Described herein are embodiments directed to additive manufacturing (AM), including three-dimensional (3D) printing, of metal nitride ceramics. In some embodiments herein, AM may comprise powder bed fusion (PBF) techniques. Also described herein are metal nitride ceramic components formed by AM techniques and methods for forming metal nitrides capable of being used in AM processes.

The present invention relates to a Fe-based alloy for melt-solidification-shaping containing : 0.05 mass% ≤ C ≤0.25 mass%, 0.01 mass% ≤ Si ≤ 2.0 mass%, 0.05 mass% ≤ Mn ≤ 2.5 mass%, 2.5 mass% ≤ Ni ≤ 9.0 mass%, 0.1 mass% ≤ Cr ≤ 8.0 mass%, and 0.005 mass% ≤ N ≤ 0.200 mass%, with the balance being Fe and unavoidable impurities, and satisfying: 11.5 < 15C+Mn+0.5Cr+Ni < 20.

A powder production method includes providing at least one elongated member including a ductile material; providing a rotating or vibrating cutter configured to repeatedly cut an end of the at least one elongated member to produce particles; and advancing the at least one elongated member or the cutter towards the other of the at least one elongated member or the cutter to cut the particles from the at least one elongated member to produce a powder comprising a plurality of the particles. The particles produced by the method can have a diameter ranging from about 10 μm to about 200 μm.

A powder production method includes providing at least one elongated member including a ductile material; providing a rotating or vibrating cutter configured to repeatedly cut an end of the at least one elongated member to produce particles; and advancing the at least one elongated member or the cutter towards the other of the at least one elongated member or the cutter to cut the particles from the at least one elongated member to produce a powder comprising a plurality of the particles. The particles produced by the method can have a diameter ranging from about 10 μm to about 200 μm.

A powder production method includes providing at least one elongated member including a ductile material; providing a rotating or vibrating cutter configured to repeatedly cut an end of the at least one elongated member to produce particles; and advancing the at least one elongated member or the cutter towards the other of the at least one elongated member or the cutter to cut the particles from the at least one elongated member to produce a powder comprising a plurality of the particles. The particles produced by the method can have a diameter ranging from about 10 μm to about 200 μm.

The invention relates to an encapsulated metal particle comprising a core encapsulated in a shell, wherein the core comprises a metallic substance, and wherein the shell comprises a insulating substance. The invention also relates to a polymer composition comprising a plurality of the encapsulated metal particles, a mixture comprising a plurality of encapsulated metal particles and plurality of polymer particles, and the use of the encapsulated metal particle as an additive for increasing the thermal conductivity and/or radio frequency (RF) conductivity of a matrix substance such as an adhesive.

The invention relates to an encapsulated metal particle comprising a core encapsulated in a shell, wherein the core comprises a metallic substance, and wherein the shell comprises a insulating substance. The invention also relates to a polymer composition comprising a plurality of the encapsulated metal particles, a mixture comprising a plurality of encapsulated metal particles and plurality of polymer particles, and the use of the encapsulated metal particle as an additive for increasing the thermal conductivity and/or radio frequency (RF) conductivity of a matrix substance such as an adhesive.

A method for preparing the prefabricated crack defects includes defining a defect area, defining a volume percentage of the crack defects in the defect area, adjusting the proportion of spherical powder, the proportion of hollow powder and process parameters of defect preparation according to the volume percentage of the crack defects, based on the technique of laser melting deposition, printing the defect area layer by layer by using the defect preparation powder and the process parameters of defect preparation, wherein the particle size of the defect preparation powder is between 45 μm and 150 μm, the proportion of spherical powder≥93% and the proportion of hollow powder<0.5%, the process parameters of defect preparation including: laser power of 450W-550W, scanning rate of 600 mm/min-1200 mm/min, powder feeding rate of 4 g/min-12 g/min, spot diameter of 1 mm-1.2 mm, scanning spacing of 0.5 mm-0.8 mm and layer thickness of 0.08 mm-0.2 mm.

A method for preparing prefabricated gas pore defects includes: defining a defect area, defining a volume percentage of the gas pore defects in the defect area, adjusting the proportion of satellite powder, the proportion of hollow powder and the process parameters of defect preparation according to the volume percentage of the gas pore defects, based on the technique of laser melting deposition, printing the defect area layer by layer by using the defect preparation powder and the process parameters of defect preparation, wherein the particle size of the defect preparation powder is between 45 μm and 106 μm, the proportion of satellite powder is 55-65% and the proportion of hollow powder is 2.9-3.1%, the process parameters of defect preparation comprises: laser power of 600W-1000W, scanning rate of 400 mm/min-800 mm/min, powder feeding rate of 12 g/min-20 g/min, spot diameter of 1 mm-2 mm, scanning spacing of 0.5 mm-1 mm and layer thickness of 0.15 mm-0.2 mm.

Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, recycled used powder, and gas atomized powders. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.