Described are porous sintered metal bodies, methods of making and using the porous sintered metal bodies, and methods of using the porous sintered metal bodies for commercial applications that include filtering a fluid, including in applications requiring high efficiency (high LRV) filtration.

Provided is an Fe-based metal powder that is suitable for a process involving rapid melt-quenching and solidification, and that provides a shaped article having superior properties. The metal powder for shaping is made of an Fe-based alloy. The Fe-based alloy contains: Ni in an amount of 15.0% to 21.0% by mass; Co in an amount of 0% to 10.0% by mass; Mo in an amount of 0% to 7.0% by mass; Ti in an amount of 0.1% to 6.0% by mass; Al in an amount of 0.1% to 3.0% by mass; and the balance composed of Fe and incidental impurities.

A method for manufacturing a foam in a conduit comprises extruding a metal conduit. A metal foam powder is injected into a cavity of the metal conduit. The metal foam powder is activated to form a metal foam in the cavity of the metal conduit. A device for producing a foamed metal comprises an extruder that comprises one or more screws for extruding a metal through a die to form a conduit. The die comprises a plurality of ports for injecting a metal foam powder into a central hollow cavity or a wall cavity of the conduit. The device comprises a pressurizing section for increasing pressure on the metal foam powder and a thermal section for increasing the temperature of the metal foam powder to facilitate its expansion into a metal foam.

A process for manufacturing a PTC heating element that includes at least one PTC component (20) and a carrier (14, 16) permanently connected to the PTC component on at least one side (24, 26) of thereof The process includes applying electrically conductive sintered material (28, 30, 36, 38) on the one side of the PTC component, which side is to be permanently connected to a carrier. Subsequently, a contact of the PTC component is established with at least one carrier such that sintered material, which was applied between the PTC component and the carrier and is intended for establishing a connection between the at least one PTC component and the at least one carrier, is positioned. The sintered material, which material has been positioned between the PTC component and the carrier, is sintered by heating or/and by applying pressure.

A method for manufacturing a powder magnetic core, the method including: forming a soft magnetic powder (SMP) layer by putting an SMP having a surface on which an insulating coating film is formed into a space surrounded by a lower punch and a die; forming a pressed powder by compressing the SMP layer in the die by the lower punch and an upper punch; and causing the pressed powder and the die to slide relative to each other and then removing the pressed powder from the die is provided. In forming the SMP layer, a different powder different from the SMP is put into the space before and after the SMP is put into the space and a different powder layer having a spring back rate higher than that of the SMP layer by 0.6-1.1% is formed on upper and lower sides of the SMP layer.

The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

A three-dimensional shaped article production method according to the invention is a method for producing a three-dimensional shaped article by stacking layers formed in a predetermined pattern, wherein a series of steps including a composition supply step of supplying a composition containing a plurality of particles to a predetermined part, and a bonding step of bonding the particles by irradiation with a laser light is performed repeatedly, and the composition supply step includes a step of forming a first region using a first composition containing first particles as the composition, and a step of forming a second region using a second composition containing second particles which are different from the first particles as the composition, and the bonding of the particles in the first region and the bonding of the particles in the second region are performed by irradiation with laser lights with a different spectrum.

A superhard polycrystalline construction comprises a body of polycrystalline superhard material formed of a mass of superhard grains exhibiting inter-granular bonding and defining a plurality of interstitial regions therebetween, and a non-superhard phase at least partially filling a plurality of the interstitial regions and having an associated shape factor of greater than around 0.65 and a substrate bonded to the body of superhard material along an interface, the substrate having a region adjacent the interface comprising hinder material in an amount at least 5% less than the remainder of the substrate.

An open-pored metal body, which is formed having a core layer (A) consisting of Ni, Co, Fe, Cu, Ag or an alloy formed having one of said chemical elements, wherein one of said chemical elements is present in the alloy at more than 25 at %, and a gradated layer (B) is formed on surfaces of the core layer (A), said gradated layer being formed by intermetallic phase or mixed crystals of Al, and a layer (C), which is formed having aluminum oxide, is formed on the gradated layer (B).

A system includes a layered structure. The layered structure includes first and second coalesced layers and an intermediate layer disposed between the first and second coalesced layers. The first and second coalesced layers have a higher degree of coalescence than the intermediate layer.