A method for manufacturing a sintered body having one or more hard constituents in a metallic binder phase, the method including the steps of forming a green body from a powder composition including at least the one or more hard constituents, the metallic binder phase, and an organic binder system, forming a pattern in a surface of the green body such as to provide a tag enabling individual identification of the green body, and sintering the green body with the tag to form a sintered body having a smaller volume than the green body. The pattern is formed such that the tag is readable after the sintering operation.

The disclosed method includes selecting a suspension ceramic or metal photocurable composition (CPC or MPC); preparing a sacrificial organic material (SOM) forming a photocurable layer destroyed by heating; for manufacturing pieces, on the working tray, forming successive layers of SOM cured by irradiation, the one or more CPC or MPC-based pieces being manufactured by machining a recess in a layer of cured SOM; depositing the CPC or MPC within the recesses; curing the CPC or MPC to obtain a hard horizontal surface level with the adjacent layer of cured SOM, when forming each recess, it is delimited by previously defined patterns, the depth(s) selected in order to ensure the continuity of the one or more pieces to be manufactured; and obtaining one or more green pieces inserted in the SOM, which are subjected to debinding by heating in order to destroy the SOM in which they are trapped.

A continuous method of manufacturing permanent magnets and the permanent magnets created thereby. A fine powder is created from a combination of magnetic metals. The powder (a metal alloy) is placed in a non-magnetic container of any desired shape which could be, for example, a tube. The metal alloy and tube are swaged while a magnetic field is applied. Once swaging is complete, the metal alloy and tube are sintered and then cooled. Instead of sintering, a bonding agent can mixed into the powder. Following cooling, the metal alloy is magnetized by placing it between poles of powerful electromagnets with the desired field direction. The process of the invention enables mass-produced, cost-effective PM products, which are more robust, easily assembled into products, enables new “wire like” shapes with arbitrary magnetization direction. The process enables mass production of permanent magnets of any desired cross section, produces permanent magnets continuously that may be cut to any length, and may, in an embodiment, result in directional magnets.

A continuous method of manufacturing permanent magnets and the permanent magnets created thereby. A fine powder is created from a combination of magnetic metals. The powder (a metal alloy) is placed in a non-magnetic container of any desired shape which could be, for example, a tube. The metal alloy and tube are swaged while a magnetic field is applied. Once swaging is complete, the metal alloy and tube are sintered and then cooled. Instead of sintering, a bonding agent can mixed into the powder. Following cooling, the metal alloy is magnetized by placing it between poles of powerful electromagnets with the desired field direction. The process of the invention enables mass-produced, cost-effective PM products, which are more robust, easily assembled into products, enables new “wire like” shapes with arbitrary magnetization direction. The process enables mass production of permanent magnets of any desired cross section, produces permanent magnets continuously that may be cut to any length, and may, in an embodiment, result in directional magnets.

A powder metal alloy composition is used in the production of a sintered powder metal insert for casting into an aluminum casting. The powder metal alloy composition includes an iron powder metal base, copper such that the copper is 3.5 weight percent or more of the powder metal alloy composition, and carbon in an amount of 0.1 to 1.0 weight percent of the powder metal alloy composition. Upon compacting and sintering the powder metal alloy composition to form the sintered powder metal insert, the sintered powder metal insert has a copper gradient that provides a higher concentration of copper on the surface of the sintered powder metal insert than in a center of the grains of the sintered powder metal insert. The higher concentration of copper at the surface of the insert enables a strong metallurgical bond to be formed with the aluminum casting during casting.

A powder metal alloy composition is used in the production of a sintered powder metal insert for casting into an aluminum casting. The powder metal alloy composition includes an iron powder metal base, copper such that the copper is 3.5 weight percent or more of the powder metal alloy composition, and carbon in an amount of 0.1 to 1.0 weight percent of the powder metal alloy composition. Upon compacting and sintering the powder metal alloy composition to form the sintered powder metal insert, the sintered powder metal insert has a copper gradient that provides a higher concentration of copper on the surface of the sintered powder metal insert than in a center of the grains of the sintered powder metal insert. The higher concentration of copper at the surface of the insert enables a strong metallurgical bond to be formed with the aluminum casting during casting.

A method of manufacturing a three-dimensional shaped object, which is a method of shaping a three-dimensional shaped object using a cutting tool configured to cut a first length in a cutting direction, includes: a first portion shaping step of stacking a shaping material to shape a first portion having a length in the cutting direction shorter than the first length; a first portion cutting step of cutting the first portion in the cutting direction by the cutting tool; and a second portion shaping step of stacking the shaping material to couple to a first end surface of the first portion in a direction opposite to the cutting direction, and to shape a second portion having a length in the cutting direction shorter than that of the first portion.

A method of manufacturing a three-dimensional shaped object, which is a method of shaping a three-dimensional shaped object using a cutting tool configured to cut a first length in a cutting direction, includes: a first portion shaping step of stacking a shaping material to shape a first portion having a length in the cutting direction shorter than the first length; a first portion cutting step of cutting the first portion in the cutting direction by the cutting tool; and a second portion shaping step of stacking the shaping material to couple to a first end surface of the first portion in a direction opposite to the cutting direction, and to shape a second portion having a length in the cutting direction shorter than that of the first portion.

The present disclosure provides a metal-ceramic composite structure and a fabrication method thereof. The metal-ceramic composite structure includes a ceramic substrate having a groove on a surface thereof; a metal member filled in the groove, including a main body made of zirconium base alloy, and a reinforcing material dispersed in the main body and selected from at least one of W, Mo, Ni, Cr, stainless steel, WC, TiC, SiC, ZrC, ZrO.sub.2, BN, Si.sub.3N.sub.4, TiN and Al.sub.2O.sub.3; a luminance value L of the metal member surface is in a range of 36.92-44.07 under a LAB Chroma system.

The present disclosure provides a metal-ceramic composite structure and a fabrication method thereof. The metal-ceramic composite structure includes a ceramic substrate having a groove on a surface thereof; a metal member filled in the groove, including a main body made of zirconium base alloy, and a reinforcing material dispersed in the main body and selected from at least one of W, Mo, Ni, Cr, stainless steel, WC, TiC, SiC, ZrC, ZrO.sub.2, BN, Si.sub.3N.sub.4, TiN and Al.sub.2O.sub.3; a luminance value L of the metal member surface is in a range of 36.92-44.07 under a LAB Chroma system.