A gear includes a multiple of gear teeth that extend from an outer portion of a rim about an axis and an inner portion of the rim about the axis, the inner portion of the rim additive manufactured.

Provided is an insert adapter for direct ink writing printers (DIW) and methods of fiber alignment in direct ink writing. The insert adapter is sized to fit snugly inside a print barrel DIW 3D printer. The adapter includes channels. The DIW printer with insert adapter, can be used in a passive method for microfiber alignment in DIW printing. The method includes feeding a non-Newtonian ink including microfibers through the print barrel such that the ink flows into the channels of the insert adapter before exiting through a print nozzle, causing the microfibers to align along the direction of ink flow.

Provided is an insert adapter for direct ink writing printers (DIW) and methods of fiber alignment in direct ink writing. The insert adapter is sized to fit snugly inside a print barrel DIW 3D printer. The adapter includes channels. The DIW printer with insert adapter, can be used in a passive method for microfiber alignment in DIW printing. The method includes feeding a non-Newtonian ink including microfibers through the print barrel such that the ink flows into the channels of the insert adapter before exiting through a print nozzle, causing the microfibers to align along the direction of ink flow.

A sintered body manufacturing method includes: a preparation step of preparing a raw material powder containing an iron-based metal powder; a molding step of subjecting the raw material powder to uniaxial pressing using a die to produce a green compact having an overall average relative density of 93% or more; a machining step of machining the green compact to produce a machined compact; and a sintering step of sintering the machined compact to obtain a sintered body.

The present invention provides an alloy, an alloy powder, an alloy member, and a composite member which are excellent in corrosion resistance and wear resistance, have crack resistance, and are suitable for an additive manufacturing method and the like. An alloy and an alloy powder include, by mass %, Cr: 18 to 22%, Mo: 18 to 28%, Ta: 1.5 to 57%, C: 1.0 to 2.5%, Nb: 0 to 42%, Ti: 0 to 15%, V: 0 to 27%, Zr: 0 to 29%, and a remainder consisting of Ni and unavoidable impurities, where a molar ratio of (Ta+0.7Nb+Ti+0.6V+Zr)/C=0.5 to 1.5 is satisfied. An alloy member is an additively manufactured product or a cast having such a solidification structure, and the solidification structure is a dendrite-like crystal structure having a metal phase having a face-centered cubic structure and carbides.

It has been found that duplex monolithic parts can be manufactured in high volume at low cost by using powder metal technology to mold and sinter an inner component of the part into an outer component of the part. This technique reduces the cost of manufacturing intricate metal products by taking advantage of the attributes of powder metal technology in making the inner component of the part. The outer component of the part can be wrought machined, stamped or forged, or made by double press double sinter or forging a powder metal component of the part. In any case, this technique can beneficially be used in making a wide variety of toroid parts, such as gears, clutches, sprags, bearing races, one-way diodes, and the like.

The invention relates to a method for producing at least one gear, in particular a helically toothed gear, wherein the gear is produced from a gear blank pressed and sintered with an oversize in the region of the set of teeth, wherein the gear blank has two opposite end faces and a circumference. In the method, the gear blank is clamped in a clamping means. The gear blank is compressed in the region of the oversize by means of the engagement of at least one circumferential tool having a set of mating teeth that engages with the set of teeth of the gear blank, wherein the gear blank is radially clamped over the circumference by the clamping means at both end faces during the compression of the gear blank, wherein each individual tooth of the set of teeth of the gear blank is supported by the clamping means substantially over the entire tooth height. In this way, the quality of the set of teeth can be improved. The invention further relates to a device and to a clamping means.

Embodiments of the invention relate to methods of making articles having portions of polycrystalline diamond bonded to a surface of a substrate and polycrystalline diamond compacts made using the same. In an embodiment, a molding technique is disclosed for forming cutting tools comprising polycrystalline diamond portions bonded to the outer surface of a substrate.

The present invention provides a method of manufacturing combination gears and compound gears having challenging geometries using powder metal technology. This method allows for the production of combination gears and compound gears having any combination of straight or helical gear faces even in cases where the smaller gear intersects the flange of the larger gear creating an inside corner. The subject invention more specifically relates to a method for manufacturing a combination gear or a compound gear having a larger diameter gear face and a smaller diameter gear face, said method comprising molding a powder metal composition into a green preform having the smaller diameter gear face and a larger diameter cylindrical blank face, and subsequently machining the larger diameter cylindrical blank face into the larger diameter gear face.

Embodiments of the invention relate to methods of making articles having portions of polycrystalline diamond bonded to a surface of a substrate and polycrystalline diamond compacts made using the same. In an embodiment, a molding technique is disclosed for forming cutting tools comprising polycrystalline diamond portions bonded to the outer surface of a substrate.