A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

Provided is a method for producing a sliding member formed by impregnating a porous base member made of a bronze-based alloy with a resin material, the sliding member including a sliding surface where both the porous base member and the resin material are exposed, the method including: a step of preparing a back metal layer; a porous base member formation step of forming the porous base member by depositing particles of the bronze-based alloy on a surface of the back metal layer and sintering the particles; an impregnation step of impregnating the porous base member with the resin material; a deformation step of deforming an end edge of the back metal layer in a direction away from the sliding surface; and a cutting step of cutting the porous base member impregnated with the resin material to form the sliding surface.

Provided is a method for producing a sliding member formed by impregnating a porous base member made of a bronze-based alloy with a resin material, the sliding member including a sliding surface where both the porous base member and the resin material are exposed, the method including: a step of preparing a back metal layer; a porous base member formation step of forming the porous base member by depositing particles of the bronze-based alloy on a surface of the back metal layer and sintering the particles; an impregnation step of impregnating the porous base member with the resin material; a deformation step of deforming an end edge of the back metal layer in a direction away from the sliding surface; and a cutting step of cutting the porous base member impregnated with the resin material to form the sliding surface.

Carbon fiber reinforced steel matrix composites have carbon fiber impregnated in the steel matrix and chemically bonded to the steel. Chemical bonding is shown by the presence of a unique amorphous carbon layer at the carbon fiber/steel interface, and by canting of steel crystal edges adjacent to the interface. Methods for forming carbon fiber reinforce steel composites include sintering steel nanoparticles around a reinforcing carbon fiber structure, thereby chemically bonding a sintered steel matrix to the carbon fiber. This unique bonding likely contributes to enhanced strength of the composite, in comparison to metal matrix composites formed by other methods.

The present disclosure relates to a process to integrate sintered components in a laminate substrate. The disclosed process starts with providing a precursor substrate, which includes a substrate body having an opening through the substrate body, and a first foil layer. Herein, the first foil layer is formed underneath the substrate body, so as to fully cover a bottom of the opening. Next, a sinterable base material is applied into the opening and over the first foil layer, and then sintered at a first sintering temperature to create a sintered base component. A sinterable contact material is applied over the sintered base component, and then sintered at a second sintering temperature to create a sintered contact film. The sintered base component is confined within the opening by the substrate body on sides, by the first foil layer on bottom, and by the sintered contact film on top.

The present disclosure relates to a process to integrate sintered components in a laminate substrate. The disclosed process starts with providing a precursor substrate, which includes a substrate body having an opening through the substrate body, and a first foil layer. Herein, the first foil layer is formed underneath the substrate body, so as to fully cover a bottom of the opening. Next, a sinterable base material is applied into the opening and over the first foil layer, and then sintered at a first sintering temperature to create a sintered base component. A sinterable contact material is applied over the sintered base component, and then sintered at a second sintering temperature to create a sintered contact film. The sintered base component is confined within the opening by the substrate body on sides, by the first foil layer on bottom, and by the sintered contact film on top.

Methods for fabricating an interconnect for a fuel cell stack that include providing a protective layer over at least one surface of an interconnect formed by powder pressing pre-alloyed particles containing two or more metal elements and annealing the interconnect and the protective layer at elevated temperature to bond the protective layer to the at least one surface of the interconnect.

Methods for fabricating an interconnect for a fuel cell stack that include providing a protective layer over at least one surface of an interconnect formed by powder pressing pre-alloyed particles containing two or more metal elements and annealing the interconnect and the protective layer at elevated temperature to bond the protective layer to the at least one surface of the interconnect.

The present disclosure provides downhole tools, methods for three dimensional printing hardfacing on such downhole tools, and systems for implementing such methods.