A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a constituent layer formation step of forming a constituent layer which corresponds to a constituent region of the three-dimensional shaped article, a support layer formation step of forming a support layer which is in contact with the constituent layer and supports the constituent layer, and a sintering step of sintering the constituent layer, wherein the support layer is configured such that as compared with the volume decrement accompanying the sintering step of a space surrounded by the constituent layer from at least two directions, the volume decrement accompanying the sintering step of the support layer which supports the constituent layer in the space is larger.

A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a constituent layer formation step of forming a constituent layer which corresponds to a constituent region of the three-dimensional shaped article, a support layer formation step of forming a support layer which is in contact with the constituent layer and supports the constituent layer, and a sintering step of sintering the constituent layer, wherein the support layer is configured such that as compared with the volume decrement accompanying the sintering step of a space surrounded by the constituent layer from at least two directions, the volume decrement accompanying the sintering step of the support layer which supports the constituent layer in the space is larger.

A method of producing a three-dimensionally shaped object includes a step of equipping an additive manufacturing apparatus with a plate, a step of forming a support portion by depositing raw material powder on the plate and radiating light, a step of forming a three-dimensionally shaped object by depositing raw material powder on the support portion and radiating light, and a step of separating the three-dimensionally shaped object from the support portion. In the step of forming the support portion, a low-density support portion and a high-density support portion are formed. The low-density support portion has a lower density than a three-dimensionally shaped portion formed in the step of forming the three-dimensionally shaped object. The high-density support portion has a higher density than the low-density support portion.

A method of producing a three-dimensionally shaped object includes a step of equipping an additive manufacturing apparatus with a plate, a step of forming a support portion by depositing raw material powder on the plate and radiating light, a step of forming a three-dimensionally shaped object by depositing raw material powder on the support portion and radiating light, and a step of separating the three-dimensionally shaped object from the support portion. In the step of forming the support portion, a low-density support portion and a high-density support portion are formed. The low-density support portion has a lower density than a three-dimensionally shaped portion formed in the step of forming the three-dimensionally shaped object. The high-density support portion has a higher density than the low-density support portion.

Provided is a method for bonding dissimilar metals to each other, the method comprising: dissimilar metal layer-forming steps (P2), (P3), (P4) for supplying, to form dissimilar metal layers; a second metal layer-forming step (P5) for supplying, on the surface of the dissimilar metal layers, a filler material formed of a second metal, and heating the filler material formed of the second metal to a temperature equal to or higher than a melting point of the second metal, to form a second metal layer formed of the second metal; and a second material-to-be-bonded welding step (P6) for welding a second material to be bonded that is formed of the second metal, onto the second metal layer.

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

[Object] There is provided a porous sintered body has a uniform porosity, a high level of freedom in body formation which allows formation into varieties shapes and various levels of porosity, and a very large surface area. [Solution] The porous sintered body includes: hollow cores which follow a vanished shape of an interlaced or otherwise structured fibriform vanisher material; sintered walls 226 which extend longitudinally of the cores and obtained by sintering a first sintering powder held around the cores; and voids formed between the sintered walls. The cores and the voids communicate with each other via absent regions formed in the sintered walls. The sintered walls have surfaces formed with a sintered microparticulate layer 232 made from a material containing a second sintering powder which has a smaller diameter than the first sintering powder, and has predetermined pores 231.

[Object] There is provided a porous sintered body has a uniform porosity, a high level of freedom in body formation which allows formation into varieties shapes and various levels of porosity, and a very large surface area. [Solution] The porous sintered body includes: hollow cores which follow a vanished shape of an interlaced or otherwise structured fibriform vanisher material; sintered walls 226 which extend longitudinally of the cores and obtained by sintering a first sintering powder held around the cores; and voids formed between the sintered walls. The cores and the voids communicate with each other via absent regions formed in the sintered walls. The sintered walls have surfaces formed with a sintered microparticulate layer 232 made from a material containing a second sintering powder which has a smaller diameter than the first sintering powder, and has predetermined pores 231.

A transient liquid phase (TLP) composition includes a plurality of first high melting temperature (HMT) particles, a plurality of second HMT particles, and a plurality of low melting temperature (LMT) particles. Each of the plurality of first HMT particles have a core-shell structure with a core formed from a first high HMT material and a shell formed from a second HMT material that is different than the first HMT material. The plurality of second HMT particles are formed from a third HMT material that is different than the second HMT material and the plurality of LMT particles are formed from a LMT material. The LMT particles have a melting temperature less than a TLP sintering temperature of the TLP composition and the first, second, and third HMT materials have a melting point greater than the TLP sintering temperature.