Methodologies and manufacturing processes to manufacture components by electron beam melting additive manufacturing, particularly components of molybdenum or a molybdenum-based alloy and particularly of complex nuclear component geometries. Input parameters are provided for controlling electron beam melting additive manufacturing equipment, such as electron beam melting machines. The input parameters relate to various process steps, including build set-up, initial thermal treatment, initial layering of powder, pre-consolidation thermal treatment, consolidation, post-consolidation thermal treatment, indexing of layers, and post-build thermal treatment. The methodologies and manufacturing processes allow manufacture of components of molybdenum having a purity of ≥99.0% and a density of ≥99.75%. Metallographic cross-sections of the manufactured molybdenum components were porosity-free and crack-free.

A porous titanium-based sintered body, having a porosity of 45% to 65%, an average pore diameter of 5 μm to 15 μm, and a bending strength of 100 MPa or more. According to the present invention, a porous titanium-based sintered body having good pore diameter and porosity that are compatible with each other and having a high strength can be provided.

A porous titanium-based sintered body, having a porosity of 45% to 65%, an average pore diameter of 5 μm to 15 μm, and a bending strength of 100 MPa or more. According to the present invention, a porous titanium-based sintered body having good pore diameter and porosity that are compatible with each other and having a high strength can be provided.

The present disclosure is directed at methods of preparing rare earth-based permanent magnets having improved coercivity and remanence, the method comprising one or more steps comprising: (a) homogenizing a first population of particles of a first GBM alloy with a second population of particles of a second core alloy to form a composite alloy preform, the first GBM alloy being substantially represented by the formula: AC.sub.bR.sub.xCo.sub.yCu.sub.dM.sub.z, the second core alloy being substantially represented by the formula G.sub.2Fe.sub.14B, where AC, R, M, G, b, x, y, and z are defined; (b) heating the composite alloy preform particles to form a population of mixed alloy particles; (c) compressing the mixed alloy particles, under a magnetic field of a suitable strength to align the magnetic particles with a common direction of magnetization and inert atmosphere, to form a green body; (d) sintering the green body; and (e) annealing the sintered body. Particular embodiments include magnets comprising neodymium-iron-boron core alloys, including Nd.sub.2Fe.sub.14B.

The present disclosure is directed at methods of preparing rare earth-based permanent magnets having improved coercivity and remanence, the method comprising one or more steps comprising: (a) homogenizing a first population of particles of a first GBM alloy with a second population of particles of a second core alloy to form a composite alloy preform, the first GBM alloy being substantially represented by the formula: AC.sub.bR.sub.xCo.sub.yCu.sub.dM.sub.z, the second core alloy being substantially represented by the formula G.sub.2Fe.sub.14B, where AC, R, M, G, b, x, y, and z are defined; (b) heating the composite alloy preform particles to form a population of mixed alloy particles; (c) compressing the mixed alloy particles, under a magnetic field of a suitable strength to align the magnetic particles with a common direction of magnetization and inert atmosphere, to form a green body; (d) sintering the green body; and (e) annealing the sintered body. Particular embodiments include magnets comprising neodymium-iron-boron core alloys, including Nd.sub.2Fe.sub.14B.

A polycrystalline diamond construction has a body of polycrystalline diamond (PCD) material; and a cemented carbide substrate bonded to the body of polycrystalline material along an interface. The cemented carbide substrate has tungsten carbide particles bonded together by a binder material, the binder material comprising Co; and the tungsten carbide particles form at least around 70 weight percent and at most around 95 weight percent of the substrate. The cemented carbide substrate has a bulk volume, the bulk volume of the cemented carbide substrate having at least around 0.1 vol. % of inclusions of free carbon having a largest average size in any one or more dimensions of less than around 40 microns.

A polycrystalline diamond construction has a body of polycrystalline diamond (PCD) material; and a cemented carbide substrate bonded to the body of polycrystalline material along an interface. The cemented carbide substrate has tungsten carbide particles bonded together by a binder material, the binder material comprising Co; and the tungsten carbide particles form at least around 70 weight percent and at most around 95 weight percent of the substrate. The cemented carbide substrate has a bulk volume, the bulk volume of the cemented carbide substrate having at least around 0.1 vol. % of inclusions of free carbon having a largest average size in any one or more dimensions of less than around 40 microns.

The present invention may comprise processes, methods, and systems for powder processing aimed at and characterized in reduction of adsorbed gases, vapors, particulates, and moisture through high-temperature vacuum out-gassing by disintegrating the powder bulk or flow into separate particles. Heat may be transferred to powder particles in vacuum by multiple interactions during intimate contact with heated metal balls within a tube or other container.

The present invention may comprise processes, methods, and systems for powder processing aimed at and characterized in reduction of adsorbed gases, vapors, particulates, and moisture through high-temperature vacuum out-gassing by disintegrating the powder bulk or flow into separate particles. Heat may be transferred to powder particles in vacuum by multiple interactions during intimate contact with heated metal balls within a tube or other container.

Provided is a chamber system for solid free form fabrication, the chamber system having a deposition chamber, a service chamber and one or more loading/unloading chambers. The chamber system allows for a more efficient and cost effective process to service the deposition apparatus, load holding substrates, and unload workpieces without requiring having to adjust the atmosphere in the deposition chamber.