Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, and recycled used powder. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

A method for heat treating a powder part preform including a titanium-based alloy, wherein the method includes the heat treatment of the preform in a furnace at a predetermined temperature, wherein the preform is on a holder during the heat treatment, wherein the holder includes a zirconium-based alloy having a zirconium content greater than or equal to 95% by weight, wherein the holder material has a melting temperature higher than the predefined temperature of the heat treatment, and wherein an anti-diffusion barrier is arranged between the preform and the holder in order to prevent welding of the preform to the holder.

Disclosed herein are embodiments of mechanically alloyed powder feedstock and methods for spheroidizing them using microwave plasma processing. The spheroidized powder can be used in metal injection molding processes, hot isostatic processing, and additive manufacturing. In some embodiments, mechanical milling, such as ball milling, can be used to prepare high entropy alloys for microwave plasma processing.

In additive manufacturing operations, powders used in stereolithographic processes need to be precisely spread out in a uniform fashion at every pass of the stereolithographic process to ensure predictability in powder surface morphology. Typically, this is difficult to achieve with conventional powders because often these powders suffer from poor flowability, which may further deteriorate over time, and impairs the efficiency of the stereolithographic processes. The present disclosure describes additive manufacturing powders having improved physical characteristics such as flowability and tap density, which are less sensitive or insensitive to ambient humidity. For example, there is described a powder that includes spherical particles having a particle size distribution of less than 1000 micrometers and having a measurable flowability as determined in accordance with ASTM B213 at 75% relative humidity.

A method for producing a metallic green compact 61 relates to a method for producing the green compact 61 having at least one recess 62, including a step of subjecting a raw material powder filled in a resin mold 1 to cold isostatic pressing while placing a resin core material 11 having a shape corresponding to the recess 62 at a position corresponding to the recess 62 in the resin mold 1.

Systems and methods for developing tough hypoeutectic amorphous metal-based materials for additive manufacturing, and methods of additive manufacturing using such materials are provided. The methods use 3D printing of discrete thin layers during the assembly of bulk parts from metallic glass alloys with compositions selected to improve toughness at the expense of glass forming ability. The metallic glass alloy used in manufacturing of a bulk part is selected to have minimal glass forming ability for the per layer cooling rate afforded by the manufacturing process, and may be specially composed for high toughness.

Orthopedic implants produced by additive manufacture, followed by refinement of exterior and interior surfaces trough mechanical erosion, chemical erosion, or a combination of mechanical and chemical erosion. Surface refinement removes debris, and also produces bone-growth enhancing micro-scale and nano-scale structures.

Metal bond abrasive articles and methods of making metal bond abrasive articles via a focused beam are disclosed. In an aspect, a metal bond abrasive article includes a metallic binder material having abrasive particles retained therein, where the abrasive particles have at least one coating disposed thereon. The coating includes a metal, a metal oxide, a metal carbide, a metal nitride, a metalloid, or combinations thereof, and the at least one coating has an average thickness of 0.5 micrometers or greater. The metal bond abrasive article includes a number of layers directly bonded to each other. Metal bond abrasive articles prepared by the method can include abrasive articles having arcuate or tortuous cooling channels, abrasive segments, abrasive wheels, and rotary dental tools. Further, methods are provided, including receiving, by a manufacturing device having one or more processors, a digital object comprising data specifying a metal bond abrasive article; and generating, with the manufacturing device by an additive manufacturing process, the metal bond abrasive article based on the digital object. A system is also provided, including a display that displays a 3D model of a metal bond abrasive article; and one or more processors that, in response to the 3D model selected by a user, cause a 3D printer to create a physical object of the metal bond abrasive article.

The invention relates to an aluminum alloy includes, in mass percentages 3 to 6% titanium, 1.5 to 3% manganese, 1 to 2% iron, 1 to 2% chromium, 0.5 to 1.5% vanadium, 0.5 to 1.5% nickel, 0.2 to 1% zirconium, 0 to 0.5% cerium, 0 to 0.5% lanthanum, the remainder being aluminum and unavoidable impurities.

A Ti—Zr alloy in powder form is described. Sintered pellets containing the Ti—Zr alloy powder of the present invention, as well as capacitor anodes, are further described.