A method includes designing a part. The part includes at least one internal structure. The internal structure is designed to provide strain mitigation, energy dissipation, or impact resistance for the part during an emergency condition. The part is built by a layer-by-layer additive manufacturing process. While building the part, the internal structure is connected to the part.

There is provided a compact for a magnet which can produce a magnetic member having high coercive force. The compact for a magnet is produced by compression-molding a rare earth-iron-based alloy powder containing a plurality of particles of a rare earth-iron-based alloy containing a rare earth element and iron, wherein the rare earth-iron-based alloy satisfies configurations (a) to (c) below and has 5% by volume or more and 20% by volume or less of voids formed therein. (a) Having a structure containing 10% by mass or more and 30% by mass or less of Sm, 10% by mass or less of Mn, and the balance consisting of Fe and inevitable impurities. (b) A composition, Sm.sub.2MN.sub.xFe.sub.17-x (x=0.1 or more and 2.5 or less). (c) An average crystal grain diameter of 700 nm or less.

One example provides a method of manufacturing. The method comprises printing multiple layers comprising a metal material by an additive manufacturing technique, wherein each of the multiple layers comprises an array of cavities each having a cross-section of a polygon; and assembling at least two of the multiple layers to form an article having an array of three-dimensional hollow cells collectively having a honeycomb structure.

A blade outer airseal has a body comprising: an inner diameter (ID) surface; an outer diameter (OD) surface; a leading end; and a trailing end. The airseal body has a metallic substrate and a coating system atop the substrate along at least a portion of the inner diameter surface. At least over a first area of the inner diameter surface, the coating system comprises an abradable layer comprising a metallic matrix and a solid lubricant; and the metallic matrix comprises, by weight, ≧35% nickel, 12.0-20.0% cobalt, 5.0-15.0% aluminum, and 5.0-15.0% chromium.

A blade outer airseal has a body comprising: an inner diameter (ID) surface; an outer diameter (OD) surface; a leading end; and a trailing end. The airseal body has a metallic substrate and a coating system atop the substrate along at least a portion of the inner diameter surface. At least over a first area of the inner diameter surface, the coating system comprises an abradable layer comprising a metallic matrix and a solid lubricant; and the metallic matrix comprises, by weight, ≧35% nickel, 12.0-20.0% cobalt, 5.0-15.0% aluminum, and 5.0-15.0% chromium.

A single-piece regenerator having at least two portions, at least one of the portions having a porosity which differs from a porosity of an adjacent portion, and each of the portions of the regenerator being made of a porous rigid material with a given porosity.

A method for producing a porous element is presented. A powdery metal-ceramic composite material is produced. The composite material has a metal matrix and a ceramic portion amounting to less than 25 percent by volume. The metal matrix is at least partially oxidized to obtain a metal oxide. The metal-ceramic composite material is grinded and mixed with powdery ceramic supporting particles to obtain a metal-ceramic/ceramic mixture. The metal-ceramic/ceramic mixture is shaped into the porous element. The porous element can be used as an energy storage medium in a battery.

A method for producing a porous element is presented. A powdery metal-ceramic composite material is produced. The composite material has a metal matrix and a ceramic portion amounting to less than 25 percent by volume. The metal matrix is at least partially oxidized to obtain a metal oxide. The metal-ceramic composite material is grinded and mixed with powdery ceramic supporting particles to obtain a metal-ceramic/ceramic mixture. The metal-ceramic/ceramic mixture is shaped into the porous element. The porous element can be used as an energy storage medium in a battery.

A method of: providing an emulsion having a zinc powder and a liquid phase; drying the emulsion to form a sponge; sintering the sponge in an inert atmosphere to form a sintered sponge; heating the sintered sponge in an oxidizing atmosphere to form an oxidized sponge having zinc oxide on the surface of the oxidized sponge; and heating the oxidized sponge in an inert atmosphere at above the melting point of the zinc. A method of: providing an emulsion comprising a zinc powder and a liquid phase; placing the emulsion into a mold, wherein the emulsion is in contact with a metal substrate; and drying the emulsion to form a sponge.

A method of: providing an emulsion having a zinc powder and a liquid phase; drying the emulsion to form a sponge; sintering the sponge in an inert atmosphere to form a sintered sponge; heating the sintered sponge in an oxidizing atmosphere to form an oxidized sponge having zinc oxide on the surface of the oxidized sponge; and heating the oxidized sponge in an inert atmosphere at above the melting point of the zinc. A method of: providing an emulsion comprising a zinc powder and a liquid phase; placing the emulsion into a mold, wherein the emulsion is in contact with a metal substrate; and drying the emulsion to form a sponge.