Provided are a ferritic/martensitic oxide dispersion strengthened steel with increased high temperature creep resistance, including 0.02 to 0.2 wt % of carbon (C), 8 to 12 wt % of chromium (Cr), 0.1 to 0.5 wt % of yttria (Y.sub.2O.sub.3), 0.2 to 2 wt % of molybdenum (Mo), 0.01 to 0.5 wt % of titanium (Ti), 0.01 to 1 wt % of manganese (Mn), 0.01 to 0.3 wt % of vanadium (V), 0 to 0.3 wt % of zirconium (Zr), 0 to 0.5 wt % of nickel (Ni), and the remaining content of iron (Fe), and a method of manufacturing the same. The ferritic/martensitic oxide dispersion strengthened steel may be useful as a material for core structural components of a nuclear power system, ultra supercritical pressure steam generator components of a thermal power plant, or engine components of an airplane due to a high tensile strength at 700 C. and excellent creep resistance.

The present invention relates to a high speed steel with a chemical composition that comprises, in % by weight: 0.6-2.1 C 3-5 Cr 4-14 Mo max 5 W max 15 Co 0.5-4 V, balance Fe and impurities from the manufacturing of the material, which steel is powder metallurgically manufactured and has a content of Si in the range of 0.7<Si2.

The present application provides a container for use in manufacturing a metal billet from a metal powder in a hot isostatic pressing process. The container may include a top, a bottom, a wall extending between the top and the bottom, an enhanced directional consolidation feature in the wall, and a sleeve positioned about the enhanced directional consolidation feature.

An apparatus for increasing the bulk density of metal powder includes a sealed chamber, a nozzle, and a target. The sealed chamber has an inert environment. The nozzle is coupled to an inert gas source and is configured to introduce raw metal powder into a flow of the inert gas for discharge as a cold spray mixture of the raw metal powder and the inert gas into the sealed chamber. The target is housed within the sealed chamber and is configured to receive an impact of the cold spray mixture. The nozzle and the target are configured to flatten the raw metal particles into flattened metal particles in response to the cold spray mixture impacting the target.

An apparatus for increasing the bulk density of metal powder may include a sealed chamber, a nozzle, and a target. The sealed chamber may include an inert environment. The nozzle may be coupled to an inert gas source and may be configured to introduce raw metal powder into a flow of the inert gas for discharge as a cold spray mixture of the raw metal powder and the inert gas into the chamber. The target may be housed within the sealed chamber and may be configured to receive an impact of the cold spray mixture. The nozzle and the target may be configured to flatten the raw metal particles into flattened metal particles in response to the cold spray mixture impacting the target.

A method for manufacturing a metallic component including the steps of providing a capsule, which defines at least a portion of the shape of the metallic component, arranging metallic material in the capsule, sealing the capsule, subjecting the capsule to Hot Isostatic Pressing for a predetermined time, at a predetermined pressure and at a predetermined temperature, and optionally, removing the capsule. The metallic material is at least one pre-manufactured coherent body, which pre-manufactured coherent body being made of metallic powder, wherein at least a portion of the metallic powder is consolidated such that the metallic powder is held together into a pre-manufactured coherent body. At least one portion of the pre-manufactured coherent body is manufactured by Additive Manufacturing by subsequently arranging superimposed layers of metallic powder.

A method for manufacturing near net shapes of complex configuration components. The method includes mixing a plurality of powdered metals to form a blended powder; gravity sintering a sand mold filled with the blended powder to form a gravity sintered preform; and vacuum hot-pressing the gravity sintered preform to form a near net shape component.

A method for fabrication of an anisotropic magnet comprises placing magnet alloy feedstock particles in a deformable metallic container and thermomechanically working the filled container in a manner to elongate the filled container and reduce its cross-sectional area to consolidate the magnet alloy particles to an elongated shape and impart a preferential grain texture to the consolidated, elongated shape. The consolidated, elongated shape is machined to a near-final magnet shape that has a smaller dimension such as magnet length and that includes a metallic tubular skin thereon.

A method for fabrication of an anisotropic magnet comprises placing magnet alloy feedstock particles in a deformable metallic container and thermomechanically working the filled container in a manner to elongate the filled container and reduce its cross-sectional area to consolidate the magnet alloy particles to an elongated shape and impart a preferential grain texture to the consolidated, elongated shape. The consolidated, elongated shape is machined to a near-final magnet shape that has a smaller dimension such as magnet length and that includes a metallic tubular skin thereon.

A method for continuous manufacture of permanent magnets. A material sheet is formed into an open tube, having a lengthwise opening. Magnetic powder may be poured into the lengthwise opening on a continuous basis. The tube opening is then formed closed and sealed. The magnetic powder is magnetically pre-aligned by subjecting it to a first magnetic field. The tube containing the powder may be compressed into a desired shape, forming an elongated permanent magnet. After compression, the elongated magnet is magnetized by a second magnetic field in two-step process, wherein the elongated permanent magnet is subjected to a magnetic field from first magnetizing coil that is pulsed with a first electric current in a first direction, followed by a second magnetizing coil being pulsed with a second magnetizing electric current in a second direction. The elongated magnet may be formed into any arbitrary shape, such as a ring or coil.