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 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.

High-density thermodynamically stable nanostructured copper-based metallic systems, and methods of making, are presented herein. A ternary high-density thermodynamically stable nanostructured copper-based metallic system includes: a solvent of copper (Cu) metal; that comprises 50 to 95 atomic percent (at. %) of the metallic system; a first solute metal dispersed in the solvent that comprises 0.01 to 50 at. % of the metallic system; and a second solute metal dispersed in the solvent that comprises 0.01 to 50 at. % of the metallic system. The internal grain size of the solvent is suppressed to no more than 250 nm at 98% of the melting point temperature of the solvent and the solute metals remain uniformly dispersed in the solvent at that temperature. Processes for forming these metallic systems include: subjecting powder metals to a high-energy milling process, and consolidating the resultant powder metal subjected to the milling to form a bulk material.

High-density thermodynamically stable nanostructured copper-based metallic systems, and methods of making, are presented herein. A ternary high-density thermodynamically stable nanostructured copper-based metallic system includes: a solvent of copper (Cu) metal; that comprises 50 to 95 atomic percent (at. %) of the metallic system; a first solute metal dispersed in the solvent that comprises 0.01 to 50 at. % of the metallic system; and a second solute metal dispersed in the solvent that comprises 0.01 to 50 at. % of the metallic system. The internal grain size of the solvent is suppressed to no more than 250 nm at 98% of the melting point temperature of the solvent and the solute metals remain uniformly dispersed in the solvent at that temperature. Processes for forming these metallic systems include: subjecting powder metals to a high-energy milling process, and consolidating the resultant powder metal subjected to the milling to form a bulk material.

A complex concentrated alloy (CCA) and/or high entropy alloy (HEA) additive manufacturing nozzle can include a nozzle body defining at least four powder channels. Each powder channel can be configured to be connected to a powder supply of a plurality of powder supplies to receive a powder from the powder supply for ejecting the powder toward a build area to form an additively manufactured article having a CCA and/or an HEA.

A complex concentrated alloy (CCA) and/or high entropy alloy (HEA) additive manufacturing nozzle can include a nozzle body defining at least four powder channels. Each powder channel can be configured to be connected to a powder supply of a plurality of powder supplies to receive a powder from the powder supply for ejecting the powder toward a build area to form an additively manufactured article having a CCA and/or an HEA.

Disclosed herein is a process that includes: (a) providing a powder blend comprising (1) one or more hydrogenated titanium powders containing around 0.2 to around 3.4 weight % of hydrogen, and (2) one or more master alloys, comprising Al, V, or a combination thereof, (b) consolidating the powder blend by compacting the powder blend to provide a green compact, (c) heating the green compact to a temperature ranging from around 400° C. to around 900° C., thereby releasing the majority or all of the hydrogen from the hydrogenated titanium, and partially sintering the green compact without fully sintering it, to obtain a partially sintered article having a density of about 60% to about 85% of theoretical density, (d) sizing the partially sintered article at a temperature at or around room temperature to obtain an sized article having a density of about 80% to about 95% of theoretical density, (e) heating the sized article in vacuum thereby sintering the article to form a sintered dense compact having a density of 99% of theoretical density or higher.

Disclosed herein is a process that includes: (a) providing a powder blend comprising (1) one or more hydrogenated titanium powders containing around 0.2 to around 3.4 weight % of hydrogen, and (2) one or more master alloys, comprising Al, V, or a combination thereof, (b) consolidating the powder blend by compacting the powder blend to provide a green compact, (c) heating the green compact to a temperature ranging from around 400° C. to around 900° C., thereby releasing the majority or all of the hydrogen from the hydrogenated titanium, and partially sintering the green compact without fully sintering it, to obtain a partially sintered article having a density of about 60% to about 85% of theoretical density, (d) sizing the partially sintered article at a temperature at or around room temperature to obtain an sized article having a density of about 80% to about 95% of theoretical density, (e) heating the sized article in vacuum thereby sintering the article to form a sintered dense compact having a density of 99% of theoretical density or higher.

Disclosed herein is a process that includes: (a) providing a powder blend comprising (1) one or more hydrogenated titanium powders containing around 0.2 to around 3.4 weight % of hydrogen, and (2) one or more master alloys, comprising Al, V, or a combination thereof, (b) consolidating the powder blend by compacting the powder blend to provide a green compact, (c) heating the green compact to a temperature ranging from around 400° C. to around 900° C., thereby releasing the majority or all of the hydrogen from the hydrogenated titanium, and partially sintering the green compact without fully sintering it, to obtain a partially sintered article having a density of about 60% to about 85% of theoretical density, (d) sizing the partially sintered article at a temperature at or around room temperature to obtain an sized article having a density of about 80% to about 95% of theoretical density, (e) heating the sized article in vacuum thereby sintering the article to form a sintered dense compact having a density of 99% of theoretical density or higher.

The invention relates to an alloy produced by powder metallurgy and having a non-amorphous matrix, the alloy consists of in weight % (wt. %): C 0-2.5 Si 0-2.5 Mn 0-15 Cr 0-25 Mo 4-35 B 0.2-2.8 optional elements, balance Fe and/or Ni apart from impurities, wherein the alloy comprises 3-35 volume % hard phase particles, the hard phase particles comprises at least one of borides, nitrides, carbides and/or combinations thereof, at least 90% of the hard phase particles have a size of less than 5 μm and at least 50% of the hard phase particles have a size in the range of 0.3-3 μm.