Methods for forming an electrode for use in forming a honeycomb extrusion die. The method includes forming, by means of an additive manufacturing process, an electrode includes a base having a web extending from the base. The web defines a matrix of cellular openings. The method further includes forming a secondary electrode having a plurality of pins. The plurality of pins are shaped and arranged so as to mate with the matrix of cellular openings defined by the web of the electrode. The method further includes machining the electrode using the secondary electrode to smooth surfaces of the electrode formed by the additive manufacturing process.

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.

Methods for producing final bodies that contain a fine-grained refractory complex concentrated alloy (RCCA), as well as RCCAs, intermediate materials and final bodies containing the RCCAs, and high-temperature devices formed by such final bodies. Such a method includes providing a precursor with one or more precursor compounds containing elements of an RCCA, reducing the precursor compounds in the precursor via reaction with a reducing agent so as to generate the RCCA and a compound comprising a product of the reaction between the reducing agent and the precursor compounds, generating a solid material that contains at least the RCCA, forming with the solid material a porous intermediate body, and consolidating the porous intermediate body so as to partially or completely remove the pore volume from the porous intermediate body, and in doing so yield either a denser final body or a denser film.

A method for manufacturing a component of a rotating machine comprises the steps of forming a structural inner portion by additive manufacturing from a first material; covering the structural inner portion with a protective outer portion made of a second material; the first material has a melting point higher than a second material.

Additive manufacturing method for producing moldings comprising or consisting of an element selected from the group of refractory metals, wherein refractory metal powder having an oxygen content of at least 500 mol ppm is used for the additive manufacturing method.

One exemplary embodiment of this disclosure relates to a gas turbine engine, including a component having a first portion formed using one of a casting and a forging process, and a second portion formed using an additive manufacturing process.

A method of forming a fuel cell interconnect includes depositing a Cr alloy powder, sintering the Cr alloy powder, and repeating the depositing and the sintering to form the fuel cell interconnect. The Cr alloy powder may include a pre-alloyed powder containing from about 4 wt. % to about 6 wt. % Fe, and from about 94 wt. % to about 96 wt. % Cr.

A metal powder has a chromium content of at least 90 Ma %, a nanohardness according to EN ISO 14577-1 of ≤4 GPa and/or a green strength measured according to ASTM B312-09 of at least 7 MPa at a compression pressure of 550 MPa.

Devices, systems, and methods are directed to the use of nanoparticles for improving strength fabrication of three-dimensional objects formed through layer-by-layer process in which an ink is delivery of a binder delivered onto successive layers of a powder of inorganic particles in a powder bed. More specifically, nanoparticles of inorganic material can may be introduced into one or more layers of the metal powder in the powder bed and thermally processed to facilitate sinter necking, in the powder bed, of the metal particles forming the three-dimensional object. Such sinter necking in the powder bed can may improve strength of the three-dimensional objects being fabricated and, also or instead, can may reduce the likelihood of defects associated with subsequent processing of the three-dimensional objects (e.g., slumping and shrinking in a final sintering stage and/or inadequate densification of the final part).

A liner (18) for a shaped-charge (10) that is compressively formed from a mixture of powdered metal, powdered metal binder, and a selected quantity of nanoparticle material, is used to achieve improved penetration depths during perforation of a wellbore. Exemplary nanoparticles include lead, tin, copper, molybdenum, etc. Such nanoparticles increase the density, sound speed, or acoustic impedance of the liner. In another embodiment, the added nanoparticles comprise reactive materials which, after penetration into the formation, cause secondary reactions in the perforations.