Disclosed here is a method for making a nanoporous material, comprising aerosolizing a solution comprising at least one metal salt and at least one solvent to obtain an aerosol, freezing the aerosol to obtain a frozen aerosol, and drying the frozen aerosol to obtain a nanoporous metal compound material. Further, the nanoporous metal compound material can be reduced to obtain a nanoporous metal material.

Disclosed here is a method for making a nanoporous material, comprising aerosolizing a solution comprising at least one metal salt and at least one solvent to obtain an aerosol, freezing the aerosol to obtain a frozen aerosol, and drying the frozen aerosol to obtain a nanoporous metal compound material. Further, the nanoporous metal compound material can be reduced to obtain a nanoporous metal material.

Some variations provide a system for producing a functionalized powder, comprising: an agitated pressure vessel; first particles and second particles contained within the agitated pressure vessel; a fluid contained within the agitated pressure vessel; an exhaust line for releasing the fluid from the agitated pressure vessel; and a means for recovering a functionalized powder containing the second particles disposed onto surfaces of the first particles. A preferred fluid is carbon dioxide in liquefied or supercritical form. The carbon dioxide may be initially loaded into the pressure vessel as solid carbon dioxide. The pressure vessel may be batch or continuous and is operated under reaction conditions to functionalize the first particles with the second particles, thereby producing a functionalized powder, such as nanofunctionalized metal particles in which nanoparticles act as grain refiners for a component ultimately produced from the nanofunctionalized metal particles. Methods for making the functionalized powder are also disclosed.

According to the invention, a method is provided for additively manufacturing a component, in particular a metallic component, said method having the steps of: ? providing at least one substrate (I), in particular a substrate plate, the substrate being formed from one or more metallic substrate materials which has a martensite start temperature (Ms) below 140? C., the martensite start temperature (Ms) being below the manufacturing temperature (Tp); ? building the component on a building surface (5) of the substrate (I) by layered application of at least one material at a manufacturing temperature (Tp) to form a component-substrate composite (7) over a boundary surface (6); ? after building of the component (3) is complete, cooling at least the substrate (I) in the component-substrate composite (7) to a temperature below the martensite start temperature (Ms), wherein, as a result of martensitic transformation and the associated volume expansion of the metallic substrate material, a transformation stress is induced in the substrate (I), at least in the boundary surface (6) to the component (3); and ? separating the component (3) from the substrate (I). The invention further relates to a substrate (I) for use in such a method.

According to the invention, a method is provided for additively manufacturing a component, in particular a metallic component, said method having the steps of: ? providing at least one substrate (I), in particular a substrate plate, the substrate being formed from one or more metallic substrate materials which has a martensite start temperature (Ms) below 140? C., the martensite start temperature (Ms) being below the manufacturing temperature (Tp); ? building the component on a building surface (5) of the substrate (I) by layered application of at least one material at a manufacturing temperature (Tp) to form a component-substrate composite (7) over a boundary surface (6); ? after building of the component (3) is complete, cooling at least the substrate (I) in the component-substrate composite (7) to a temperature below the martensite start temperature (Ms), wherein, as a result of martensitic transformation and the associated volume expansion of the metallic substrate material, a transformation stress is induced in the substrate (I), at least in the boundary surface (6) to the component (3); and ? separating the component (3) from the substrate (I). The invention further relates to a substrate (I) for use in such a method.

A friction member includes a stainless-steel-based sintered body having a pore, and a resin material that is present in at least one portion of an inside of the pore, wherein the resin material is a silicone-based resin material, and has a maximum absorption peak intensity ratio Ia/Ib of 0.10 or more in a spectrum acquired based on an infrared spectroscopic analysis, where Ia is a maximum absorption peak intensity caused by stretching vibration of SiH bond in a range of 2079 cm.sup.?1 to 2415 cm.sup.?1, and Ib is a maximum absorption peak intensity caused by stretching vibration of SiOSi bond in a range of 1000 cm.sup.?1 to 1070 cm.sup.?1.

A manufacturing method of alloy powder comprises a liquid film forming step, a supplying step and a dividing step. In the liquid film forming step, a high speed fluid made of coolant liquid is shaped into a liquid film which has a predetermined thickness of 0.1 mm or more and receives a predetermined acceleration of 2.0?10.sup.4G or more along a thickness direction. In the supplying step, molten alloy which is not divided into a size of the predetermined thickness or less is supplied to the liquid film. In the dividing step, the molten alloy is divided into the size of the predetermined thickness or less by the high speed fluid to make alloy particles and keeping the alloy particles in the liquid film by the predetermined acceleration so that the alloy particles are continuously cooled in the high speed fluid.

A manufacturing method of alloy powder comprises a liquid film forming step, a supplying step and a dividing step. In the liquid film forming step, a high speed fluid made of coolant liquid is shaped into a liquid film which has a predetermined thickness of 0.1 mm or more and receives a predetermined acceleration of 2.0?10.sup.4G or more along a thickness direction. In the supplying step, molten alloy which is not divided into a size of the predetermined thickness or less is supplied to the liquid film. In the dividing step, the molten alloy is divided into the size of the predetermined thickness or less by the high speed fluid to make alloy particles and keeping the alloy particles in the liquid film by the predetermined acceleration so that the alloy particles are continuously cooled in the high speed fluid.

A method for fabricating a metal foam component from an aerogel containing a polymer and nanoparticles is disclosed. The method may comprise: 1) exposing the aerogel to a reducing condition at an elevated temperature for a reaction time to provide a metal foam; and 2) using the metal foam to fabricate the metal foam component. At least one of the elevated temperature and the reaction time may be selected so that at least some ligaments of the metal foam have a desired ligament diameter or at least some pores of the metal foam have a desired pore size. The desired ligament diameter may be less than about one micron and the component may be a component of a gas turbine engine.

A method for fabricating a metal foam component from an aerogel containing a polymer and nanoparticles is disclosed. The method may comprise: 1) exposing the aerogel to a reducing condition at an elevated temperature for a reaction time to provide a metal foam; and 2) using the metal foam to fabricate the metal foam component. At least one of the elevated temperature and the reaction time may be selected so that at least some ligaments of the metal foam have a desired ligament diameter or at least some pores of the metal foam have a desired pore size. The desired ligament diameter may be less than about one micron and the component may be a component of a gas turbine engine.