A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

Channel boxes for a boiling water reactor and methods of manufacture thereof are provided. The channel box comprises a substrate and a first layer. The substrate comprises a tubular shape. The substrate comprises silicon carbide fibers. The first layer is deposited on a first surface of the substrate and the first layer comprises a corrosion resistant metallic composition.

Composite materials include a steel matrix with reinforcing carbon fiber integrated into the matrix. The composite materials have substantially lower density than steel, and are expected to have appreciable strength. Methods for forming composite steel composites includes combining a reinforcing carbon fiber component, such as a woven polymer, with steel nanoparticles and sintering the steel nanoparticles in order to form a steel matrix with reinforcing carbon fiber integrated therein.

Composite materials include a steel matrix with reinforcing carbon fiber integrated into the matrix. The composite materials have substantially lower density than steel, and are expected to have appreciable strength. Methods for forming composite steel composites includes combining a reinforcing carbon fiber component, such as a woven polymer, with steel nanoparticles and sintering the steel nanoparticles in order to form a steel matrix with reinforcing carbon fiber integrated therein.

Composite materials include a steel matrix with reinforcing carbon fiber formed of individual fibers penetrating into the matrix to substantial depth. The fibers typically have defined diameters and large ratios of penetration depth to fiber diameter. Specified methods for forming the composite materials have a unique ability to achieve the large ratios of penetration depth to fiber diameter.

Composite materials include a steel matrix with reinforcing carbon fiber formed of individual fibers penetrating into the matrix to substantial depth. The fibers typically have defined diameters and large ratios of penetration depth to fiber diameter. Specified methods for forming the composite materials have a unique ability to achieve the large ratios of penetration depth to fiber diameter.

Composite materials include a steel matrix with reinforcing carbon fiber integrated into the matrix, and having unreinforced regions suitable for stamping or other deformation. The composite materials have substantially lower density than steel, and are expected to have appreciable strength within regions having the reinforcing carbon fiber, while having greater deformability in unreinforced regions. Methods for forming composite steel composites includes combining at least two laterally spaced apart reinforcing carbon fiber components, such as a carbon fiber weave, with steel nanoparticles and sintering the steel nanoparticles in order to form a steel matrix with reinforcing carbon fiber integrated therein, and unreinforced regions located in the lateral spaces between carbon fiber components.

Composite materials include a steel matrix with reinforcing carbon fiber integrated into the matrix, and having unreinforced regions suitable for stamping or other deformation. The composite materials have substantially lower density than steel, and are expected to have appreciable strength within regions having the reinforcing carbon fiber, while having greater deformability in unreinforced regions. Methods for forming composite steel composites includes combining at least two laterally spaced apart reinforcing carbon fiber components, such as a carbon fiber weave, with steel nanoparticles and sintering the steel nanoparticles in order to form a steel matrix with reinforcing carbon fiber integrated therein, and unreinforced regions located in the lateral spaces between carbon fiber components.

Provided is a method for processing and manufacturing a metal structural material by knitting metal wires into metal screen mesh strips, tightly coiling the metal screen mesh strips to form a coiled blank body which is coated layer-by-layer and in which an outer-layer material tightly covers an inner-layer material; sintering the coiled blank body; reducing gaps within the coiled blank body material by plastic processing to reach a porosity that fulfills requirements, and manufacturing mechanical structural parts therefrom.

A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.