A metal-ceramic article and method for creating the same is disclosed in which the article has undergone machining to remove outer surface volume. The article is then treated to enhance the characteristics of at least the machined surface to be comparable to the original surface. In the disclosed application the machining does not extend to an inner layer of the article in which the article consists purely of a metal.

Elements formed from magnetic materials and their methods of manufacture are presented. Magnetic materials include a magnetic alloy material, such as, for example, an Fe-Co alloy material (e.g., the Fe-Co-V alloy Hiperco-50(R)). The magnetic alloy materials may comprise a powdered material suitable for use in additive manufacturing techniques, such as, for example direct energy deposition or laser powder bed fusion. Manufacturing techniques include the use of variable deposition time and energy to control the magnetic and structural properties of the materials by altering the microstructure and residual stresses within the material. Manufacturing techniques also include post deposition processing, such as, for example, machining and heat treating. Heat treating may include a multi-step process during which the material is heated, held and then cooled in a series of controlled steps such that a specific history of stored internal energy is created within the material. Magnetic elements may include, for example, motors, generators, solenoids and swtiches, sensors, transformers, and hall thrusters, among other elements.

Elements formed from magnetic materials and their methods of manufacture are presented. Magnetic materials include a magnetic alloy material, such as, for example, an Fe-Co alloy material (e.g., the Fe-Co-V alloy Hiperco-50(R)). The magnetic alloy materials may comprise a powdered material suitable for use in additive manufacturing techniques, such as, for example direct energy deposition or laser powder bed fusion. Manufacturing techniques include the use of variable deposition time and energy to control the magnetic and structural properties of the materials by altering the microstructure and residual stresses within the material. Manufacturing techniques also include post deposition processing, such as, for example, machining and heat treating. Heat treating may include a multi-step process during which the material is heated, held and then cooled in a series of controlled steps such that a specific history of stored internal energy is created within the material. Magnetic elements may include, for example, motors, generators, solenoids and swtiches, sensors, transformers, and hall thrusters, among other elements.

A sintered bearing includes, on an inner peripheral surface, a cylindrical portion and a one-side increased-diameter portion, which are provided so as to be continuous in the axial direction. An end portion of one side in the axial direction of the cylindrical portion and an end portion of another side in the axial direction of the increased-diameter portion coincide, and the cylindrical portion and the increased-diameter portion are molded by performing sizing on a sintered compact having a tubular shape, which is introduced into a die.

A sintered bearing includes, on an inner peripheral surface, a cylindrical portion and a one-side increased-diameter portion, which are provided so as to be continuous in the axial direction. An end portion of one side in the axial direction of the cylindrical portion and an end portion of another side in the axial direction of the increased-diameter portion coincide, and the cylindrical portion and the increased-diameter portion are molded by performing sizing on a sintered compact having a tubular shape, which is introduced into a die.

A system is provided for additively manufacturing a part. This additive manufacturing system includes a base, a solidification device and a detection device. The base is adapted to support material; e.g., powder material. The solidification device is adapted to solidify at least a portion of the supported material to form at least a portion of the part. The detection device is adapted to detect emissions produced by the solidification of at least a portion of the material.

A system is provided for additively manufacturing a part. This additive manufacturing system includes a base, a solidification device and a detection device. The base is adapted to support material; e.g., powder material. The solidification device is adapted to solidify at least a portion of the supported material to form at least a portion of the part. The detection device is adapted to detect emissions produced by the solidification of at least a portion of the material.

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

A method of creating a functionally-graded multi-material (FGM) part in multi-material additive manufacturing includes providing a part digitized into voxels, generating a lattice structure having a series of repeating unit cells, where each is the smallest nonrepeating constituent of the lattice structure and is generated by a continuous surface defined by a continuous function. The method further includes taking an inverse volume of the lattice structure within the part, creating a material gradient by varying a thickness of the surface at the boundary between the lattice structure and the inverse volume, assigning one of the two FGM component materials to the voxels in the volume occupied by the lattice structure and assigning the other to the voxels occupied by the inverse volume, outputting the voxels each with a designated material, the lattice structure and the inverse volume forming a mechanical interlock at the interface of the two component materials.