A syntactic metal foam composite that is substantially fully dense except for syntactic porosity is formed from a mixture of ceramic microballoons and matrix forming metal. The ceramic microballoons have a uniaxial crush strength and a much higher omniaxial crush strength. The mixture is continuously constrained while it is consolidated. The constraining force is less than the omniaxial crush strength. The substantially fully dense syntactic metal foam composite is then constrained and deformation worked at a substantially constant volume. The deformation working is typically performed at a yield strength that is adjusted by way of selecting a working temperature at which the yield strength is approximately less than the omniaxial crush strength of the included ceramic microballoons. This deformation causes at least work hardening and grain refinement in the matrix metal.

Provided is a titanium cast product made of commercially pure titanium, the titanium cast product being produced by electron-beam remelting or plasma arc melting, comprising: a melted and resolidified layer in a range of 1 mm or more in depth at a surface serving as a surface to be rolled, the melted and resolidified layer being obtained by adding one or more kinds of β stabilizer elements to the surface and melting and resolidifying the surface. An average value of β stabilizer element(s) concentration in a range of within 1 mm in depth is higher than β stabilizer element(s) concentration in a base material by, in mass %, equal to or more than 0.08 mass % and equal to or less than 1.50 mass %. As the material containing the β stabilizer element, powder, a chip, wire, or foil is used. As means for melting a surface layer, electron-beam heating and plasma arc heating are used.

Provided is a titanium cast product made of commercially pure titanium, the titanium cast product being produced by electron-beam remelting or plasma arc melting, comprising: a melted and resolidified layer in a range of 1 mm or more in depth at a surface serving as a surface to be rolled, the melted and resolidified layer being obtained by adding one or more kinds of β stabilizer elements to the surface and melting and resolidifying the surface. An average value of β stabilizer element(s) concentration in a range of within 1 mm in depth is higher than β stabilizer element(s) concentration in a base material by, in mass %, equal to or more than 0.08 mass % and equal to or less than 1.50 mass %. As the material containing the β stabilizer element, powder, a chip, wire, or foil is used. As means for melting a surface layer, electron-beam heating and plasma arc heating are used.

Disclosed are an aluminum-scandium alloy target with high scandium content and a preparation method thereof. The method comprises: preparing aluminum and scandium; melting the scandium; mixing the aluminum into the scandium, smelting and cooling to obtain an aluminum-scandium alloy through a plurality of cycles; ball-milling the alloy to obtain alloy powder and drying in vacuum, then pre-pressing and sintering in vacuum to obtain an aluminum-scandium alloy target billet; performing a thermal deformation process on the target billet to obtain the target, comprising hot forging, hot rolling and finish machining. In the present disclosure, the target has more uniform structure and chemical composition, higher relative density (up to 99.0% or more), finer grain size and higher ductility; reduce defects of shrinkage cavity and porosity, save material cost, solve problem of alloys with high brittleness, unable to process targets, meeting the requirements on wiring materials for large-scale integrated circuits.

Disclosed are an aluminum-scandium alloy target with high scandium content and a preparation method thereof. The method comprises: preparing aluminum and scandium; melting the scandium; mixing the aluminum into the scandium, smelting and cooling to obtain an aluminum-scandium alloy through a plurality of cycles; ball-milling the alloy to obtain alloy powder and drying in vacuum, then pre-pressing and sintering in vacuum to obtain an aluminum-scandium alloy target billet; performing a thermal deformation process on the target billet to obtain the target, comprising hot forging, hot rolling and finish machining. In the present disclosure, the target has more uniform structure and chemical composition, higher relative density (up to 99.0% or more), finer grain size and higher ductility; reduce defects of shrinkage cavity and porosity, save material cost, solve problem of alloys with high brittleness, unable to process targets, meeting the requirements on wiring materials for large-scale integrated circuits.

A method of titanium wire additive manufacturing is disclosed. The method may comprise mixing a plurality of powdered metals comprising titanium, iron, vanadium, and aluminum to produce a powder blend, sintering the powder blend to form a billet, performing a wire forming operation to produce a worked wire, heat treating the worked wire to produce a heat treaded wire, loading the heat treated wire into a wirefeed additive manufacturing machine, and producing a metallic component from the heat treated wire. The titanium may be a titanium hydride powder.

A method of titanium wire additive manufacturing is disclosed. The method may comprise mixing a plurality of powdered metals comprising titanium, iron, vanadium, and aluminum to produce a powder blend, sintering the powder blend to form a billet, performing a wire forming operation to produce a worked wire, heat treating the worked wire to produce a heat treaded wire, loading the heat treated wire into a wirefeed additive manufacturing machine, and producing a metallic component from the heat treated wire. The titanium may be a titanium hydride powder.

Aspects are provided for additively manufacturing a component based on direct energy deposition (DED). An apparatus may include a DED system configured to additively manufacture a part. The apparatus may further include a forging tool configured to forge a region of the part during the additive manufacturing. In various embodiments, a solid body is used opposite to the forging tool during the forgery. For example, the solid body may include a mandrel against which the region of the part is forged.

Aspects are provided for additively manufacturing a component based on direct energy deposition (DED). An apparatus may include a DED system configured to additively manufacture a part. The apparatus may further include a forging tool configured to forge a region of the part during the additive manufacturing. In various embodiments, a solid body is used opposite to the forging tool during the forgery. For example, the solid body may include a mandrel against which the region of the part is forged.

Disclosed are a rolled (FeCoNiCrR.sub.n/Al)-2024Al composite panel and a preparation method therefor. The preparation method involves taking pure aluminum as a matrix, adding an FeCoNiCrR.sub.n medium-entropy alloy with a high strength and toughness as an reinforcing phase to prepare an FeCoNiCrR.sub.n/Al composite material, then laminating the FeCoNiCrR.sub.n/Al composite material with aluminum alloy 2024, and preparing the (FeCoNiCrR.sub.n/Al)-2024Al composite board by means of hot-rolling recombination, which solves the problem that high-strength aluminum matrix composites (AMCs) are prone to instantaneous breakability and low ductility, thereby improving the overall performance of the material. The present disclosure adopts microwave sintering (MWS) to fabricate a medium-entropy alloy-reinforced AMC, and adopts hot-roll bonding to fabricate the (FeCoNiCrR.sub.n/Al)-2024Al metal composite panel. The composite panel fabricated by the present disclosure has excellent comprehensive mechanical properties, and has high application values for promoting the application of modern lightweight and high-efficiency industrial materials in aerospace, new energy vehicles, and the like.