An implant is produced by fabricating first and second layers. The first layer of repeated and truncated building units is fused together to define pores. The second layer of repeated and truncated building units are fused together to define pores and fused onto the first layer of truncated building units. The first and the second layers form at least part of a porous portion of the implant. The formed porous portion is attached onto a base portion of an implant. The truncated building units of each of the first and the second layers are in the form of spatially overlapping three-dimensional shapes.

Provided is an alloyed steel powder for powder metallurgy that has excellent compressibility and enables obtaining a sintered body having improved strength as sintered. An alloyed steel powder for powder metallurgy comprises: Cu: 2.0 mass % or more and 8.0 mass % or less; Mo: more than 0.50 mass % and 2.00 mass % or less; one or both of Mn: 0.1 mass % or more and 1.0 mass % or less and Cr: 0.3 mass % or more and 3.5 mass % or less; and a balance consisting of Fe and inevitable impurities, wherein the alloyed steel powder contains particulate oxide, and a total amount of Mn and Cr in the particulate oxide is 0.15 mass % or less with respect to 100 mass % of the alloyed steel powder, and a number ratio of particulate oxide in contact with Cu of FCC structure to the particulate oxide is 50% or more.

Provided is an alloyed steel powder for powder metallurgy that has excellent compressibility and enables obtaining a sintered body having improved strength as sintered. An alloyed steel powder for powder metallurgy comprises: Cu: 2.0 mass % or more and 8.0 mass % or less; Mo: more than 0.50 mass % and 2.00 mass % or less; one or both of Mn: 0.1 mass % or more and 1.0 mass % or less and Cr: 0.3 mass % or more and 3.5 mass % or less; and a balance consisting of Fe and inevitable impurities, wherein the alloyed steel powder contains particulate oxide, and a total amount of Mn and Cr in the particulate oxide is 0.15 mass % or less with respect to 100 mass % of the alloyed steel powder, and a number ratio of particulate oxide in contact with Cu of FCC structure to the particulate oxide is 50% or more.

Production of a bulk Al-RE alloy body (product) using cast billets/ingots (cooling rates <100 C/s) or rapidly solidified Al-RE particulates (cooling rates 10.sup.2-10.sup.6° C./second) that have beneficial microstructural refinements that are further refined by subsequent consolidation to produce a consolidated bulk alloy product having excellent mechanical properties over a wide temperature range such as up to and above 230° C.

A method for manufacturing a sintered magnet includes molding a green compact formed by compacting a magnet powder by press-molding the magnet powder, the green compact forming an R—Fe—B based sintered magnet having Nd as the principal component and containing a rare earth element R, sintering the green compact by heating to a sintering temperature, so as to mold a sintered magnet, pressure molding the sintered magnet by heating to a temperature not exceeding the sintering temperature, so as to correct dimensions of the sintered magnet, and adjusting the texture of the sintered magnet by aging heat treatment using heated atmosphere produced when correcting the dimensions of the sintered magnet at a temperature not exceeding the temperature during the pressure molding.

A method for manufacturing a sintered magnet includes molding a green compact formed by compacting a magnet powder by press-molding the magnet powder, the green compact forming an R—Fe—B based sintered magnet having Nd as the principal component and containing a rare earth element R, sintering the green compact by heating to a sintering temperature, so as to mold a sintered magnet, pressure molding the sintered magnet by heating to a temperature not exceeding the sintering temperature, so as to correct dimensions of the sintered magnet, and adjusting the texture of the sintered magnet by aging heat treatment using heated atmosphere produced when correcting the dimensions of the sintered magnet at a temperature not exceeding the temperature during the pressure molding.

A monolithic substrate including a silica material fused to bulk copper is provided for coupling with electronic components, along with methods for making the same. The method includes arranging a base mixture in a die mold. The base mixture includes a bottom portion with copper micron powder and an upper portion with copper nanoparticles. The method includes arranging a secondary mixture on the upper portion of the base mixture. The secondary mixture includes a bottom portion with silica-coated copper nanoparticles and an upper portion with silica nanoparticles. The method includes heating and compressing the base mixture and the secondary mixture in the die mold at a temperature, pressure, and time sufficient to sinter and fuse the base mixture with the secondary mixture to form a monolithic substrate. The resulting monolithic substrate defines a first major surface providing thermal conductivity, and a second major surface providing an electrically resistive surface.

A monolithic substrate including a silica material fused to bulk copper is provided for coupling with electronic components, along with methods for making the same. The method includes arranging a base mixture in a die mold. The base mixture includes a bottom portion with copper micron powder and an upper portion with copper nanoparticles. The method includes arranging a secondary mixture on the upper portion of the base mixture. The secondary mixture includes a bottom portion with silica-coated copper nanoparticles and an upper portion with silica nanoparticles. The method includes heating and compressing the base mixture and the secondary mixture in the die mold at a temperature, pressure, and time sufficient to sinter and fuse the base mixture with the secondary mixture to form a monolithic substrate. The resulting monolithic substrate defines a first major surface providing thermal conductivity, and a second major surface providing an electrically resistive surface.

In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, a first plurality of particles positioned on the build platform, and a particle containment system positioned on the build platform. The particle containment system includes a particle containment wall. The particle containment wall at least partially surrounds the first plurality of particles and includes a second plurality of particles consolidated together. The particle containment wall includes a top end spaced apart from the build platform, an inner face positioned against the first plurality of particles and extending between the build platform and the top end, and an outer face that faces a substantially particle-free region, the outer face positioned opposite the inner face and extending between the build platform and the top end.

A sintered bearing is made of a sintered compact containing nickel silver (Cu—Ni—Zn) as a base. In the sintered bearing, P is not added in the sintered compact. Alternatively, a content of P in the sintered compact is less than 0.05 mass % in terms of mass ratio to a total mass. Consequently, crystal grains constituting the sintered compact can be micronized. In particular, in the sintered bearing, an average crystal particle diameter of the crystal grains constituting the sintered compact is 20 μm or less. Consequently, the mechanical strength and the vibration resisting properties can be improved, and the rotation shaft can be prevented from being damaged.