A method loading powder into a mold can include immersing the mold comprising one or more microchannels into a suspension comprising the powder and a surfactant suspended in a dispersant, wherein the powder comprises particles having an average particle size of less than 100 μm, wherein the mold is substantially entirely covered by the suspension; heating the suspension having the mold immersed therein under a temperature condition suitable to lower the stability of the particles of the powder in the suspension such that the particles settle out of solution and into the one or more microchannels; and applying an ultrasonic wave to the heated suspension to further settle the particles of the powder into the one or more microchannels thereby filling the one or more microchannels of the mold with the powder.

A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.

A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.

A method for manufacturing a dust core, includes: applying energy to a surface of a soft magnetic powder coated with an insulating body containing a compound having an aluminum-oxygen bond; exposing the soft magnetic powder to an atmosphere having a dew point of −30° C. or higher and 15° C. or lower under an atmospheric pressure; and forming a molded product by pressing the soft magnetic powder at 20 MPa or more and 400 MPa or less.

A method for manufacturing a dust core, includes: applying energy to a surface of a soft magnetic powder coated with an insulating body containing a compound having an aluminum-oxygen bond; exposing the soft magnetic powder to an atmosphere having a dew point of −30° C. or higher and 15° C. or lower under an atmospheric pressure; and forming a molded product by pressing the soft magnetic powder at 20 MPa or more and 400 MPa or less.

A system and a method for fabrication of bulk nanocrystal alloys is provided. The method may include subjecting powders of at least one material to an ultrasonic vibration at a first amplitude. The method may also include heating the powders in response to the ultrasonic vibration at a first temperature elevating rate corresponding to the first amplitude, and treating the powders in a temperature range corresponding to the first temperature elevating rate. The method may further include obtaining a bulk material composed of a plurality of crystal grains, the plurality of crystal grains having an average linear dimension equal to or larger than 10 nm. The method may further include obtaining a bulk material with amorphous structure with sufficient temperature cooling rate.

A system and a method for fabrication of bulk nanocrystal alloys is provided. The method may include subjecting powders of at least one material to an ultrasonic vibration at a first amplitude. The method may also include heating the powders in response to the ultrasonic vibration at a first temperature elevating rate corresponding to the first amplitude, and treating the powders in a temperature range corresponding to the first temperature elevating rate. The method may further include obtaining a bulk material composed of a plurality of crystal grains, the plurality of crystal grains having an average linear dimension equal to or larger than 10 nm. The method may further include obtaining a bulk material with amorphous structure with sufficient temperature cooling rate.

A system and a method for fabrication of bulk nanocrystal alloys is provided. The method may include subjecting powders of at least one material to an ultrasonic vibration at a first amplitude. The method may also include heating the powders in response to the ultrasonic vibration at a first temperature elevating rate corresponding to the first amplitude, and treating the powders in a temperature range corresponding to the first temperature elevating rate. The method may further include obtaining a bulk material composed of a plurality of crystal grains, the plurality of crystal grains having an average linear dimension equal to or larger than 10 nm. The method may further include obtaining a bulk material with amorphous structure with sufficient temperature cooling rate.

A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations. Methods for generation of different periodic and non-periodic structures and joints using the process-controlled solid-state additive manufacturing system are also disclosed.

A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations. Methods for generation of different periodic and non-periodic structures and joints using the process-controlled solid-state additive manufacturing system are also disclosed.