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.

A metal composite comprises: a first matrix comprising magnesium, a magnesium alloy, or a combination thereof; a second matrix comprising aluminum, an aluminum alloy, steel, a zinc alloy, a tin alloy, or a combination comprising at least one of the foregoing; a corrosion reinforcement material; and a boundary layer disposed between the first matrix and the second matrix; wherein the boundary layer has a thickness of 10 nm to 200 μm.

Examples for refining the microstructure of metallic materials used for additive manufacturing are described herein. An example can involve generating a first layer of an integral object by heating a metallic material to a molten state such that the metallic material includes a solid-liquid interface. The example can further involve applying an electromagnetic field or vibrations to the metallic material of the first layer. In some instances, the electromagnetic fields or vibrations perturb the first layer of metallic material causing nucleation sites to form at the solid-liquid interface of the metallic material in the molten state. The example also includes generating a second layer coupled to the first layer of the integral object. Generating the second layer increases a number of nucleation sites at the solid-liquid interface of the metallic material in the molten state. Each nucleation site can grows a crystal at a spatially-random orientation.

A shaped charge liner may include an apex portion and a skirt portion extending from the apex portion. The skirt portion may include a body connected to the apex portion, a perimeter spaced apart from the apex portion, and a carbide layer extending between and spaced apart from the perimeter and the apex portion. A shaped charge for creating a perforation hole in a wellbore casing may include a shaped charge liner having at least one material having hardness that is greater than a corresponding hardness of the wellbore casing. The at least one material is configured to bond to at least one of an outer surface and an inner surface of the perforation hole upon detonation of the shaped charge and penetration of the casing by a perforation jet.

A joint prosthesis system is suitable for cementless fixation. The system has two metal implant components and a bearing. One of the metal implant components has an articulation surface for articulation with the bearing. The other metal implant component has a mounting surface for supporting the bearing. One of the metal implant components includes a solid metal portion and a porous metal portion. The porous metal portion has surfaces with different characteristics, such as roughness, to improve bone fixation, ease removal of the implant component in a revision surgery, reduce soft tissue irritation, improve the strength of a sintered bond between the solid and porous metal portions, or reduce or eliminate the possibility of blood traveling through the porous metal portion into the joint space. A method of making the joint prosthesis is also disclosed. The invention may also be applied to discrete porous metal implant components, such as augment.

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.

A porous copper sintered material (10) includes: a plurality of copper fibers (11) sintered each other, wherein the copper fibers (11) are made of copper or copper alloy, a diameter R of the copper fibers (11) is in a range of 0.02 mm or more and 1.0 mm or less, and a ratio L/R of a length L of the copper fibers to the diameter R is in a range of 4 or more and 2500 or less (11), redox layers (12) formed by redox treatment are provided on surfaces of copper fibers (11, 11), and concavities and convexities are formed by the redox layer (12), and each of redox layers (12, 12) formed on each of the copper fibers (11) is integrally bonded in a junction of the copper fibers (11).

A process for producing an electrode material by infiltrating a highly conductive metal such as Cu into a porous object containing heat-resistant elements. Before an infiltration step in which the highly conductive metal is infiltrated, a HIP treatment is given to a powder containing the heat-resistant elements (or to a molded object obtained by molding a powder containing the heat-resistant elements). The composition is controlled so that the HIP treatment yields a porous object which has a degree of filling of 70% or higher, more preferably 75% or higher. The highly conductive metal is infiltrated into the porous object having the controlled composition.

Polycrystalline diamond compacts having parting compound within the interstitial volumes are disclosed herein. In one embodiment, a polycrystalline diamond compact includes a polycrystalline diamond body having a plurality of diamond grains bonded together in diamond-to-diamond bonds, interstitial volumes positioned between the adjacent diamond grains, and a parting compound positioned in at least a portion of the interstitial volumes of the polycrystalline diamond body.

A metal matrix composite tool includes a body having hard composite portion that includes reinforcing particles dispersed in a binder material. At least some of the reinforcing particles comprise a monolithic particle structure including a core having irregular outer surface features integral with the core.