A method for forming a vehicular brake rotor involving loading a shaped metal substrate with a mixture of metal alloying components and ceramic particles in a dieheating the contents of the die while applying pressure to melt at least one of the metal components of the alloying mixture whereby to densify the contents of the die and form a ceramic particle-containing metal matrix composite coating on the metallic substrate; and cooling the resulting coated product.

A powder metal composition for a powder metal material to be compacted, sintered, and heat treated is comparable to wrought 6063 aluminum alloy. The powder metal composition consists essentially of an aluminum powder metal with no pre-alloyed alloying additions, an aluminum-silicon powder metal, an elemental magnesium powder metal, optionally an elemental tin powder metal, and optionally a ceramic addition (which is not included when calculating the weight percentages of the alloying elements). A weight percent of silicon is in a range of 0.2 to 0.6 wt % of the powder metal composition, of magnesium is in a range of 0.5 to 0.9 wt %, and of tin is in a range of 0.0 to 1.0 wt %. This powder metal is compactable to form a green compact which is further sinterable and heat treatable to provide a powder metal composition comparable to a wrought 6063 aluminum alloy and which offers exceptional thermal conductivity.

The present disclosure relates to aluminum-based products having 1-30 vol. % of a ceramic phase. The aluminum alloy products may be produced via additive manufacturing techniques to facilitate production of the aluminum-based products having the 1-30 vol. % of the ceramic phase.

The present disclosure relates to aluminum-based products having 1-30 vol. % of a ceramic phase. The aluminum alloy products may be produced via additive manufacturing techniques to facilitate production of the aluminum-based products having the 1-30 vol. % of the ceramic phase.

An aluminum-based composite material and a brake disc made of the composite material are provided. The material includes a base material and a reinforcing phase. The base material includes the following components in mass percentage: 4.0-7.0% of Cu, 0.4-1.2% of Mg, and 0.1-0.8% of Ag, with the balance being Al. The reinforcing phase can be SiC particles having a volume percentage of 10-40%.

A method of manufacturing a piece of metal alloy or of metal matrix composite materials includes making a preform by additive manufacturing by adding material in successive layers, and subjecting the preform to a forging operation taking place in a single step and between two dies with a view to obtaining the final shape of the piece.

A computer-controlled method of component manufacture is disclosed, which includes winding a thread of material around a shaping element to form a first layer formed of adjacent turns of the thread. The winding is repeated to form a second layer of adjacent turns of the thread on top of the first layer. A laser beam is then applied between adjacent turns of each layer to attach them at predetermined points.

The present disclosure relates to new metal powders for use in additive manufacturing, and aluminum alloy products made from such metal powders via additive manufacturing. The composition(s) and/or physical properties of the metal powders may be tailored. In turn, additive manufacturing may be used to produce a tailored aluminum alloy product.

A zirconium-doped aluminum powder metal and a method of making this powder metal are disclosed. The method of making includes forming an aluminumzirconium melt in which a zirconium content of the aluminumzirconium melt is less than 2.0 percent by weight. The aluminumzirconium melt then powderized to form a zirconium-doped aluminum powder metal. The powderization may occur by, for example, air atomization.

A zirconium-doped aluminum powder metal and a method of making this powder metal are disclosed. The method of making includes forming an aluminumzirconium melt in which a zirconium content of the aluminumzirconium melt is less than 2.0 percent by weight. The aluminumzirconium melt then powderized to form a zirconium-doped aluminum powder metal. The powderization may occur by, for example, air atomization.