A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

An R-T-B based permanent magnet includes R-T-B based compounds as main-phase crystal grains. R is a rare earth element. T is iron group element(s) essentially including Fe or Fe and Co. B is boron. A two-grain boundary is contained between the two adjacent main-phase crystal grains. An average grain size of the main-phase crystal grains is 0.9 μm or more and 2.8 μm or less. A thickness of the two-grain boundary is 5 nm or more and 200 nm or less.

An R-T-B based permanent magnet includes R-T-B based compounds as main-phase crystal grains. R is a rare earth element. T is iron group element(s) essentially including Fe or Fe and Co. B is boron. A two-grain boundary is contained between the two adjacent main-phase crystal grains. An average grain size of the main-phase crystal grains is 0.9 μm or more and 2.8 μm or less. A thickness of the two-grain boundary is 5 nm or more and 200 nm or less.

A method of producing a sintered magnet is disclosed herein. In some embodiments, a method of producing a sintered magnet comprises, sintering a R—Fe—B based magnetic powder to produce a sintered magnet; wherein the R is Nd, Pr, Dy, Ce or Tb, and infiltrating a eutectic alloy into the sintered magnet, wherein the eutectic alloy contains Pr, Al, Cu and Ga, and wherein infiltration the eutectic alloy includes applying the eutectic alloy to the sintered magnet and heat-treating the sintered magnet to which the eutectic alloy is applied.

A method of producing a sintered magnet is disclosed herein. In some embodiments, a method of producing a sintered magnet comprises, sintering a R—Fe—B based magnetic powder to produce a sintered magnet; wherein the R is Nd, Pr, Dy, Ce or Tb, and infiltrating a eutectic alloy into the sintered magnet, wherein the eutectic alloy contains Pr, Al, Cu and Ga, and wherein infiltration the eutectic alloy includes applying the eutectic alloy to the sintered magnet and heat-treating the sintered magnet to which the eutectic alloy is applied.

According to the present invention, there are provided processes for preparing a porous composite material comprising a metal and a two-dimensional nanomaterial. In one aspect, the processes comprise the steps of: providing a powder comprising metal particles; heating the powder such that the metal particles fuse to form a porous scaffold; and forming a two-dimensional nanomaterial on a surface of the porous scaffold by chemical vapour deposition (CVD). Also provided are materials obtainable by the present processes, and products comprising said materials.

According to the present invention, there are provided processes for preparing a porous composite material comprising a metal and a two-dimensional nanomaterial. In one aspect, the processes comprise the steps of: providing a powder comprising metal particles; heating the powder such that the metal particles fuse to form a porous scaffold; and forming a two-dimensional nanomaterial on a surface of the porous scaffold by chemical vapour deposition (CVD). Also provided are materials obtainable by the present processes, and products comprising said materials.

A compact, a superabrasive compact and a method of making the compact and superabrasive compact are disclosed. A compact may include a plurality of carbide particles, a binder, and a species. The binder may be dispersed among the plurality of tungsten carbide particles. The species may be dispersed in the compact, wherein the binder has a melting point from about 600° C. to about 1350° C. at ambient pressure. A superabrasive compact may include a diamond table and a substrate. The diamond table may be attached to the substrate. The substrate may have a binder. The melting point of the binder is from about 600° C. to about 1350° C. at high pressure from about 30 kbar to about 100 kbar.

A method of producing a microstructure of a high-alloy steel includes heating the metal stock to a temperature between 1270° C. and 1280° C., at a rate between 40° C./s and 45° C./s, followed by compression applied to the metal stock in a thixotropic process, after which the stock is cooled to ambient temperature. A microstructure is also shown, which includes undissolved metal carbides in the form of globular particles of austenite microstructure and of martensite microstructure.