of said granular resin.8. The granular mounting medium according to any one or more of the foregoing claims claim 1 , wherein said granular metal filler is aluminium.91025. A sample material () embedded in the granular mounting medium () ...

ADDITIVELY MANUFACTURED IMPELLER

An impeller including a blade section, a shroud section, and a hub is made of a monolithic structure. The impeller is made by loading a 3D image file into an additive manufacturing device, using it to generate 2D files which correspond to a plurality of cross-sectional layers of the impeller, and solidifying corresponding portions of pulverant material layers to create the impeller. 1. An impeller comprising:a blade section including a plurality of blades, wherein the blade section has a diameter and the blades extend radially from a hub; anda shroud section circumscribing the blade section, connected to the radially outermost portions of the plurality of blades, whereinthe blade section, the shroud section, and the hub comprise a monolithic structure of a material.2. The impeller of claim 1 , wherein the diameter of the shroud section is less than 20 cm.3. The impeller of claim 1 , wherein the monolithic structure extends less than 12 cm. axially.4. The impeller of claim 1 , wherein the material has a stable surface oxide.5. The impeller of claim 4 , wherein the material is a titanium-based alloy.6. The impeller of claim 1 , further comprising a shaft connected to the monolithic structure.7. The impeller of claim 6 , wherein the monolithic structure includes the shaft.8. A method of making an impeller claim 6 , the method comprising:loading a 3D image file into an additive manufacturing device;generating 2D files from the 3D image file which correspond to a plurality of cross-sectional layers of the impeller; andsolidifying a portion of a pulverant material layer corresponding to each of the plurality of cross-sectional layers in a layerwise fashion to create the impeller.9. The method of claim 8 , wherein the pulverant material layer comprises a material having a stable surface oxide.10. The method of claim 9 , wherein the material having a stable surface oxide is a titanium-based alloy.11. The method of claim 8 , wherein solidifying the pulverant material layer ...

THREE-DIMENSIONAL SHAPING APPARATUS

A three-dimensional shaping apparatus includes a stage, a first material supply unit that supplies a first material, a second material supply unit that supplies a second material having a thermal expansion coefficient larger than a thermal expansion coefficient of the first material, a laser irradiation unit, and a control unit that controls the laser irradiation unit by selecting a first laser irradiation mode and a second laser irradiation mode in which heat diffusion to a lower layer is smaller than in the first laser irradiation mode, wherein the control unit controls the laser irradiation unit by selecting the second laser irradiation mode when a second material shaped layer is formed on a first material shaped layer, and the second material shaped layer is irradiated with a laser from the laser irradiation unit.

THREE-DIMENSIONAL SHAPING APPARATUS

A three-dimensional shaping apparatus includes a stage, a first material supply unit that supplies a first material, a second material supply unit that supplies a second material, a laser irradiation unit, and a control unit that controls the laser irradiation unit separately between a first laser irradiation scan and a second laser irradiation scan, wherein when a first material region and a second material region are adjacently disposed in the shaped layer for one layer, the control unit irradiates the first material region with a laser in the first laser irradiation scan, and irradiates the second material region with a laser in the second laser irradiation scan.

Composite material and method for producing composite material

A composite material including a first porous metal body having a three-dimensional mesh-like skeleton, a second porous metal body having a three-dimensional mesh-like skeleton, and a bonding portion formed by entanglement of the skeleton of the first porous metal body and the skeleton of the second porous metal body. The porosity of the first porous metal body may be different from the porosity of the second porous metal body.

Functionally Graded Metal-Metal Composite Structures

Methods and devices are disclosed for creating a multiple alloy composite structure by forming a three-dimensional arrangement of a first alloy composition in which the three-dimensional arrangement has a substantially open and continuous porosity. The three-dimensional arrangement of the first alloy composition is infused with at least a second alloy composition, where the second alloy composition comprises a shape memory alloy. The three-dimensional arrangement is consolidated into a fully dense solid structure, and the original shape of the second alloy composition is set for reversible transformation. Strain is applied to the fully dense solid structure, which is treated with heat so that the shape memory alloy composition becomes memory activated to recover the original shape. An interwoven composite of the first alloy composition and the memory-activated second alloy composition is thereby formed in the multiple alloy composite structure. 1. A layered bi-metallic composite material , comprising:a three-dimensional interior structure of an interwoven composite of a first alloy composition and a shape memory alloy composition; anda three-dimensional exterior structure surrounding the interior structure, wherein the exterior structure comprises solid walls of the first alloy composition,wherein the bi-metallic composite material has an overall net compressive residual stress field.2. The bi-metallic composite material of claim 1 , wherein the exterior structure is a box structure.3. The bi-metallic composite material of claim 2 , wherein the box structure is a five-sided box structure.4. The bi-metallic composite material of claim 3 , wherein the bi-metallic composite material is configured to be used in structural components in order to reduce propagation of surface cracks in the structural components.5. The bi-metallic composite material of claim 1 , wherein the first alloy composition comprises an open cell metallic cellular structure having a random design or ...

Method for Manufacturing Rare Earth Sintered Magnet

A rare earth sintered magnet is manufactured by preparing a R-T-X sintered body having a major phase of RTX composition wherein Ris a rare earth element(s) and essentially contains Pr and/or Nd, T is Fe, Co, Al, Ga, and/or Cu, and essentially contains Fe, and X is boron and/or carbon, forming an alloy powder containing 5≤R≤60, 5≤M≤70, and 20 Подробнее

Compound roll

A compound roll includes a sintered inner core of a first cemented carbide and at least one sintered outer sleeve of a second cemented carbide disposed around the inner core. The outer sleeve and inner core each have a joining surface, wherein when the inner core and outer sleeve are assembled each joining surface contact to form a bonding interface therebetween. When the assembled, sintered inner core and outer sleeve are heated to a predetermined temperature the sintered inner core and outer sleeve are fused together at the bonding interface to form the unitary compound roll. To reduce the overall cost of the compound roll, a lower cost cemented carbide, or a cemented carbide with a lower density can be used for the inner core and fused to an outer sleeve of a virgin cemented carbide, thereby reducing the powder cost and/or reducing the overall mass of the compound roll.

Forged Composite Inner Race for a CVJ

A forged composite inner race for a constant velocity joint is forged from a composite preform compact including a first powder metal material and a second powder metal material. The forged composite inner race includes a plurality of ball tracks formed on an outer section of the forged composite inner race with corresponding lands between adjacent ball tracks and an axially-extending splined opening formed in an inner section of the forged composite inner race. The outer section comprises the first powder metal material in a higher concentration than the second powder metal material and the inner section comprises the second powder metal material in a higher concentration than the first powder metal material. 1. A forged composite inner race for a constant velocity joint forged from a composite preform compact including a first powder metal material and a second powder metal material , the forged composite inner race comprising:a plurality of ball tracks formed on an outer section of the forged composite inner race with corresponding lands between adjacent ball tracks, the outer section comprising the first powder metal material in a higher concentration than the second powder metal material; andan axially-extending splined opening formed in an inner section of the forged composite inner race, the inner section comprising the second powder metal material in a higher concentration than the first powder metal material.2. The forged composite inner race of claim 1 , wherein the first powder metal material of the outer section has greater hardness than the second powder metal material of the inner section.3. The forged composite inner race of claim 1 , wherein the first powder metal material has a greater hardenability than the second powder metal material.4. The forged composite inner race of claim 1 , wherein the first powder metal material has a higher carbon content than the second powder metal material.5. The forged composite inner race of claim 1 , wherein the ...

Forged Composite Bevel Gear

A forged composite bevel gear is forged from a composite preform compact including a first powder metal material and a second powder metal material. The forged composite bevel gear includes a gear core formed in an inner section of the forged composite bevel gear with the gear core defining a rotational axis and a plurality of teeth formed on an outer section of the forged composite bevel gear and extending from the gear core. The plurality of teeth extend in the same general direction as the rotational axis of the gear core, but are also inclined with respect to the rotational axis of the gear core. The outer section comprises the first powder metal material in a higher concentration than the second powder metal material. 1. A forged composite bevel gear forged from a composite preform compact including a first powder metal material and a second powder metal material compacted to from the composite preform compact , the forged composite bevel gear comprising:a gear core formed in an inner section of the forged composite bevel gear, the gear core defining a rotational axis;a plurality of teeth formed on an outer section of the forged composite bevel gear and extending from the gear core, the plurality of teeth extending in the same general direction as the rotational axis of the gear core, but also angularly inclined with respect to the rotational axis of the gear core, the outer section comprising the first powder metal material in a higher concentration than the second powder metal material.2. The forged composite bevel gear of claim 1 , wherein the first powder metal material at least partially forms the plurality of teeth and the second powder metal material forms the gear core and partly forms a core of the plurality of teeth claim 1 , the first powder metal material and the second powder metal material being sintered and forged to form a continuous variable boundary profile between the first powder metal material and second powder metal material.3. The forged ...

Method for producing a machining segment for an abrasive machining tool

A method of producing a machining segment, in which a green body () is constructed from a machining zone (), wherein the machining zone () is produced from a first metallic powder material () and hard material particles (), the green body () is compacted under pressure with a compression pressure to result in a compact body and the compact body is sintered thermally at a sintering temperature to result in the finished machining segment, wherein the machining zone () is produced by layer-by-layer application of material layers of the first metallic powder material () and particle layers of the hard material particles (), wherein the hard material particles () in one particle layer are placed into the previously applied material layer of the first metallic powder material (). 120-. (canceled)21: A method of producing a machining segment , the method comprising:constructing a green body from a machining zone produced from a first metallic powder material and hard material particles;compacting the green body under pressure with a compression pressure to result in a compact body, with the compact body having essentially a final geometry of the machining segment; andthermally sintering the compact body at a sintering temperature to result in the finished machining segment,the machining zone being produced by layer-by-layer application of material layers of the first metallic powder material and particle layers of the hard material particles, where the hard material particles in one of the particle layers are placed into a previously applied material layer of the material layers.22: The method as recited in wherein a number of the material layers is N claim 21 , and a number of the particle layers is M claim 21 , N being not less than M.23: The method as recited in wherein the hard material particles of the one particle layer are placed into the previously applied material layer with a lateral distance of greater than 50 μm.24: The method as recited in wherein the placing ...

MIXED POWDER HIGH-DENSITY MOLDING METHOD, MIXED POWDER HIGH-DENSITY MOLDING SYSTEM, AND HIGH-DENSITY THREE-LAYER GREEN COMPACT

A first die is sequentially filled with a first-layer mixed powder that is a mixture of a basic metal powder having a small particle size and a low-melting-point lubricant powder, a second-layer mixed powder that is a mixture of the basic metal powder having a large particle size and the low-melting-point lubricant powder, and a third-layer mixed powder that is a mixture of the basic metal powder having a small particle size and the low-melting-point lubricant powder. A first pressure is applied to each mixed powder to form an intermediate green compact. The intermediate green compact is heated, and placed in a second die. A second pressure is applied to the intermediate green compact to form a high-density three-layer green compact. 1. A mixed powder high-density molding method comprising:filling a first die sequentially with a first-layer mixed powder that is a mixture of a basic metal powder having a small particle size and a low-melting-point lubricant powder, a second-layer mixed powder that is a mixture of the basic metal powder having a large particle size and the low-melting-point lubricant powder, and a third-layer mixed powder that is a mixture of the basic metal powder having a small particle size and the low-melting-point lubricant powder;applying a first pressure to the third-layer mixed powder, the second-layer mixed powder, and the first-layer mixed powder in the first die to form a mixed powder intermediate compressed body;heating the mixed powder intermediate compressed body removed from the first die to a melting point of the lubricant powder;placing the heated mixed powder intermediate compressed body in a second die; andapplying a second pressure to the mixed powder intermediate compressed body in the second die to form a high-density mixed powder final compressed body.2. The mixed powder high-density molding method as defined in claim 1 ,wherein the particle size of the basic metal powder included in the first-layer mixed powder, the second- ...

Three-dimensional, additive manufacturing system, and a method of manufacturing a three-dimensional object

A three-dimensional, additive manufacturing system is disclosed. The first and second printer modules form sequences of first patterned single-layer objects and second patterned single-layer objects on the first and second carrier substrates, respectively. The patterned single-layer objects are assembled into a three-dimensional object on the assembly plate of the assembly station. A controller controls the sequences and patterns of the patterned single-layer objects formed at the printer modules, and a sequence of assembly of the first patterned single-layer objects and the second patterned single-layer objects into the three-dimensional object on the assembly plate. The first transfer module transfers the first patterned single-layer objects from the first carrier substrate to the assembly apparatus in a first transfer zone and the second transfer module transfers the second patterned single-layer objects from the second carrier substrate to the assembly apparatus in a second transfer zone. The first and second printer modules are configured to deposit first and second materials under first and second deposition conditions, respectively. The first and second materials are different and/or the first and second deposition conditions are different.

Materials and Process Using a Three Dimensional Printer to Fabricate Sintered Powder Metal Components

A process and materials are disclosed to enable the formation of metal powder-polymer/plastic preform articles by three dimensional printing a green state article, debinding the polymer/plastic from the metal powder, and sintering the article to a final shape. 1. A process for forming a soldering tip or de-soldering nozzle comprising the steps of:formulating at least one powder metal-plastic binder feedstock material suitable for use in a 3D printer in a solid or semi-solid state;fabricating a green state article from said at least one powder metal-plastic binder feedstock in a 3D printer;removing said green state article from said 3D printer and subjecting the green state article to a de-binding process;sintering the de-binded article to fuse the powder metal to a final net shape.2. The process of claim 1 , wherein the step of formulating said at least one powder metal-plastic feedstock material further comprises:combining one or more metal powders having a grain size in the range of 1 μm to 50 μm with a binder to a uniform consistency in an extrusion molding machine under heat and pressure;extruding the blended material to form a filament suitable for use in said 3D printer.3. The process of claim 2 , wherein the step of combining one or more metal powders with said binder further comprises:selecting the metal powder from the group consisting of iron, nickel, cobalt and copper, said metal powders having a grain size diameter less than 20 μm;selecting the binder from the group consisting of polyethelyne and polypropylene; andmixing about 35 to 45 by volume percentage binder and the balance metal powder.4. The process of claim 1 , wherein the de-binding process is carried out by submersion in a fluid bath to dissolve and remove the plastic binder.5. The process of claim 1 , wherein the de-binding process is carried out by heating to gasify the plastic binder.6. The process of claim 5 , wherein the thermal de-binding process comprises heating the green article to a ...

MANUFACTURING METHOD FOR THREE-DIMENSIONAL STRUCTURE, MANUFACTURING APPARATUS FOR THREE-DIMENSIONAL STRUCTURE, AND CONTROL PROGRAM FOR MANUFACTURING APPARATUS

A manufacturing method for a three-dimensional structure includes forming unit layers using at least one of a first flowable composition including first powder and a second flowable composition including second powder and solidifying at least one of the first flowable composition including the first powder and the second flowable composition including the second powder in the unit layers. In the forming the unit layers, both of the first flowable composition and the second flowable composition are caused to be present in plane directions crossing a thickness direction of the unit layers. 1. A manufacturing method for a three-dimensional structure comprising:forming unit layers using at least one of a first flowable composition including first powder and a second flowable composition including second powder; andsolidifying at least one of the first powder and the second powder in the unit layers, whereinin the forming the unit layers, both of the first flowable composition and the second flowable composition are caused to be present in a plane direction crossing a thickness direction of the unit layers.2. The manufacturing method for the three-dimensional structure according to claim 1 , further comprising repeating the forming the unit layers in a stacking direction.3. The manufacturing method for the three-dimensional structure according to claim 1 , wherein the forming the unit layers is performed by setting presence ratios and presence positions the first powder and the second powder in the unit layers for each of parts (layers) in a stacking direction of the three-dimensional structure.4. The manufacturing method for the three-dimensional structure according to claim 1 , wherein the first flowable composition including the first powder and the second flowable composition including the second powder are caused to be present to at least partially overlap when viewed from a stacking direction between the unit layers adjacent to each other.5. The manufacturing ...

ADDITIVE MANUFACTURING PART IDENTIFICATION METHOD AND PART

A part including a material of the part having a first material property. A second material property of the first material or a different material, one of the first material property or the second material property being arranged to form a mark. A method for producing a part. 1. A part comprising:a material of the part having a first material property;a second material property of the first material or a different material, one of the first material property or the second material property being arranged to form a mark.2. The part as claimed in wherein the one of the first material property or the second material property being arranged to form a mark is within the material of the other of the first material property and second material property.3. The part as claimed in wherein the material is metal claim 1 , plastic or ceramic.4. The part as claimed in wherein the first or second material property is density.5. The part as claimed in wherein the first or second material property is thermal conductivity.6. The part as claimed in wherein the first or second material property is electrical conductivity.7. The part as claimed in wherein the first or second material property is porosity.8. The part as claimed in wherein the first or second material property is magnetic.9. The part as claimed in wherein the mark is one of subsurface or surface of the part.10. The part as claimed in wherein the mark is invisible to a human eye at a surface of the part.11. The part as claimed in wherein the mark is partly visible to a human eye at a surface of the product.12. The part as claimed in wherein the mark is detectable using an imaging technology.13. The part as claimed in wherein the imaging technology is one of thermography claim 12 , eddy current testing claim 12 , ultrasonic testing claim 12 , magnetic resonance imaging claim 12 , Magnetic Flux Leakage claim 12 , Computer Tomography and x-ray14. The part as claimed in wherein the mark is three dimensional.15. The part as ...

FABRICATING MULTI-PART ASSEMBLIES

Techniques are disclosed for fabricating multi-part assemblies. In particular, by forming release layers between features such as bearings or gear teeth, complex mechanical assemblies can be fabricated in a single additive manufacturing process. 1. A printer for three-dimensional fabrication , the printer comprising:a build plate;a print head;a robotic system operable to move the print head relative to the build plate; and fabricate a first object from a first material, wherein the first material includes a powdered material and a binder system, the binder system including one or more binders that resist deformation of a net shape of the first object during processing of the first object into a final part;', 'apply an interface layer adjacent to a first surface of the first object, the interface layer reducing to a powder during sintering of the first material; and', 'fabricate a second surface of a second object from a second material at a location adjacent to the interface layer and opposing the first surface of the first object, wherein the second object is structurally independent from and mechanically related to the first object, and wherein the interface layer resists bonding of the first surface to the second surface during sintering., 'a processor configured by computer executable code to move the robotic system along a build path relative to the build plate to2. The printer of wherein the first material and the second material are supplied from a single source of build material and have a substantially common composition.3. The printer of wherein the first material and the second material have substantially similar shrinkage rates during a thermal sintering cycle.4. The printer of wherein the first object and the second object form a multi-part mechanical assembly.5. The printer of wherein the multi-part mechanical assembly includes one or more moving parts within a casing.6. The printer of wherein the processor is further configured to move the robotic ...

Friction Stir Welding Tool and Method for the Production Thereof

A welding tool for joining at least two workpieces by friction stir welding includes a pin for applying frictional heat to the workpieces. The pin includes a first pin region formed from a first material and a second pin region formed from a second material. 115-. (canceled)16. A friction stir welding tool for joining at least two workpieces , the friction stir welding tool comprising:a pin configured to apply frictional heat to the at least two workpieces during friction stir welding,wherein the pin includes a first pin region formed from a first material and a second pin region formed from a second material.17. The friction stir welding tool of claim 16 , whereinthe first pin region has a support region for supporting the pin during the friction stir welding,the second pin region has a friction surface configured to apply frictional heat to the at least two workpieces.18. The friction stir welding tool of claim 16 , whereinthe first material has a higher E modulus than the second material, orthe first material has a higher strength than the second material,wherein the second material is heat-resistant, toughened, or heat-conducting.19. The friction stir welding tool of claim 18 , wherein the first material has a higher E modulus that is greater than the second material by 20%-50%.20. The friction stir welding tool of claim 16 , wherein{'sub': 2', '4', '2', '3', '2', '2', '3, 'the first material is formed with ceramic that is SiN—YOor ZrO—YO, or'}the second material is an MP 159 metal composite.21. The friction stir welding tool of claim 16 , wherein the first material has a higher coefficient of thermal expansion than the second material.22. The friction stir welding tool of claim 16 , wherein the pin extends along a longitudinal axis of the welding tool and a shoulder that surrounds the pin is provided for separating a joining region of the workpieces from surroundings claim 16 , wherein the pin is held so that it rotates about the longitudinal axis.23. The ...

SANDWICH STRUCTURE WITH LATTICE HAVING HARD POINTS

A sandwich structure includes two face plates, with a lattice structure between the plates, and with hard points at selected locations. The face plates, and the lattice structure with its hard points, may all be made as a single continuous piece by an additive manufacturing process. The hard points may be strengthened and/or stiffened areas of the lattice that may be used for connecting fasteners, or for other purposes. The hard points may be located at the junction between the lattice and one of the faces, and may be a locally thickened portion on one of the faces, for example being a cylindrical or parallelepiped protrusion out from the face. The hard points may serve the purpose of a built-in nut plate, such as themselves containing threaded holes, or by having a threaded inserts put into holes or recesses in the hard points. 1. A sandwich structure comprising:a pair of face plates; anda lattice structure between the face plates;wherein the lattice structure includes stiffened hard points that are stiffer than surrounding regions of the lattice structure.2. The sandwich structure of claim 1 , wherein the hard points are located at junctions between the lattice structure and one of the face plates.3. The sandwich structure of claim 1 , wherein the lattice structure is additively manufactured as a unitary piece.4. The sandwich structure of claim 3 , wherein at least one of the face plates is also additively manufactured as part of the unitary piece that includes the lattice structure.5. The sandwich structure of claim 1 , wherein the lattice structure and at least one of the face plates are made of the same material.6. The sandwich structure of claim 1 , wherein the lattice structure includes ribs.7. The sandwich structure of claim 6 , wherein some of the ribs are stiffer than other of the ribs.8. The sandwich structure of claim 6 , wherein some of the ribs are made of different material(s) than other of the ribs.9. The sandwich structure of claim 6 , wherein some ...

Method For The Production Of A Metal Bearing Layer On A Cylinder Barrel Of A Hydrostatic Displacement Machine

A method for the production of a metal bearing layer (L) on a cylinder barrel () of a hydrostatic displacement machine (), in particular of an axial piston machine, in which the metal bearing layer (L) is produced from a sintering powder in a sintering process. In a first production step, a dimensionally stable green compact () is produced from a sintering powder by a cold pressing process. In a second subsequent production step, the green compact () produced by the cold pressing process is sintered onto the cylinder barrel () in a sintering process. 1. A method for production of a metal bearing layer on a cylinder barrel of a hydrostatic displacement machine , comprising:producing a dimensionally stable green compact from a sintering powder by a cold pressing process in a first production step; andsintering the green compact onto the cylinder barrel by a sintering process in a second production step.2. The method as recited in claim 1 , wherein the dimensionally stable green compact is produced in the cold pressing process by a cold press.3. The method as recited in claim 1 , wherein a disk-shaped green compact is produced in the cold pressing process.4. The method as recited in claim 1 , wherein the cold pressing process is performed using dry sintering powder.5. The method as recited in claim 1 , wherein a press form with a predefined fill volume is filled with the sintering powder in the cold pressing process.6. The method as recited in claim 5 , wherein a pressing tool comprises an upper punch and a lower punch and is pressurized at a specified pressing force claim 5 , and wherein the displacement of the pressing tool is measured.7. The method as recited in claim 6 , wherein in the event of a variation of the displacement of the pressing tool at the specified pressing force claim 6 , the amount of sintering powder is adjusted.8. The method as recited in claim 5 , wherein the green compact produced by the cold pressing process is weighed after the cold pressing ...

ADDITIVE MANUFACTURE OF ELECTRICALLY CONDUCTIVE MATERIALS

A method of additive manufacturing includes depositing a layer of absorptive material onto a workpiece, depositing a layer of additive manufacturing stock powder onto the workpiece, and fusing the stock powder to the workpiece using a focused energy source at a wavelength wherein the absorptive material has a higher absorptivity at the wavelength of the focused energy source than the absorptivity of the stock powder at that wavelength. The focused energy source can be a laser, e.g., with a 1064 nm wavelength, for example. 1. A method of additive manufacturing comprising:depositing a layer of absorptive material onto a workpiece;depositing a layer of additive manufacturing stock powder onto the workpiece; andfusing the stock powder to the workpiece using a focused energy source at a wavelength wherein the absorptive material has a higher absorptivity at the wavelength of the focused energy source than the absorptivity of the stock powder at that wavelength.2. The method as recited in claim 1 , further comprising:successively depositing the layers of the absorptive material and the stock powder and fusing each successive layer of the stock powder to the workpiece to form a multi-layer powder bed fusion component.3. The method as recited in claim 2 , wherein the multi-layer powder bed fusion component includes an electrically conductive material of greater than 95% purity.4. The method as recited in claim 3 , wherein the electrically conductive material includes at least one of copper claim 3 , aluminum or a noble metal.5. The method as recited in claim 3 , wherein the electrically conductive material includes copper of greater than 99.9% purity.6. The method as recited in claim 1 , wherein focused energy source is a laser that has a 1064 nm wavelength.7. The method as recited in claim 1 , wherein depositing the layer of stock powder includes depositing the layer of the stock powder to a thickness in the range of 10 to 200 microns claim 1 , inclusive.8. The method as ...

TURBINE COMPONENT HAVING A SEAL SLOT AND ADDITIVE MANUFACTURING PROCESS FOR MAKING SAME

A method of forming a structure in a turbine component having a seal slot, the slot including walls defining an opening therebetween, the method includes the step of using an additive manufacturing process to form a neck structure on a wall so as to reduce a size of the opening. 1. A method of forming a sealing structure in a turbine component having a seal slot , the slot including walls defining an opening therebetween , the method comprising using an additive manufacturing process to form a neck structure on at least one of the walls so as to reduce a size of the opening.2. The method according to further comprising positioning a turbine component such that powder can be contained by the seal slot; adding powder to the seal slot until the powder is at a predetermined level relative to the walls; and selectively fusing a portion of an uppermost layer of the powder.3. The method according to further comprising depositing an additional layer of powder on the uppermost layer of powder; and fusing at least some of the additional layer of powder to at least a portion of the fused section of the previous layer.4. The method according to further comprising fusing a part of a layer of powder to at least one of the walls.5. The method of further comprising repeating in a cycle the steps of depositing and fusing to build up the structure in a layer-by-layer fashion.6. The method of wherein the structure is a rib attached to a wall of the slot.7. The method of further comprising adding at least one unfused layer before reinitiating the cycle of repeating the steps of depositing and fusing to build up another structure that is spaced-apart from the first structure.8. The method of wherein the turbine component comprises a metal alloy.9. The method of wherein the powder comprises a metal alloy.10. A method of forming a sealing structure in a turbine component having a seal slot sequentially with a spline seal claim 2 , the slot including walls defining an opening therebetween ...

CONTACT ARRANGEMENT FOR USE IN AN APPARATUS FOR PRODUCING THREE-DIMENSIONAL WORK PIECES

A contact arrangement () for use in an apparatus () for producing three-dimensional work pieces by irradiating layers of a raw material powder with electromagnetic or particle radiation, the contact arrangement () comprises a replaceable building chamber () adapted to receive a work piece generated in the apparatus () by an additive layering process and a building chamber support element () adapted to support the replaceable building chamber (). A first contact element () is fastened to the replaceable building chamber () and comprises at least one first electrical conductor element (), the first electrical conductor element () being provided with a first planar conductor surface (). A second contact element () is fastened to the building chamber support element () and comprises at least one second electrical conductor element (), the second electrical conductor element () being provided with a second planar conductor surface (). The first planar conductor surface () provided on the first electrical conductor element () of the first contact element () and the second planar conductor surface () provided on the second electrical conductor element () of the second contact element () are adapted to interact with each other so as to establish an electrical contact between the replaceable building chamber () and the building chamber support element () when the replaceable building chamber () is supported on the building chamber support element (). 1. A contact arrangement for use in an apparatus for producing three-dimensional work pieces by irradiating layers of a raw material powder with electromagnetic or particle radiation , the contact arrangement comprising:a replaceable building chamber adapted to receive a work piece generated in the apparatus by an additive layering process,a building chamber support element adapted to support the replaceable building chamber,a first contact element fastened to the replaceable building chamber and comprising at least one first ...

VALVE SEAT RING

The invention relates to a highly heat conductive valve seat ring () comprising a carrier layer () and a functional layer (), wherein the carrier layer () consists of a solidified copper matrix containing 0.10 to 20% w/w of a solidifying component s and the functional layer (3) consists of a solidified copper matrix which further contains, based on the copper matrix, 5 to 35% w/w of one or more hard phases. 112323. Valve seat ring () comprising a carrier layer () and a functional layer () , characterized in that the carrier layer () consists of a solidified copper matrix containing 0.10 to 20% w/w of a solidifying/strengthening component and the functional layer () consists of a solidified copper matrix which further contains , based on the copper matrix , 5 to 35% w/w of one or more hard phases.2. Valve seat ring according to claim 1 , characterized in that the solidifying component of the copper matrix is an oxide claim 1 , in particular AlOor YO.3. Valve seat ring according to claim 1 , characterized in that the solidifying component of the copper matrix is an intermetallic phase claim 1 , in particular containing Cu claim 1 , Cr claim 1 , Zr claim 1 , Nb claim 1 , Ni and/or Si.4. Valve seat ring according to claim 1 , characterized in that the solidifying component is AlOor CrNb.5. Valve seat ring according to claim 1 , characterized in that the hard phase of the functional layer is a hard phase based on iron claim 1 , cobalt claim 1 , nickel claim 1 , a carbide claim 1 , oxide and/or nitride.6. Valve seat ring according to claim 5 , characterized in that the hard phase is a hard phase based on iron claim 5 , nickel or cobalt.7. Valve seat ring according to claim 1 , characterized in that the functional layer contains 0.1 to 5% w/w of a solid lubricant.8. Valve seat ring according to claim 7 , characterized in that the solid lubricant is MnS claim 7 , MoS claim 7 , WS claim 7 , CaFor hexagonal BN.9232. Valve seat ring according to claim 1 , characterized in that ...

METHOD FOR MANUFACTURING SINTERED BODY, STRUCTURE, AND COMPOSITE STRUCTURE

A method for manufacturing a sintered body, the method including heating a mixture that contains a plurality of particles of a metal oxide having a spinel-type structure, and a metal acetylacetonate under pressure at a temperature of from a melting point or higher of the metal acetylacetonate to 600° C. or lower, to form a sintered body that contains the metal oxide having the spinel-type structure. 1. A method for manufacturing a sintered body , the method comprising:mixing a plurality of particles of at least one metal oxide having a spinel-type structure with at least one metal acetylacetonate to produce a mixture; andheating the mixture under pressure at a temperature of from a melting point or higher of the at least one metal acetylacetonate to 600° C. or lower.2. The method according to claim 1 , wherein the mixture is heated in presence of a fluid.3. The method according to claim 2 , wherein the fluid is mixed in the mixture.4. The method according to claim 3 , wherein an amount if the fluid in the mixture is 20 wt % or less relative to a total weight of the plurality of particles of the at least one metal oxide having the spinel-type structure.5. The method according to claim 1 , wherein the metal acetylacetonate contains a metal element that is the same as at least one metal element contained in the metal oxide.6. The method according to claim 1 , wherein the mixture further contains at least one of a metal material claim 1 , a resin material claim 1 , or a carbon material.7. The method according to claim 1 , wherein the metal oxide is ferrite.8. The method according to claim 1 , wherein the metal oxide contains Ni and Mn.9. The method according to claim 1 , wherein the metal oxide contains one or more of Li claim 1 , Mg claim 1 , Al claim 1 , Cr claim 1 , Mn claim 1 , Fe claim 1 , Co claim 1 , Ni claim 1 , Cu claim 1 , and Zn.10. The method according to claim 1 , wherein the pressure 1 MPa to 5000 MPa.11. The method according to claim 1 , wherein the ...

Abrasive coating including metal matrix and ceramic particles

A system may include a powder source; a powder delivery device; an energy delivery device; and a computing device. The computing device may be configured to: control the powder source to deliver metal powder to the powder delivery device; control the powder delivery device to deliver the metal powder to a surface of an abrasive coating; and control the energy delivery device to deliver energy to at least one of the abrasive coating or the metal powder to cause the metal powder to be joined to the abrasive coating.

POWDER METALLURGY COMPOSITE CAM SHEET AND PREPARATION METHOD THEREOF

According to the invention, there are disclosed a power metallurgy composite cam sheet and a fabrication method thereof. The power metallurgy composite cam sheet is constructed by combining a power metallurgy cam be composited on a surface of a matrix. The fabrication method of the power metallurgy composite cam sheet includes sinter welding, braze welding, argon arc welding, laser welding, hot pressing and other methods. The powder metallurgy composite cam sheet fabricated by the invention has merits of stable size, good impact toughness, good abrasion resistance, low cost and so on, so that it can replace an integral cam sheet that is currently fabricated by forging, drawing, power metallurgy or other process. It is suitable for the case where a hollow camshaft is prepared by mechanical assembly, hydraulic forming, welding or other process, so that the usage requirements of an assembled camshaft can be met. 110-. (canceled)11. A power metallurgy composite cam sheet , wherein , the power metallurgy composite cam sheet is constructed by combining a power metallurgy cam on a surface of a matrix , a thickness of the matrix is in a range of 0.1-20 mm , and a thickness of the powder metallurgy cam in the powder metallurgy composite cam sheet is in a range of 0.5-50 mm.12. The composite cam sheet according to claim 11 , wherein claim 11 , the matrix in the power metallurgy composite cam sheet is a circular tube or a special-shaped tube made of steel claim 11 , nickel claim 11 , titanium claim 11 , copper claim 11 , or aluminum.13. The composite cam sheet according to claim 11 , wherein claim 11 , the power metallurgy cam in the power metallurgy composite cam sheet is of an iron-based powder metallurgy material claim 11 , a titanium-based power metallurgy material claim 11 , a nickel-based power metallurgy material or a hard alloy.14. A fabrication method of a power metallurgy composite cam sheet claim 11 , comprising the following step: combining a power metallurgy cam ...

Method of Forming a Thermal Barrier Coating System with Engineered Surface Roughness

A method of manufacturing a substrate () with a ceramic thermal barrier coating (). The interface between layers of the coating contains an engineered surface roughness () to enhance the mechanical integrity of the bond there between. The surface roughness is formed in a surface of a mold () and is infused by a subsequently cast layer of material (). The substrate may be partially sintered () prior to application of the coating layer(s) and the coated substrate and coating layer(s) may be co-sintered to form a fully coherent strain-free interlayer. 1. A thermally insulated component comprising: is integral to the green body;', 'substantially surrounds the green body; and', 'defines a first engineered surface roughness characteristic within a first region of the first surface;, 'a green body comprising a first powder, the green body defining a first surface that comprises a second powder;', 'coats the first surface;', 'defines a second surface; and', 'defines a second engineered surface roughness characteristic; and, 'a coating that coats the second surface; and', 'defines third surface., 'a ceramic insulating material that2. The thermally insulated component of claim 1 , wherein:the first engineered surface roughness characteristic is different from the second engineered surface roughness characteristic.3. The thermally insulated component of claim 1 , wherein:the first powder comprises a metallic alloy.4. The thermally insulated component of claim 1 , wherein:the second powder comprises a bond coat material.5. The thermally insulated component of claim 1 , wherein:the first surface defines a third engineered surface roughness characteristic within a second region of the first surface, the third engineered surface roughness characteristic different from the first engineered surface roughness characteristic.6. The thermally insulated component of claim 1 , wherein:the component is configured for operable use in a gas turbine engine.7. The thermally insulated ...

Dual Layer Sintered Metallic Clutch Friction Facing

A method for forming a friction facing comprises placing a bonding powder mix in to a die, and placing a performance powder mix in to the die. Pressing the performance powder mix and the bonding powder mix creates a compact. Sintering the compact forms a friction facing. A clutch disc assembly can be formed. A clutch disc can comprise a mounting hole for securing a friction facing and a backer plate can comprise a pass-through hole. A mounting mechanism joins the mounting hole to the pass-through hole. The mounting mechanism comprises a head-height for a portion of the mounting mechanism that is mounted near the sintered compact. The bonding layer comprises a thickness corresponding to the head-height of the mounting mechanism. 1. A method for forming a friction facing , comprising:placing a bonding powder mix in to a die to form a bonding layer;placing a performance powder mix in to the die to form a performance layer;pressing the performance powder mix and the bonding powder mix to create a dual-layer compact; andsintering the compact.2. The method of claim 1 , further comprising leveling the bonding layer prior to pressing; and leveling the performance layer prior to pressing.3. The method of claim 1 , further comprising pressing the bonding power mix prior to placing the performance powder mix in to the die.4. The method of claim 3 , further comprising applying a brazing layer to the pressed bonding powder mix prior to placing the performance powder mix in to the die.5. The method of claim 1 , wherein the pressing comprises a first pressing step and a second pressing step claim 1 , wherein the first pressing step forms a first compact layer claim 1 , wherein the second pressing step forms a final compact by adding a second compact layer to the first compact layer claim 1 , and wherein one of the bonding layer and the performance layer is the first compact layer and the other of the bonding layer and the performance layer is the second compact layer.6. The method ...

MANUFACTURING METHOD OF MULTILAYER SHELL-CORE COMPOSITE STRUCTURAL COMPONENT

A manufacturing method of a multilayer shell-core composite structural component comprises the following procedures: (1) respectively preparing feeding material for injection forming of a core layer, a buffer layer and a shell layer, wherein the powders of feeding material of the core layer and the shell layer are selected from one or more of metallic powder, ceramic powder or toughened ceramic powder, and are different from each other, and the powder of feeding material of the buffer layer is gradient composite material powder; (2) layer by layer producing the blank of multilayer shell-core composite structural component by powder injection molding; (3) degreasing the blank; and (4) sintering the blank to obtain the multilayer shell-core composite structural component. The multilayer shell-core composite structural component has the advantages of high surface hardness, abrasion resistance, uniform thickness of the shell layer, stable and persistent performance. 1. A method for manufacturing an acetabulum having a multilayer shell-core composite structure , comprising:preparing feedstocks of a shell layer, at least one transition layer and a core layer respectively;performing a powder injection molding with the feedstocks, to obtain a green body of the acetabulum comprising the shell layer, the at least one transition layer and the core layer;performing debinding on the green body of the acetabulum; andsintering the green body of the acetabulum after being debound, to obtain the acetabulum;wherein preparing a feedstock of each of the shell layer, the transition layer and the core layer comprises: mixing a main powder of the each layer, a binder and an additive comprising a surface active agent and a plasticizer to obtain a mixture, where the main powder of the core layer is made of a powdered ceramic material, the main powder of the shell layer is made of a metal powder material or a powdered toughened ceramic material, and the main powder of the transition layer ...

AGILE TOOLING

A system and manufactures are provided that augment various manufacturing processes by combining skinning techniques, for example from additive manufacturing methods, with modular substructures in order to provide cost and development time saving while not sacrificing end product material characteristics. Modular substructures provide a range of benefits from wide adaptability and reusability, to customized cooling channels within tooling systems. Manufacturing tooling areas afforded improvements span from stamping to injection molding. 1. (canceled)2. (canceled)3. (canceled)4. (canceled)5. (canceled)6. (canceled)7. (canceled)8. (canceled)9. (canceled)10. (canceled)11. (canceled)12. A manufacturing system for creating a manufacturing mold comprising:a substructure assembly having modular substructures that build up a near net shape of the mold; andan application of added material that applied to the substructure assembly forms at least in part a skin of the mold, said application using additive manufacturing techniques,wherein the system is enabled to be deconstructed and the modular substructures reconfigured into at least a second near net shape of a different mold.13. The manufacturing system of claim 12 , wherein the added material comprises one or more layers and the one or more layers forms at least in part the skin.14. The manufacturing system of claim 13 , wherein the skin comprises more than one material.15. The manufacturing system of claim 13 , wherein further said application further uses subtractive manufacturing techniques that provide a final outer layer of the skin.16. The manufacturing system of claim 13 , wherein the system is applied in a stamping operation and the skin provides an equivalent surface material effect to a stamping process with a unitary die for a selected material being stamped.17. The manufacturing system of claim 13 , wherein the system is applied in an injection molding operation claim 13 , and the skin and substructure assembly ...

Additive manufacturing of components with functionally graded properties

Methods of manufacturing monolithic components with complex design features and functionally graded properties in any spatial direction may include forming of outer shell with an additive manufacturing process, loading the shell with bulk material and exposing the loaded shell to a hot isostatic pressing (HIP) process. The combination of the additive manufacturing process and the HIP process forms a diffusion bond between the outer shell and the bulk material resulting in a monolithic component with functionally graded properties. The outer shell may include an exterior surface and an inner passage formed with relatively hard surfaces to accommodate fluids in a wellbore.

A method for manufacturing a metal based component comprising a protrusion

The inventive concept relates to method for manufacturing a metal based component comprising at least one protrusion. The method comprises: providing a metal based substrate comprising a surface having at least one cavity; providing a metal based protrusion element comprising a first portion and a second portion, wherein said first portion has a shape that conforms to a shape of the cavity; arranging the first portion of the protrusion element in said cavity such that at least the second portion of the protrusion element protrudes at least 5 mm from a surface of the metal based substrate, to form a substrate comprising a protrusion; placing said substrate comprising a protrusion in a canister such that a void is formed between the canister and the surface of the substrate comprising the protrusion; filling at least a portion of the void with a diamond powder such that the surface of the substrate comprising the protrusion is covered by the inert filler material; removing gas from the interface between said diamond powder and said substrate comprising

Systems and Methods for Rapid Qualification of Products Created by Additive Manufacturing Processes with Doped Materials

Additive manufacturing (AM) materials can be rapidly qualified with dopants that improve accuracy and precision of microstructure. When dopants are sensed by AM supervisory control and data acquisition (SCADA) systems, dopants facilitate targeted guidance. This capability can be used as a 3D stencil when the dopants are relayed as coordinates in 3D space. Dopants can be sensed to provide real time in situ process control, data and feedback about the additive manufacturing process. When an electrostatic or electromagnetic force is applied to the print area, doped materials can be modified to control the melt pool and change various properties of the doped material. 1. A method for detecting the presence of a feedstock during an additive manufacturing process to enable the additive manufacturing process to be modified , the method comprising:receiving a first feedstock for use in creating an object via an additive manufacturing process, the feedstock including a dopant;using the first feedstock to create a first portion of the object in accordance with one or more parameters;detecting the presence of the dopant within the first portion of the object; andbased on the detection, modifying the one or more parameters such that the use of the first feedstock is modified when a second portion of the object is created.2. The method of claim 1 , wherein the object is created with a plurality of feedstocks claim 1 , and wherein detecting the presence of the dopant with the first portion of the object comprises detecting a ratio of the first feedstock to one or more other feedstocks that are present in the first portion of the object.3. The method of claim 2 , wherein the one or more parameters control the ratio of the first feedstock to the one or more other feedstocks.4. The method of claim 3 , wherein modifying the one or more parameters comprises adjusting the ratio of the first feedstock to the one or more other feedstocks such that the second portion of the object ...

Polycrystalline Diamond Cutting Element

A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate. 1. A polycrystalline-diamond cutting element for a drill bit of a downhole tool , comprising:a substrate; anda diamond table bonded to the substrate, the diamond table comprising a polycrystalline diamond material intermixed with small polycrystalline diamond particles that are substantially free of all catalyzing and other metallic material along at least one working surface thereof;wherein the small polycrystalline diamond particles comprise small particles formed from a polycrystalline diamond blank with a metallic catalyst therein that has been subjected to a first high temperature-high pressure pressing operation, leached of substantially all of the other metallic materials, and intermixed with the polycrystalline diamond material; andwherein the diamond table is subjected to a second high temperature-high pressure pressing operation.2. The polycrystalline diamond cutting element of claim 1 , wherein the small polycrystalline diamond particles are formed by sintering and crushing the polycrystalline blank and sizing the crushed polycrystalline blank into the small particles.3. Polycrystalline diamond cutting element of claim 2 , wherein the polycrystalline diamond cutting element has a higher wear resistance than a polycrystalline diamond cutting element comprising a diamond table ...

METHOD FOR HEAT TREATING A PREFORM MADE OF TITANIUM ALLOY POWDER

A method for heat treating a powder part preform including a titanium-based alloy, wherein the method includes the heat treatment of the preform in a furnace at a predetermined temperature, wherein the preform is on a holder during the heat treatment, wherein the holder includes a zirconium-based alloy having a zirconium content greater than or equal to 95% by weight, wherein the holder material has a melting temperature higher than the predefined temperature of the heat treatment, and wherein an anti-diffusion barrier is arranged between the preform and the holder in order to prevent welding of the preform to the holder. 1. A method for heat treating a powder part preform comprising a titanium-based alloy , wherein the method comprises the heat treatment of the preform in a furnace at a predetermined temperature , wherein the preform is on a holder during the heat treatment ,wherein the holder comprises a zirconium-based alloy having a zirconium content greater than or equal to 95% by weight,wherein the holder material has a melting temperature higher than the predefined temperature of the heat treatment, andwherein an anti-diffusion barrier is arranged between the preform and the holder in order to prevent welding of the preform to the holder.2. The method according to claim 1 , wherein the holder comprises a zirconium alloy selected from among the following: Zircaloy-2 claim 1 , Zircaloy-4.3. The method according to claim 1 , wherein the holder has a thickness of between 0.1 mm and 20 mm.4. The method according to claim 1 , wherein the anti-diffusion barrier comprises alumina or yttrium oxide.5. The method according to claim 1 , wherein the holder is stripped.6. The method according to claim 1 , wherein the heat treatment of the preform is sintering of the preform claim 1 , wherein the predefined temperature of the heat treatment is the temperature of a sintering step.7. A method for heat treating a powder part preform of a turbomachine part comprising a titanium ...

Monolithic contact system and method of forming

A circuit breaker having a monolithic structure and method of making is disclosed. The monolithic structure includes an arm portion having copper and a contact portion having a composite material. The composite material has a metallic matrix and a second phase disposed in the metallic matrix. The method of making the monolithic structure includes introducing a first powder into a first region of a mold, introducing a second powder into a second region of the mold, and consolidating the first powder and the second powder together. The first region of the mold corresponds to a contact portion, and the second region corresponds to an arm portion of the monolithic structure of the circuit breaker.

Erosion resistant material and turbine blade

An erosion resistant material has a continuous portion and discontinuous portions. The continuous portion has a continuous structure. The discontinuous portions are arranged inside the continuous portion to have a discontinuous structure. The discontinuous portions are formed of particles having an average particle diameter of 1 μm or less. Further, the discontinuous portions are formed of a material having a surface hardness and a Young's modulus higher than those of the continuous portion.

VEHICLE COMPONENT AND METHOD OF CONSTRUCTING

A method of constructing a vehicle component includes depositing a layer of a first metal, extruding a filament of a second metal onto the layer, and depositing a second layer of the first metal on the filament. 1. A method of constructing a vehicle component , comprising:depositing a layer of a first metal;extruding a filament of a second metal onto the layer; anddepositing a second layer of the first metal on the filament.2. The method of claim 1 , wherein an elastic modulus of the second metal is higher than an elastic modulus of the first metal.3. The method of claim 1 , wherein a density of the first metal is lower than a density of the second metal.4. The method of claim 1 , wherein the first metal is one of aluminum and magnesium.5. The method of claim 1 , wherein the second metal is stainless steel.6. The method of claim 1 , further comprising extruding the filament by heating a nozzle and feeding a feed of the second metal through the nozzle.7. The method of claim 1 , wherein the filament has a substantially circular cross-section.8. The method of claim 1 , wherein the layer and the second layer of the first metal extend around a surface area of the filament.9. The method of claim 1 , further comprising extruding a second filament of the second metal on the layer of the first metal.10. The method of claim 1 , further comprising extruding a second filament of the second metal on the second layer of the first metal and depositing a third layer of the first metal on the second filament.11. The method of claim 1 , further comprising extruding the filament along a longitudinal axis.12. The method of claim 1 , wherein the layer has a first longitudinal edge and a second longitudinal edge claim 1 , the method further comprising extruding the filament closer to the first longitudinal edge than the second longitudinal edge.13. The method of claim 12 , further comprising extruding a second filament of the second metal on the layer between the filament and the first ...

MULTI-MATERIAL TOOLING AND METHODS OF MAKING SAME

Multi-material tooling and methods of making multi-material tooling are provided. The multi-material tooling includes a core formed of a first material having a hardness (Rockwell C scale) of up to 30 HRC, and a shell layer adjacent to the core. The shell layer is formed of a second material having a hardness of 33 HRC to 70 HRC. The method of making multi-material includes depositing a first layer of a first material using an additive manufacturing technique to form a core. The first material that forms the core has a hardness of up to 30 HRC. The method also includes depositing a second layer of a second material to form a shell layer adjacent to the core. The second material that forms the shell layer has a hardness of 33 HRC to 70 HRC. 1. A method of making multi-material tooling , the method comprising:depositing a first material using an additive manufacturing technique to form a core, wherein the first material has a hardness of up to 30 HRC;depositing a second material to form a shell layer adjacent to at least a portion of the core, wherein the second material has a hardness of 33 HRC to 70 HRC.2. The method according to claim 1 , wherein the first material comprises a low alloy steel.3. The method according to claim 1 , wherein the second material comprises one or more of a nanostructured steel claim 1 , a chromium carbide alloy claim 1 , a cobalt alloy claim 1 , a martensitic stainless steel claim 1 , a maraging steel claim 1 , and a tool steel.4. The method according to claim 1 , wherein the first material has a hardness of 15 HRC to 30 HRC.5. The method according to claim 4 , wherein the second material has a hardness of 38 HRC to 68 HRC.6. The method according to claim 1 , wherein the second material is deposited using an additive manufacturing technique claim 1 , a thermal spray process claim 1 , and combinations thereof.7. The method according to claim 1 , further comprising depositing a third material using an additive manufacturing technique to ...

Additive manufacturing of complex objects using refractory matrix materials

A method for the manufacture of a three-dimensional object using a refractory matrix material is provided. The method includes the additive manufacture of a green body from a powder-based refractory matrix material followed by densification via chemical vapor infiltration (CVI). The refractory matrix material can be a refractory ceramic (e.g., silicon carbide, zirconium carbide, or graphite) or a refractory metal (e.g., molybdenum or tungsten). In one embodiment, the matrix material is deposited according to a binder-jet printing process to produce a green body having a complex geometry. The CVI process increases its density, provides a hermetic seal, and yields an object with mechanical integrity. The residual binder content dissociates and is removed from the green body prior to the start of the CVI process as temperatures increase in the CVI reactor. The CVI process selective deposits a fully dense coating on all internal and external surfaces of the finished object.

Apparatus and method for adjusting and controlling the stacking-up layer manufacturing

An apparatus of adjusting and controlling the stacking-up layer manufacturing comprises a target, a powder providing unit, an energy generating unit, and a magnetism unit. The powder providing unit is coupled on a top of the target. The energy generating unit is also coupled on the top of the target. The powder providing unit provides a powder to a surface of the target. The energy generating unit provides the energy beam to selectively heat the powder on the surface of the target to form a melted or sintered powder layer. The magnetism unit provides a magnetic field to control the solidification of the melted or sintered powder layer.

ALUMINUM ALLOY, MANUFACTURING METHOD OF LAMINATED MOLDING AND LAMINATED MOLDING

The present disclosure provides an aluminum alloy to be used in laminate molding containing Si, Fe, Mn and inevitable impurities, in which α-phase Al—Si—Fe intermetallic compound is present in the aluminum alloy. In addition, a manufacturing method of a laminated molding is provided which laminate molds using powder of this aluminum alloy. Further, a laminate molding of this aluminum alloy is provided. 1. An aluminum alloy to be used in laminate molding , the aluminum alloy comprising:Si, Fe, Mn and inevitable impurities,wherein α-phase Al—Si—Fe intermetallic compound is present in the aluminum alloy.2. The aluminum alloy according to claim 1 ,wherein content of Si is at least 3% by mass and no more than 20% by mass,content of Fe is at least 0.5% by mass and no more than 7% by mass, andcontent of Mn is at least 0.1% by mass and no more than 7% by mass.3. The aluminum alloy according to claim 1 , further comprising Be or Zr.4. The aluminum alloy according to claim 3 ,wherein content of Be is at least 0.05% by mass and no more than 1% by mass, andcontent of Zr is at least 0.2% by mass and no more than 5% by mass.5. The aluminum alloy according to claim 1 , further comprising Cu claim 1 , Zn claim 1 , Mg claim 1 , Ti and Ni.6. A manufacturing method of laminated molding claim 1 , comprising a step of laminate molding using powder of the aluminum alloy according to .7. A laminated molding of the aluminum alloy according to . This application is based on and claims the benefit of priority from Japanese Patent Application No. 2021-052963, filed on 26 Mar. 2021, the content of which is incorporated herein by reference.The present invention relates to an aluminum alloy used in laminate molding, a manufacturing method of laminated molding and a laminated molding.A method of manufacturing a laminated molding of aluminum alloy using a metal 3D printer has been known. At this time, a process of solidification is repeated after spreading aluminum alloy powder and dissolving ...

Coil component

A coil component includes a magnetic body part and a coil part. The magnetic body part has first and second magnetic layers stacked together alternately in one axis direction, and cover parts covering the first and second magnetic layers from the one axis direction. The coil part has conductor patterns provided on the second magnetic layers. The magnetic body part includes: oblate soft magnetic grain-containing layers extending over the entire range of the magnetic body part in the direction perpendicular to the one axis direction, exposed in the direction perpendicular to the one axis direction, and formed by oblate soft magnetic grains whose thickness direction is oriented in the one axis direction; and spherical grain-containing layers adjoining the oblate soft magnetic grain-containing layers in the one axis direction, and formed by insulative spherical grains.