A method of 3D printing a metal or alloy product includes providing a layer of a powder bed which comprises a compound of a first metal, and optionally also said first metal in elemental form and/or optionally other elemental metal(s) which are suitable for alloying with said first metal; jetting a functional binder onto selected parts of said layer, wherein said functional binder infiltrates into pores in the powder bed, reacts with said compound of a first metal to form said first metal in elemental form, and locally fuses elemental metal particles of the powder bed in situ, sequentially repeating said steps of applying a layer of powder on top and selectively jetting functional binder, multiple times, to provide a powder bed bonded at selected locations by printed functional binder and; taking the resultant bound 3D structure out of the powder bed.

A compositionally-graded structure including a body having a first major surface and a second major surface opposed from the first major surface along a thickness axis, the body including a metallic component and a ceramic component, wherein a concentration of the ceramic component in the body is a function of location within the body along the thickness axis, wherein transitions of the concentration of the ceramic component in the body are continuous such that distinct interfaces are not macroscopically established within the body, and wherein the concentration of the ceramic component is at least 95 percent by volume at at least one location within the body along the thickness axis.

Components made of a metal matrix composite and methods for the manufacture thereof. The metal matrix composite contains TiB.sub.2 particles, Al.sub.3Ti particles, and particles of an intermetallic compound of aluminum and at least one rare earth element dispersed in an aluminum matrix. Methods include casting a first melt to produce an ingot, remelting the ingot to form a second melt, forming a powder from the second melt using an atomization process, and fabricating a component utilizing the powder in an additive manufacturing process. The ingot and the powder include an aluminum matrix that contains dispersions of TiB.sub.2 particles and Al.sub.3Ti particles.

New aluminum alloys having iron, vanadium, silicon, and copper, and with a high volume of ceramic phase therein are disclosed. The new products may include from 3 to 12 wt. % Fe, from 0.1 to 3 wt. % V, from 0.1 to 3 wt. % Si, from 1.0 to 6 wt. % Cu, from 1 to 30 vol. % ceramic phase, the balance being aluminum and impurities. The ceramic phase may be homogenously distributed within the alloy matrix.

Methods for manufacturing components that include casting a first melt to produce an ingot, remelting the ingot to form a second melt, forming a powder from the second melt using an atomization process, and fabricating a component utilizing the powder in an additive manufacturing process. The ingot and the powder include an aluminum matrix that contains dispersions of TiB.sub.2 particles and Al.sub.3Ti particles and the component is a metal matrix composite having an aluminum matrix that contains dispersions of TiB.sub.2 particles and Al.sub.3Ti particles. Optionally, the metal matrix composite may include particles of an intermetallic compound of aluminum and at least one alloying element.

Provided is a nickel-based composite coating, method for producing the same and use thereof. A powder mixture is coated on the surface of a substrate to obtain a nickel-based composite coating, wherein the powder mixture comprises nickel-chromium-boron-silicon powders and barium titanate powders. The barium titanate powders are added to the nickel-based powders as a second phase to form BaTiO.sub.3—NiCrBSi metal-based ceramic composite coating. The nickel-based barium titanate composite coating has an excellent damping shock absorbing performance and gives the substrate strength as well. Comparing with the conventional coating materials, the coating obtained by the present disclosure through plasma cladding technique not only bonds with the substrate in a metallurgic way, but also has a small heat affected zone, specifically, an excellent damping shock absorbing performance. In embodiments of the present disclosure, vibration and noise generated by the cylinder head is reduced 20% by using the shock absorbing cladding coating.

A method of forming tungsten tetraboride, by combining tungsten and boron in a molar ratio of from about 1:6 to about 1:12, respectively, and firing the combined tungsten and boron in the hexagonal boron nitride crucible at a temperature of from about 1600 C to about 2000 C, to form tungsten tetraboride.

Components made of a metal matrix composite and methods for the manufacture thereof. The metal matrix composite contains TiB.sub.2 particles, Al.sub.3Ti particles, and particles of an intermetallic compound of aluminum and at least one rare earth element dispersed in an aluminum matrix. Methods include casting a first melt to produce an ingot, remelting the ingot to form a second melt, forming a powder from the second melt using an atomization process, and fabricating a component utilizing the powder in an additive manufacturing process. The ingot and the powder include an aluminum matrix that contains dispersions of TiB.sub.2 particles and Al.sub.3Ti particles.

A three-dimensional (3D) metal object manufacturing apparatus is equipped with a borate solution application system to either build support structures with a borate solution containing silica particles or to apply such a borate solution to a surface of a metal support structure prior to manufacture of a metal object feature that is supported by the support structure. The silica particles in the borate solution structure form a glassy, brittle structure on which the metal object feature is formed. This glassy, brittle structure is removed relatively easily from the object after the object is manufactured.

Implementations provide gas atomized metal matrix composite (“GAMMC”)-based feedstock for cold spray additive manufacturing (“CSAM”) enabling complex structural repairs. The feedstock is prepared by arranging a metal matrix composite (MMC) material in a gas atomization system, wherein the MMC material includes metal particles and ceramic particles. The feedstock is further prepared by performing gas atomization of the MMC material using the gas atomization system to atomize the MMC material, and producing a feedstock powder comprised of metal particles that are embedded with the ceramic particles from the atomized MMC material. The GAMMC-based feedstock comprises metallic (for binding to the substrate of the damaged part) and ceramic (for reinforcement) particles bonded together such that the ceramic particles bond directly to and within the metallic particles. GAMMC-based feedstock strengthens the repaired part and prevents degradation of the mechanical properties of the repaired part below stock specifications.