The invention provides a catalyst enhanced MgAl-based hydrogen storage material, which is prepared by the following method: provide Mg and Al metal raw materials: weigh the Mg and Al metal raw materials according to a molar ratio of Mg: Al=(16-18): (11-13); perform the first vacuum melting on the Mg and Al metal raw materials; and crush the primary Mg alloy ingots to obtain the primary Mg alloy blocks; provide Ti, Zr and V metal raw materials weigh the primary Mg alloy blocks, and the Ti, Zr and V metal raw materials; perform ball milling treatment to obtain composite metal powder; press the composite metal powder into the loose alloy ingots; perform hot pressing treatment on the loose alloy ingots to obtain the dense alloy ingots, perform heat treatment on the dense alloy ingot; and wire cut the dense alloy ingots after heat treatment.

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.

The present invention relates to a Si-containing high-strength and low-modulus medical titanium alloy, and an additive manufacturing method and use thereof. The additive manufacturing method comprises alloy ingredient design, powder preparation, model construction and substrate preheating, and additive manufacturing molding; wherein the Si-containing high-strength and low-modulus medical titanium alloy is designed in the ingredient proportion of Ti 60-70 at. %, Nb 16-24 at. %, Zr 4-14 at. %, Ta 1-8 at. %, Si 0.1-5 at. %. The principle of the present invention is design of a medical ?-type titanium alloy having high-strength and low-modulus and good biocompatibility by using d-electron theory; reducing the difference of thermal expansion between the silicide and the ?-Ti phase by preheating, and at the same time, ensuring that there is a sufficient degree of cooling in the additive manufacturing process to promote the transition of the alloy from the divorced eutectic reaction to the precipitation reaction, thereby solving the common problems, such as the deterioration of mechanical properties caused by the continuous distribution of the Si-containing phase along the grain boundary and the cracking caused by the difference of thermal expansion coefficient between different phases.

There is provided a titanium alloy sintered part in which the oxygen content is reduced and the fatigue strength is enhanced, and a method for producing the titanium alloy sintered part. The method for producing a titanium alloy sintered part by a metal injection molding method includes a mixing process of producing a compound of a metal powder and a binder, an injection process of subjecting the compound to injection molding to produce a green part, a degreasing process of degreasing the green part to remove the binder, and a sintering process of sintering the green part from which the binder was removed to obtain a sintered body, and the sintering process is performed at a sintering temperature of 800 to 995? C. for a sintering time of 6 to 200 hours.

A method for manufacturing a wrought metallic article from metallic-powder compositions comprises steps of (1) compacting the metallic-powder composition to yield a compact, having a surface, a cross-sectional area, and a relative density of less than 100 percent, (2) reducing the cross-sectional area of the compact via an initial forming pass of a rotary incremental forming process so that the compact has a decreased cross-sectional area, and (3) reducing the decreased cross-sectional area of the compact via a subsequent forming pass of the rotary incremental forming process by a greater percentage than that, by which the cross-sectional area of the compact was reduced during the initial forming pass.

A process is provided to remove a selective amount of material from a metal part fabricated by additive manufacturing in a self-terminating manner. The process can be used to remove support structures and trapped powder from a metal part as well as to smooth surfaces of a 3D printed metal part. In one embodiment, selected surfaces of the metal part are treated to make the selected surfaces at least one of mechanically and chemically unstable. The unstable portion of the metal support can then be removed chemically, electrochemically, with a pressure differential, and/or through vapor-phase etching. In one embodiment, the metal part may comprise one or more of an aluminum alloy, a titanium alloy, and a copper alloy. The process can be used to modify any fluid or vapor-accessible regions and surfaces of a 3D printed metal part.

A metal component is disclosed. The metal component has a first dimension greater than 5 mm, and a second dimension greater than 5 mm. The metal component may include where the alloy includes titanium, aluminum, vanadium, carbon, nitrogen, and oxygen. The alloy may include zirconium, titanium, copper, nickel, and beryllium. The metal component is not die-cast, melt-spun, or forged. An ejector and a method for jetting the metal component is also disclosed.

Some variations provide a process for additive manufacturing of a nanofunctionalized metal alloy, comprising: providing a nanofunctionalized metal precursor containing metals and grain-refining nanoparticles; exposing a first amount of the nanofunctionalized metal precursor to an energy source for melting the precursor, thereby generating a first melt layer; solidifying the first melt layer, thereby generating a first solid layer; and repeating many times to generate a plurality of solid layers in an additive-manufacturing build direction. The additively manufactured, nanofunctionalized metal alloy has a microstructure with equiaxed grains. Other variations provide an additively manufactured, nanofunctionalized metal alloy comprising metals selected from aluminum, iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; and grain-refining nanoparticles selected from zirconium, tantalum, niobium, titanium, or oxides, nitrides, hydrides, carbides, or borides thereof, wherein the additively manufactured, nanofunctionalized metal alloy has a microstructure with equiaxed grains.

Provided is a method for manufacturing a porous metal body, which can manufacture a porous metal body with a suppressed variation in thickness in spite of using a molding plate having a relatively thin thickness multiple times. The method for manufacturing a porous metal body includes a plurality of steps including: a depositing step of depositing metal powder in a dry process onto a molding plate 100 made of carbon, the molding plate 100 having a thickness of 30 mm or less and an area of a surface for depositing the metal powder of 36 cm.sup.2 or more; after the depositing step, a sintering step of sintering the metal powder on the molding plate 100, wherein the plurality of steps are performed using the same molding plate 100, and wherein at least one step of the plurality of steps further includes, between the depositing step and the sintering step, a thickness adjusting step of adjusting a thickness of a deposited layer of the metal powder on the molding plate 100 while flattening the surface 105 of the molding plate 100.

The technologies disclosed herein relate to systems and methods of manufacturing an alloy. In accordance with various embodiments, the alloy produced via the disclosed systems and/or methods include engineering of duplex microstructures in the alloy to improve poor mechanical performance of additive manufactured metals. In various embodiments, the alloy may be subjected to thermo-mechanical treatment where simultaneous heat and pressure is applied with a deliberately high density of fusion defects. In accordance with various embodiments, the systems and methods disclosed in the present application have the potential to improve damage tolerance of critical structures experiencing fatigue loading and impact loading.