A process for producing a metal foam includes mechanically working a metallic powder such that oxide particles are finely dispersed within a metallic matrix and annealing the mechanically worked metallic powder in a vacuum the annealed metallic powder such that intraparticle porosity is formed by decomposition of the oxide particles at elevated temperature to reduce the oxide particles to metallic form and liberate the oxygen atoms in gaseous form, thereby creating porosity.

A composite material of Angstrom-scale nanowire arrays in zeolite and its fabrication methods are provided. The zeolite can be prepared by a hydrothermal method and the Angstrom-scale nanowire arrays can be prepared by using zeolite as a template. The zeolite can have porous structures with an average pore size of 0.74 nm and the plurality of nanowires can have an average diameter smaller than 1 nm and can be dispersed on internal or external surfaces of the porous structures. The Angstrom-scale nanowire arrays can be made of aluminum (Al), gallium (Ga), zinc (Zn), or carbon (C). A composite material of the Angstrom-scale aluminum (Al), gallium (Ga), or zinc (Zn) nanowire arrays in zeolite can exhibit characteristics of one-dimensional (1D) superconductor.

A composite material of Angstrom-scale nanowire arrays in zeolite and its fabrication methods are provided. The zeolite can be prepared by a hydrothermal method and the Angstrom-scale nanowire arrays can be prepared by using zeolite as a template. The zeolite can have porous structures with an average pore size of 0.74 nm and the plurality of nanowires can have an average diameter smaller than 1 nm and can be dispersed on internal or external surfaces of the porous structures. The Angstrom-scale nanowire arrays can be made of aluminum (Al), gallium (Ga), zinc (Zn), or carbon (C). A composite material of the Angstrom-scale aluminum (Al), gallium (Ga), or zinc (Zn) nanowire arrays in zeolite can exhibit characteristics of one-dimensional (1D) superconductor.

A thermal mechanical treatment method includes consolidating a powder by a severe plastic deformation process and ageing the consolidated powder at low temperature. The method may include cryomilling the powder before consolidating the powder by a severe plastic deformation process; hot isostatic pressing the consolidated powder into a dense powder before aging the consolidated powder; hot extruding the dense powder into a stock shape before aging the consolidated powder; hot-working the stock shape on a gyrating forge at a predetermined temperature before aging the consolidated powder; or heating the consolidated powder to a predetermined temperature, and maintaining the consolidated powder at the predetermined temperature for a predetermined time.

A thermal mechanical treatment method includes consolidating a powder by a severe plastic deformation process and ageing the consolidated powder at low temperature. The method may include cryomilling the powder before consolidating the powder by a severe plastic deformation process; hot isostatic pressing the consolidated powder into a dense powder before aging the consolidated powder; hot extruding the dense powder into a stock shape before aging the consolidated powder; hot-working the stock shape on a gyrating forge at a predetermined temperature before aging the consolidated powder; or heating the consolidated powder to a predetermined temperature, and maintaining the consolidated powder at the predetermined temperature for a predetermined time.

A method includes placing an additively manufactured article having one or more internal channels in a non-reactive liquid to remove remainder powder from within the one or more internal channels, wherein the non-reactive liquid is a gas at room temperature and/or pressure. Placing the additively manufactured article in the non-reactive liquid includes can include placing the additively manufactured article in liquid nitrogen.

A method includes placing an additively manufactured article having one or more internal channels in a non-reactive liquid to remove remainder powder from within the one or more internal channels, wherein the non-reactive liquid is a gas at room temperature and/or pressure. Placing the additively manufactured article in the non-reactive liquid includes can include placing the additively manufactured article in liquid nitrogen.

New types of particle feedstocks and heterogeneous grain structures are provided for rare earth permanent magnets (REPMs) and their production in a manner to significantly enhance toughness of the magnet with little or no sacrifice in the hard magnetic properties. The novel tough REPMs made from the feedstock have heterogeneous grain structures, such as bi-modal, tri-modal, multi-modal, laminated, gridded, gradient fine/coarse grain structures, or other microstructural heterogeneity and configurations, without changing the chemical compositions of magnets.

New types of particle feedstocks and heterogeneous grain structures are provided for rare earth permanent magnets (REPMs) and their production in a manner to significantly enhance toughness of the magnet with little or no sacrifice in the hard magnetic properties. The novel tough REPMs made from the feedstock have heterogeneous grain structures, such as bi-modal, tri-modal, multi-modal, laminated, gridded, gradient fine/coarse grain structures, or other microstructural heterogeneity and configurations, without changing the chemical compositions of magnets.

New types of particle feedstocks and heterogeneous grain structures are provided for rare earth permanent magnets (REPMs) and their production in a manner to significantly enhance toughness of the magnet with little or no sacrifice in the hard magnetic properties. The novel tough REPMs made from the feedstock have heterogeneous grain structures, such as bi-modal, tri-modal, multi-modal, laminated, gridded, gradient fine/coarse grain structures, or other microstructural heterogeneity and configurations, without changing the chemical compositions of magnets.