A sliding member (1) is formed of a sintered compact. The sintered compact includes: a base layer (3), which mainly contains an Fe-based structure and further contains 1.0 wt % to 5.0 wt % of Cu, a metal having a melting point lower than a melting point of Cu, and C; and a sliding layer (2), which is sintered together with the base layer (3) in a state of being held in contact with the base layer (3) and has a sliding surface (A). The sliding layer (2) mainly contains an Fe-based structure containing at least one kind of alloy element selected from Ni, Mo, Mn, and Cr and further contains Cu and C, and the content of Cu in the sliding layer (2) is larger than the content of Cu in the base layer.

According to one embodiment of this disclosure a core includes a first end and a second end spaced generally opposite from the first end. The core further includes a stacking axis defined between the first end and second end and a first toroidal structure located between the first end and the second end. The first toroidal structure includes a first passage extending through the first toroidal structure in a first direction that is perpendicular to and passes through the stacking axis. The core also includes a second toroidal structure located between the first toroidal structure and the second end. The second toroidal structure includes a second passage extending through the second toroidal structure in a second direction. The first direction and the second direction are oriented along the stacking axis at a non-zero degree angle with respect to each other.

A method for manufacturing a cutting insert having a through-hole that extends in a direction that is non-parallel to the main pressing direction. The method includes the steps of moving first and second punches within a die cavity toward each other along a first pressing axis and compacting a powder around a core rod into a cutting insert green body, wherein, during at least a portion of the compaction step, the core rod is turned a predetermined angle in alternating direction around its longitudinal axis.

Embodiments of a gas turbine engine rotor including stress relief features are provided, as are embodiments of method for producing a gas turbine engine rotor. In one embodiment, the method includes producing a hub preform in which a plurality of elongated sacrificial cores are embedded. Blades are attached to an outer circumference of the hub preform by, for example, bonding a blade ring to the outer circumference of the preform. The blades are spaced about the rotational axis of the gas turbine engine rotor and circumferentially interspersed with the plurality of elongated sacrificial cores. The plurality of elongated sacrificial cores are then removed from the hub preform to yield a plurality of stress distribution tunnels extending in the hub preform.

A method of removing partially sintered powder from an internal passage in a metal component formed by electron beam additive manufacturing (EBAM) includes co-forming a solid wire cutter in the passage during the EBAM forming process and removing partially sintered powder from the cavity by extracting the cutter from the cavity.

A method of removing partially sintered powder from an internal passage in a metal component formed by electron beam additive manufacturing (EBAM) includes co-forming a solid wire cutter in the passage during the EBAM forming process and removing partially sintered powder from the cavity by extracting the cutter from the cavity.

A method of making a part including a solid portion with an internal passage includes building the part using an additive manufacturing process that builds the part on a layer-by-layer basis. The solid portion of the part is formed. A solid core is formed within at least a portion of the internal passage. Forming the solid core includes forming an attachment feature and forming a shearing feature. Material that is not fused, either semi-sintered or un-sintered, is positioned between the solid portion and the solid core. A force selected from the group consisting of a tensile, compressive, vibratory, and torsional force is applied to the solid core at the attachment feature. The material is then shorn with the shearing feature.

A method of making a part including a solid portion with an internal passage includes building the part using an additive manufacturing process that builds the part on a layer-by-layer basis. The solid portion of the part is formed. A solid core is formed within at least a portion of the internal passage. Forming the solid core includes forming an attachment feature and forming a shearing feature. Material that is not fused, either semi-sintered or un-sintered, is positioned between the solid portion and the solid core. A force selected from the group consisting of a tensile, compressive, vibratory, and torsional force is applied to the solid core at the attachment feature. The material is then shorn with the shearing feature.

A method of forming a component having an internal passage defined therein is provided. The method includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed at least partially by an additive manufacturing process, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core is positioned to define the internal passage within the component.

A method of forming a component having an internal passage defined therein is provided. The method includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed at least partially by an additive manufacturing process, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core is positioned to define the internal passage within the component.