A method for the layer-by-layer additive manufacturing of a composite material having the selective irradiation of a base material to produce a first, dense material phase and to produce a second, porous material phase, wherein the production of the first material phase and the production of the second material phase take place alternately. A correspondingly produced composite material and to a component has the composite material.

A method for manufacturing a continuous casting mold in which cracking and spalling are less likely to occur in a filling laminate. The method includes filling a plurality of concave portions formed on an inner surface of a copper-made mold copper plate or a copper alloy-made mold copper plate used for continuously casting steel at least in a region including a meniscus position of molten steel in a casting process with a metal having a thermal conductivity different from that of the mold copper plate.

A metal foam ball, several millimeters in diameter, is manufactured to have an open-pore structure to absorb fluid (e.g., gas and liquid) such as water or lubricant. As an example, a copper foam ball is manufactured via a freeze casting method using prepared oxide powder slurry where a spherical silica gel mold is used to freeze the slurry, which is subsequently dried at low temperature in vacuum and then sintered at high temperature. For improved oxidation, copper alloy foam ball or copper foam ball coated with tin can also be manufactured through the same method. For improved strength, steel, copper-nickel alloy, or titanium foam ball can also be manufactured through the same method.

A soft magnetic alloy and the like which simultaneously satisfy a high saturation magnetic flux density Bs and a high corrosion resistance. A soft magnetic alloy includes Mn and a component expressed by a compositional formula of ((Fe.sub.(1−(α+β))Co.sub.αNi.sub.β).sub.1−γX1.sub.γ).sub.(1−(a+b+c+d+e))B.sub.aP.sub.bSi.sub.cC.sub.dCr.sub.e (atomic ratio). X1 is one or more selected from Ti, Zr, Hf, Nb, Ta, Mo, W, Al, Ga, Ag, Zn, S, Ca, Mg, V, Sn, As, Sb, Bi, N, O, Au, Cu, rare earth elements, and platinum group elements. Further, a to e and α to γ are within predetermined ranges. Mn amount f (at %) is within a range of 0.002≤f<3.0. The soft magnetic alloy satisfies a corrosion potential of −630 mV or more and −50 mV or less and a corrosion current density of 0.3 μA/cm.sup.2 or more and 45 μA/cm.sup.2 or less.

The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

A method for producing hard metal powder suitable for manufacturing hard metal products including metal carbides and a binder is provided. An easy to carry out method that provides high quality hard metal powder includes: a) dissolving in water, water soluble raw materials and a binder source to form an aqueous solution, b) drying the aqueous solution to form a precursor powder having the raw materials homogenously distributed throughout the precursor powder, c) decomposing the precursor powder by heating the powder in an inert atmosphere to remove gas evolved in the decomposition of the raw materials, d) grinding the precursor powder and mixing it with a liquid media to produce a suspension, e) spray drying the suspension to agglomerate the precursor powder, and f) heat treating the agglomerated precursor powder to form a hard metal powder containing agglomerates of carbides evenly distributed and bonded to a metallic matrix.

A method of forming a high temperature sensor includes preparing a substrate having a surface from an electrically insulative material having a first coefficient of thermal expansion (CTE), preparing an electrical conductor from a metal material having a second CTE that is different from the first CTE, and creating an interface between the electrical conductor and the substrate with a CTE blending medium that is provided between the substrate and the electrical conductor. The CTE blending medium accommodates differing thermal expansion rates of the substrate and the electrical conductor at temperatures of at least 700° C.

Methods of forming metal multipod nanostructures. The methods may include providing a mixture that includes a metal acetylacetonate, a reducing agent, and a carboxylic acid. The mixture may be contacted with microwaves to form the metal multipod nanostructures. The methods may offer control over the structure and/or morphology of the metal multipod nanostructures.

Thermally configurable structural elements (e.g., aircraft components such as an aircraft winglet spar) capable of assuming at least first and second structural configurations are provided whereby the structural element includes an integral actuation mechanism may be formed of sintered shape memory alloy (SMA) particles and sintered non-SMA particles formed by an additive layer manufacturing (ALM) process, such as 3D printing. The ALM process thereby provides by at least one thermally configurable region, and at least one non-thermally configurable region which is unitarily contiguous with the at least one thermally configurable region. The at least one thermally configurable region is capable of assuming at least first and second positional orientations in response to the presence or absence of a thermal input to thereby cause the structural element to assume the at least first and second structural configurations, respectively.

In one aspect, additive manufacture techniques are described herein which enable the densification of green articles prior to further article processing. In some embodiments, a method of forming an article comprises providing a powder composition, and forming the powder composition into a green article by one or more additive manufacturing techniques. The green article is contacted with a powder pressure transfer media. The green article and powder pressure transfer media are then subjected to cold isostatic pressing (CIP) or warm isostatic pressing (WIP) at a pressure less than minimum isostatic compaction pressure of the powder pressure transfer media to provide a densified green article.