Aspects are provided for additively manufacturing a component based on direct energy deposition (DED). An apparatus may include a DED system configured to additively manufacture a part. The apparatus may further include a forging tool configured to forge a region of the part during the additive manufacturing. In various embodiments, a solid body is used opposite to the forging tool during the forgery. For example, the solid body may include a mandrel against which the region of the part is forged.

Aspects are provided for additively manufacturing a component based on direct energy deposition (DED). An apparatus may include a DED system configured to additively manufacture a part. The apparatus may further include a forging tool configured to forge a region of the part during the additive manufacturing. In various embodiments, a solid body is used opposite to the forging tool during the forgery. For example, the solid body may include a mandrel against which the region of the part is forged.

Methods for manufacturing dual phase soft magnetic components include combining a plurality of soft ferromagnetic particles with a plurality of paramagnetic particles to form a component structure, wherein the plurality of soft ferromagnetic particles each comprise an electrically insulative coating, and, heat treating the component structure to consolidate the plurality of soft ferromagnetic particles with the plurality of paramagnetic particles.

Methods for manufacturing dual phase soft magnetic components include combining a plurality of soft ferromagnetic particles with a plurality of paramagnetic particles to form a component structure, wherein the plurality of soft ferromagnetic particles each comprise an electrically insulative coating, and, heat treating the component structure to consolidate the plurality of soft ferromagnetic particles with the plurality of paramagnetic particles.

A bulk dual phase soft magnetic component having a three-dimensional magnetic flux and its manufacturing methods are described herein. The methods can include combining a first powder material with a second powder material to form a component structure, wherein the first powder material comprises a plurality of first particles each comprising a first core and a reactive coating, and wherein the second powder material comprises a plurality of second particles each comprising a second core and a non-reactive coating, and, consolidating the component structure to join the plurality of first particles with the plurality of second particles.

A bulk dual phase soft magnetic component having a three-dimensional magnetic flux and its manufacturing methods are described herein. The methods can include combining a first powder material with a second powder material to form a component structure, wherein the first powder material comprises a plurality of first particles each comprising a first core and a reactive coating, and wherein the second powder material comprises a plurality of second particles each comprising a second core and a non-reactive coating, and, consolidating the component structure to join the plurality of first particles with the plurality of second particles.

A method for heat treating a powder metallurgy nickel-base alloy article comprises placing the article in a furnace at a start temperature in the furnace that is 80° C. to 200° C. below a gamma prime solvus temperature, and increasing the temperature in the furnace to a solution temperature at a ramp rate in the range of 30° C. per hour to 70° C. per hour. The article is solution treated for a predetermined time, and cooled to ambient temperature.

A method for heat treating a powder metallurgy nickel-base alloy article comprises placing the article in a furnace at a start temperature in the furnace that is 80° C. to 200° C. below a gamma prime solvus temperature, and increasing the temperature in the furnace to a solution temperature at a ramp rate in the range of 30° C. per hour to 70° C. per hour. The article is solution treated for a predetermined time, and cooled to ambient temperature.

An alloy produced by powder metallurgy including a non-amorphous matrix. The alloy consists of, in weight % (wt. %): C 0-0.15, 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. 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.

An alloy produced by powder metallurgy including a non-amorphous matrix. The alloy consists of, in weight % (wt. %): C 0-0.15, 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. 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.