Methods disclosed herein include using additive manufacturing to create a joint between a first metallic material and a second metallic material that is different from the first metallic material, wherein the porosity of the joint is less than about 0.1 percent by volume measured according to ASTM B-962. The additive manufacturing can be performed such that no intermetallic brittle phase forms between the first metallic material and the second metallic material.

Methods for forming metal alloys, including refractory intermetallic alloys, and ceramic composites using reactive synthesis during additive manufacturing (AM) are provided. In the AM processes, an exothermic reaction path is used, such that the heat from the reaction drives the synthesis reaction. Using this approach, component powders that are readily available from commercial vendors or easily synthesized using conventional methods are mixed in selected amounts and subsequently reacted via AM to produce metal alloys or ceramic composites.

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.

A metallic part is disclosed. The part may comprise a functionally graded monolithic structure characterized by a variation between a first material composition of a first structural element and a second material composition of at least one of a second structural element. The first material composition may comprise an alpha-beta titanium alloy. The second material composition may comprise a beta titanium alloy.

A metal powder for additive manufacturing is used (i) which includes, as a main component, aluminum, and not less than 0.20% by mass and not more than 13% by mass of at least one alloy element other than the aluminum, selected from iron, manganese, chromium, nickel and zirconium, and (ii) in which the content of iron is less than 4.5% by mass.

Included is a method of preparing a compound for bonded magnets, the method including: coating a magnetic material having an average particle size of 10 μm or less with a thermosetting resin and a curing agent at a ratio of the equivalent weight of the curing agent to the equivalent weight of the thermosetting resin of 2 or higher and 10 or lower to obtain a coated material; granulating the coated material by compression to obtain a granulated product; milling the granulated product to obtain a milled product; and surface treating the milled product with a silane coupling agent to obtain a compound for bonded magnets, the method either including, between the granulation and the milling, heat curing the granulated product to obtain a cured product, or including, between the milling and the surface treatment, heat curing the milled product to obtain a cured product.

Nanoparticles, nanoparticle conjugates, devices for making nanoparticles and nanoparticle conjugates, and related methods of use and synthesis are described.

The present invention relates to a metal powder material containing: metal particles having a particle diameter d10 of 10 μm or more and 100 μm or less; and nanoparticles containing a metal or a metal compound, in which the particle diameter d10 is a particle diameter at which an under-sieve cumulative fraction in a mass base distribution of particle diameter reaches 10%, and the nanoparticles are adhered to or mixed with the metal particles.

An object of the invention is to provide: an alloy article that has excellent homogeneity in the alloy composition and microstructure as well as significant shape controllability, using an HEA with significant mechanical strength and high corrosion resistance; a method for manufacturing the alloy article; and a product using the alloy article. There is provided an alloy article comprising: Co, Cr, Fe, Ni, and Ti elements, each element in content of 5 to 35 atomic %; more than 0 atomic % to 8 atomic % of Mo %; and remainder substances of unavoidable impurities. And, ultrafine particles with an average diameter of 40 nm or less are dispersedly precipitated in matrix phase crystals of the alloy article.

An open-pored metal body, which is formed having a core layer (A) consisting of Ni, Co, Fe, Cu, Ag or an alloy formed having one of said chemical elements, wherein one of said chemical elements is present in the alloy at more than 25 at %, and a gradated layer (B) is formed on surfaces of the core layer (A), said gradated layer being formed by intermetallic phase or mixed crystals of Al, and a layer (C), which is formed having aluminum oxide, is formed on the gradated layer (B).