An additive manufacturing method includes using hydrogenated titanium in forming an object by additive manufacturing, the object having a first microstructure. The method includes heat treating the hydrogenated titanium and, after completing a shape of the object, dehydrogenating the object. The dehydrogenated object has a second microstructure different from the first microstructure. Also, another additive manufacturing method includes forming an object containing Ti-6Al-4V, the object having a first microstructure containing columnar structures along a build direction of the additive manufacturing and the object exhibiting mechanical property anisotropy resulting from the columnar structures. After completing a shape of the object, the method includes hydrogenating the Ti-6Al-4V, heat treating the object containing the hydrogenated titanium, and dehydrogenating the heat treated object. The method reduces mechanical property anisotropy and the dehydrogenated object has a second microstructure different from the first microstructure.

An additive manufacturing method includes using hydrogenated titanium in forming an object by additive manufacturing, the object having a first microstructure. The method includes heat treating the hydrogenated titanium and, after completing a shape of the object, dehydrogenating the object. The dehydrogenated object has a second microstructure different from the first microstructure. Also, another additive manufacturing method includes forming an object containing Ti-6Al-4V, the object having a first microstructure containing columnar structures along a build direction of the additive manufacturing and the object exhibiting mechanical property anisotropy resulting from the columnar structures. After completing a shape of the object, the method includes hydrogenating the Ti-6Al-4V, heat treating the object containing the hydrogenated titanium, and dehydrogenating the heat treated object. The method reduces mechanical property anisotropy and the dehydrogenated object has a second microstructure different from the first microstructure.

In accordance with the present invention, there are provided: a soft magnetic flattened powder having an average particle diameter, excellent sheet moldability, and a high magnetic permeability; and a method for producing the soft magnetic flattened powder. The soft magnetic flattened powder according to the present invention includes an Fe—Si—Al-based alloy, an average particle diameter D.sub.50 being 30 to less than 50 μm; a coercive force Hc measured by applying a magnetic field in the longitudinal direction of the flattened powder being 176 A/m or less; the ratio of a tap density to a true density being 0.18 or less; a specific surface area BET value being 0.6 m.sup.2/g or more; the amount of contained oxygen being 0.6 mass % or less; and the BET value and oxygen value of the soft magnetic powder satisfying expression (1): [oxygen value/BET value 0.50 (excluding zero)].

In accordance with the present invention, there are provided: a soft magnetic flattened powder having an average particle diameter, excellent sheet moldability, and a high magnetic permeability; and a method for producing the soft magnetic flattened powder. The soft magnetic flattened powder according to the present invention includes an Fe—Si—Al-based alloy, an average particle diameter D.sub.50 being 30 to less than 50 μm; a coercive force Hc measured by applying a magnetic field in the longitudinal direction of the flattened powder being 176 A/m or less; the ratio of a tap density to a true density being 0.18 or less; a specific surface area BET value being 0.6 m.sup.2/g or more; the amount of contained oxygen being 0.6 mass % or less; and the BET value and oxygen value of the soft magnetic powder satisfying expression (1): [oxygen value/BET value 0.50 (excluding zero)].

Disclosed are an apparatus and method for densifying or compacting powder material in the supply bin of an additive manufacture machine to improve the quality of the object being made. For example, a removable or portable apparatus can be applied to the surface of the supply bin once the bin has been filled. The apparatus can include a vibrational component that agitates the underlying powder to compact the material. The apparatus can then be removed during the remainder of the additive manufacturing process, which then follows in its normal course. A vacuum can also be used the remove of air or other gases that are emitted during the compaction process, for example, as voids are filled during densification.

Disclosed are an apparatus and method for densifying or compacting powder material in the supply bin of an additive manufacture machine to improve the quality of the object being made. For example, a removable or portable apparatus can be applied to the surface of the supply bin once the bin has been filled. The apparatus can include a vibrational component that agitates the underlying powder to compact the material. The apparatus can then be removed during the remainder of the additive manufacturing process, which then follows in its normal course. A vacuum can also be used the remove of air or other gases that are emitted during the compaction process, for example, as voids are filled during densification.

Components made of a metal matrix composite and methods for the manufacture thereof. The metal matrix composite contains TiB.sub.2 particles, Al.sub.3Ti particles, and particles of an intermetallic compound of aluminum and at least one rare earth element dispersed in an aluminum matrix. Methods include casting a first melt to produce an ingot, remelting the ingot to form a second melt, forming a powder from the second melt using an atomization process, and fabricating a component utilizing the powder in an additive manufacturing process. The ingot and the powder include an aluminum matrix that contains dispersions of TiB.sub.2 particles and Al.sub.3Ti particles.

An amorphous soft magnetic alloy of the formula (Fe.sub.1-αTM.sub.α).sub.100-w-x-y-zP.sub.wB.sub.xL.sub.ySi.sub.z Ti.sub.pC.sub.qMn.sub.rCu.sub.s, wherein TM is Co or Ni; L is Al, Cr, Zr, Mo or Nb; 0≦α≦0.3, 2≦w≦18 at %, 2≦x≦18 at %, 15≦w+x≦23 at %, 1<y≦5 at %, 0≦z≦4 at %; p, q, r, and s represents an addition ratio such that the total mass of Fe, TM, P, B, L and Si is 100, and 0≦p≦0.3, 0≦q≦0.5, 0≦r≦2, 0≦s≦1 and r+s>0; the composition fulfills one of the following conditions: L is Cr, Zr, Mo or Nb; or L is a combination of Al and Cr, Zr, Mo or Nb, wherein 0<Al≦5 at %, 1≦Cr≦4 at %, 0<Zr≦5 at %, 2≦Mo≦5 at %, and 2≦Nb≦5 at %; the alloy has a crystallization start temperature (Tx) which is 550° C. or less, a glass transition temperature (Tg) which is 520° C. or less, and a supercooled liquid region represented by ΔTx=Tx−Tg, which is 20° C. or more.

An amorphous soft magnetic alloy of the formula (Fe.sub.1-αTM.sub.α).sub.100-w-x-y-zP.sub.wB.sub.xL.sub.ySi.sub.z Ti.sub.pC.sub.qMn.sub.rCu.sub.s, wherein TM is Co or Ni; L is Al, Cr, Zr, Mo or Nb; 0≦α≦0.3, 2≦w≦18 at %, 2≦x≦18 at %, 15≦w+x≦23 at %, 1<y≦5 at %, 0≦z≦4 at %; p, q, r, and s represents an addition ratio such that the total mass of Fe, TM, P, B, L and Si is 100, and 0≦p≦0.3, 0≦q≦0.5, 0≦r≦2, 0≦s≦1 and r+s>0; the composition fulfills one of the following conditions: L is Cr, Zr, Mo or Nb; or L is a combination of Al and Cr, Zr, Mo or Nb, wherein 0<Al≦5 at %, 1≦Cr≦4 at %, 0<Zr≦5 at %, 2≦Mo≦5 at %, and 2≦Nb≦5 at %; the alloy has a crystallization start temperature (Tx) which is 550° C. or less, a glass transition temperature (Tg) which is 520° C. or less, and a supercooled liquid region represented by ΔTx=Tx−Tg, which is 20° C. or more.

An R-T-B based permanent magnet includes R-T-B based compounds as main-phase crystal grains. R is a rare earth element. T is iron group element(s) essentially including Fe or Fe and Co. B is boron. A two-grain boundary is contained between the two adjacent main-phase crystal grains. An average grain size of the main-phase crystal grains is 0.9 μm or more and 2.8 μm or less. A thickness of the two-grain boundary is 5 nm or more and 200 nm or less.