Disclosed are interfacially modified particulate and polymer composite material for use in injection molding processes, such as metal injection molding and additive process such as 3D printing. The composite material is uniquely adapted for powder metallurgy processes. Improved products are provided under process conditions through surface modified powders that are produced by extrusion, injection molding, additive processes such as 3D printing, Press and Sinter, or rapid prototyping.

A high quality porous aluminum body, which has excellent joint strength between the porous aluminum body and the aluminum bulk body, and a method of producing the porous aluminum complex, are provided. The porous aluminum complex includes: a porous aluminum body made of aluminum or aluminum alloy; and an aluminum bulk body made of aluminum or aluminum alloy, the porous aluminum body and the aluminum bulk body being joined each other. The junction between the porous aluminum body and the aluminum bulk body includes a TiAl compound. It is preferable that pillar-shaped protrusions projecting toward the outside are formed on outer surfaces of one of or both of the porous aluminum body and the aluminum bulk body, and the pillar-shaped protrusions include the junction.

A high quality porous aluminum body, which has excellent joint strength between the porous aluminum body and the aluminum bulk body, and a method of producing the porous aluminum complex, are provided. The porous aluminum complex includes: a porous aluminum body made of aluminum or aluminum alloy; and an aluminum bulk body made of aluminum or aluminum alloy, the porous aluminum body and the aluminum bulk body being joined each other. The junction between the porous aluminum body and the aluminum bulk body includes a TiAl compound. It is preferable that pillar-shaped protrusions projecting toward the outside are formed on outer surfaces of one of or both of the porous aluminum body and the aluminum bulk body, and the pillar-shaped protrusions include the junction.

A castable, moldable, or extrudable structure using a metallic base metal or base metal alloy. One or more insoluble additives are added to the metallic base metal or base metal alloy so that the grain boundaries of the castable, moldable, or extrudable structure includes a composition and morphology to achieve a specific galvanic corrosion rates partially or throughout the structure or along the grain boundaries of the structure. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The insoluble particles generally have a submicron particle size. The final structure can be enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final structure as compared to the non-enhanced structure.

Disclosed are interfacially modified particulate and polymer composite material for use in injection molding processes, such as metal injection molding and additive process such as 3D printing. The composite material is uniquely adapted for powder metallurgy processes. Improved products are provided under process conditions through surface modified powders that are produced by extrusion, injection molding, additive processes such as 3D printing, Press and Sinter, or rapid prototyping.

A high-quality porous aluminum sintered compact, which can be produced efficiently at a low cost; has an excellent dimensional accuracy with a low shrinkage ratio during sintering; and has sufficient strength, and a method of producing the porous aluminum sintered compact are provided. The porous aluminum sintered compact is the porous aluminum sintered compact that includes aluminum substrates sintered each other. The junction, in which the aluminum substrates are bonded each other, includes the TiAl compound and the eutectic element compound capable of eutectic reaction with Al. It is preferable that the pillar-shaped protrusions projecting toward the outside are formed on outer surfaces of the aluminum substrates, and the pillar-shaped protrusions include the junction.

Proposed are a porous transport layer (PTL), a composition for forming the same, and a method of forming the same. The porous transport layer contains 30 to 80 wt % of a metallic fiber-type material and 20 to 70 wt % of a metallic particle-type material, with respect to the total weight of the layer. In this case, each metal of the metallic fiber-type material and the metallic particle-type material includes a metal selected from the group consisting of titanium, zirconium, hafnium, nickel, stainless steel, and combinations thereof.

Proposed are a porous transport layer (PTL), a composition for forming the same, and a method of forming the same. The porous transport layer contains 30 to 80 wt % of a metallic fiber-type material and 20 to 70 wt % of a metallic particle-type material, with respect to the total weight of the layer. In this case, each metal of the metallic fiber-type material and the metallic particle-type material includes a metal selected from the group consisting of titanium, zirconium, hafnium, nickel, stainless steel, and combinations thereof.

An aluminum composite material (1, 2, 3, 4, 5) is a composite formed of an aluminum fiber structure (10) and a composite material (70, 80, 110). The aluminum fiber structure (10) includes aluminum fibers (20) partially bound to each other, and alumina layers 30 are formed on surfaces of the aluminum fibers (20). A plurality of alumina protrusions (40) each having a height larger than a thickness of the alumina layer (30) are formed on surfaces of the aluminum fibers (20) or the alumina layers (30). The alumina protrusions (40) and at least a part of the composite material (70, 80, 110) are in contact with each other.

An aluminum composite material (1, 2, 3, 4, 5) is a composite formed of an aluminum fiber structure (10) and a composite material (70, 80, 110). The aluminum fiber structure (10) includes aluminum fibers (20) partially bound to each other, and alumina layers 30 are formed on surfaces of the aluminum fibers (20). A plurality of alumina protrusions (40) each having a height larger than a thickness of the alumina layer (30) are formed on surfaces of the aluminum fibers (20) or the alumina layers (30). The alumina protrusions (40) and at least a part of the composite material (70, 80, 110) are in contact with each other.