The present invention is a system and method for electroplating and etching, which provides a solution to the problem of smoothing rough exterior features of a 3D printed or otherwise roughly manufactured object with rough exterior features. The core components of the invention are an acid bath with a first electrode and a target object as a second electrode which are in the acid bath. The first electrode and the target object are connected to a power source that causes a current to run in a first direction to etch the target object and in a second direction to plate on the target object. The amount of different metals dissolved in the acid solution will affect the composition of plated material on the target object.

The present invention is a system and method for electroplating and etching, which provides a solution to the problem of smoothing rough exterior features of a 3D printed or otherwise roughly manufactured object with rough exterior features. The core components of the invention are an acid bath with a first electrode and a target object as a second electrode which are in the acid bath. The first electrode and the target object are connected to a power source that causes a current to run in a first direction to etch the target object and in a second direction to plate on the target object. The amount of different metals dissolved in the acid solution will affect the composition of plated material on the target object.

An alloy which includes at least the following (in % by weight): carbon (C): 0.15%-0.25%; silicon (Si): 0.0%-0.08%; manganese (Mn): 0.03%-0.20%; chromium (Cr): 9.5%-10.5%; molybdenum (Mo): 0.4%-1.0%; tungsten (W): 1.6%-2.4%; cobalt (Co): 2.5%-3.5%; nickel (Ni): 0.0%-0.40%; boron (B): 0.003%-0.02%; nitrogen (N): 0.0%-0.40%; titanium (Ti): 0.02%-0.10%; vanadium (V): 0.10%-0.30%; niobium (Nb): 0.02%-0.08%; copper (Cu): 1.20%-2.10%; and aluminum (Al): 0.003%-0.06%, in particular 0.005%-0.04%; the remainder being iron (Fe).

A pre-alloyed powder having a composition consisting of, in weight % (wt. %): C, 0.02-0.04; Si, 0.1-0.4; Mn, 0.1-0.5; Cr, 11-13; Ni, 7-10; Cr+Ni, 19-23; Mo, 1-25; Al, 1.4-2.0; N, 0.01-0.75. Optionally, the pre-alloyed powder contains: Cu, 0.05-2.5; B, 0.002-2.0; S, 0.01-0.25; Nb, 0.01 max; Ti, 2 max; Zr, 2, max; Ta, 2 max; Hf, 2 max; Y, 2 max; Ca, 0.0003-0.009; Mg, 0.01 max; O, 0.003-0.80; and REM, 0.2 max. Fe and impurities comprise the balance.

A powder admixture useful for making a sintered valve seat insert includes a first iron-base powder and second iron-base powder wherein the first iron-base powder has a higher hardness than the second iron-base powder, the first iron-base powder including, in weight percent, 1-2% C, 10-25% Cr, 5-20% Mo, 15-25% Co, and 30-60 wt. % Fe, and the second iron-base powder including, in weight %, 1-1.5% C, 3-15% Cr, 5-7% Mo, 3-6% W, 1-1.7% V, and 60-85% Fe. The powder admixture can be sintered to form a sintered valve seat insert optionally infiltrated with copper.

Provided are maraging steel alloys having improved microstructures. Some variations provide maraging steel alloys including a base maraging steel alloy, a grain refiner, and optionally, a strengthening element. The base maraging steel alloy is surface-functionalized with the grain refiner. Other variations provide a method of method of manufacturing maraging steel including mixing a base maraging steel alloy with a grain refiner resulting in a maraging steel mixture, melting the maraging steel mixture, and solidifying the maraging steel mixture forming an equiaxed microstructure.

A method of forming an article includes producing a base powder including a plurality of base particles. Each base particle includes an external surface and a first material. The method further includes removing one or more oxides from the external surface of each base particle to form a cleaned powder including a plurality of cleaned particles. Each cleaned particle includes a cleaned external surface made of the first material. The method further includes coating the cleaned external surface of each cleaned particle with a second material having a greater oxidation resistance than the first material to form a coated powder including a plurality of coated particles. Each coated particle includes an external layer including the second material that fully covers the cleaned external surface made of the first material. The method further includes forming the article using the coated powder.

The present disclosure relates to an iron-based mixed powder having excellent uniformity, fluidity and moldability by applying polyamide as a binder, and a method for manufacturing the same. The iron-based mixed powder according to an embodiment of the present disclosure is composed of a mixture of a raw material of mixed powder in which iron-based powder and additive powder are mixed, and polyamide as a binder, wherein 0.03 to 1.50 parts by weight of the binder is mixed based on 100 parts by weight of the raw material of the mixed powder.

Methods of making metal bond abrasive articles via powder bed jetting are disclosed. Metal bond abrasive articles prepared by the method include abrasive articles having arcuate or tortuous cooling channels, abrasive segments, abrasive wheels, and rotary dental tools.

Techniques for using additive manufacturing (AM) to fabricate creep resistant ferritic/martensitic steel with improved high temperature strength are described. AM processing may be performed on Grade 91 steel powder. Beam powers from about 221 W to about 270 W may be used. Traverse rates from about 675 mm/s to about 825 mm/s may be used. Heat inputs ranging from about 55.7 J/mm.sup.3 to about 83.2 J/mm.sup.3 may be produced. Creep resistant ferritic/martensitic steel, produced according to the present disclosure, has improved strain yield strength and ductility as compared to wrought steel.