A method of additive manufacturing is disclosed, comprising using a powder comprising a first particulate component (1) with a first mean particle diameter, and a second particulate component (2) with a second mean particle diameter. The first mean particle diameter is at least twice the second mean particle diameter. The particles (2) of the second component are bonded to the particles (1) of the first component, and the first and second components comprise different materials. The powder is deposited.

Herein disclosed is a method of treating a component of a fuel cell, which includes the step of exposing the component of the fuel cell to a source of electromagnetic radiation (EMR). The component comprises a first material. The EMR has a wavelength ranging from 10 to 1500 nm and the EMR has a minimum energy density of 0.1 Joule/cm2. Preferably, the treatment process has one or more of the following effects: heating, drying, curing, sintering, annealing, sealing, alloying, evaporating, restructuring, foaming. In an embodiment, the substrate is a component in a fuel cell. Such component comprises an anode, a cathode, an electrolyte, a catalyst, a barrier layer, a interconnect, a reformer, or reformer catalyst. In an embodiment, the substrate is a layer in a fuel cell or a portion of a layer in a fuel cell or a combination of layers in a fuel cell or a combination of partial layers in a fuel cell.

Herein disclosed is a method of making a fuel cell including forming an anode, a cathode, and an electrolyte using an additive manufacturing machine. The electrolyte is between the anode and the cathode. Preferably, electrical current flow is perpendicular to the electrolyte in the lateral direction when the fuel cell is in use. Preferably, the method comprises making an interconnect, a barrier layer, and a catalyst layer using the additive manufacturing machine.

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.

An apparatus for manufacturing an article from powder material includes a canister, a sorter, a plurality of hoppers and at least one valve. The canister has a predetermined internal shape to define the shape of the powder metal article. The sorter sorts the powder material by the size of the powder particles, the shape of the powder particles and/or the flow characteristics of the powder particles. The hoppers contain powder material with different sizes of powder particles, different shapes of powder particles and/or powder particles with different flow characteristics. The hoppers are arranged to supply the sorted powder material to the canister. The at least one valve controls the proportions of the different powder materials supplied from the one or more of the different hoppers into the canister to control the packing density of the powder material in the canister at all positions in the canister.

A method of forming a gun barrel is disclosed that includes cold gas-dynamic spraying one or more coatings onto a mandrel. The method may also include heat treating the coating layer(s), contouring the outer coating layer, applying a ceramic top coating to the contoured outer coating layer of the gun barrel, and/or sealing the gun barrel with a liquid metal sealer. The method may also include removing the mandrel.

The present invention provides a powder for layer manufacturing including non-hydratable matrix particles, and water-soluble adhesive particles. The powder for layer manufacturing includes, as the water-soluble adhesive particles, polyvinyl alcohol resin particles with a saponification degree of 86.5 mol % to 89.0 mol %, an average degree of polymerization of 400 to 600, a viscosity of a 4 mass % aqueous solution at 20 C. of 4.6 mPa to 5.4 mPa, and an average particle diameter of 20 m to 60 m.

A sputtering target containing 20 at % to 40 at % of Te, 5 at % to 20 at % of Cu, 5 at % to 15 at % of Zr, and remainder being Al, wherein a structure of the sputtering target is comprise of an Al phase, a Cu phase, a CuTeZr phase, a CuTe phase and a Zr phase. The present invention aims to provide an AlTeCuZr-based alloy sputtering target capable of effectively suppressing the degradation of properties caused by compositional deviation, as well as a method of manufacturing the same.

Methods of removing oxygen from a metal are described. In one example, a method (100) can include forming a mixture (110) including a metal, a calcium de-oxygenation agent, and a salt. The mixture can be heated (120) at a de-oxygenation temperature for a period of time to reduce an oxygen content of the metal, thus forming a de-oxygenated metal. The de-oxygenation temperature can be above a melting point of the salt and below a melting point of the calcium de-oxygenation agent. The de-oxygenated metal can then be cooled (130). The de-oxygenated metal can then be leached with water and acid to remove by-products and obtain a product (140).

A powder for a conductive material according to an embodiment of the present invention includes a large number of particles that contain copper as a main component and having an average primary particle diameter of 1 nm or more and 200 nm or less. The particles contain titanium on surfaces or inside thereof, and a content of the titanium is 0.003 atomic percent or more and 0.5 atomic percent or less.