A method of making a gold-titanium alloy can include preparing a powder mixture of gold source powder and titanium source powder. The method can also include consolidating the powder mixture to form a consolidated body. The consolidated body can be at least partially sintered in vacuum or a reducing atmosphere to for a gold-titanium alloy sintered article.

Another example method of producing a gold-titanium alloy can include preparing a composite metal powder having composite granules including a gold source powder and a titanium source powder within the composite granules. The composite metal powder can be consolidated to form a consolidated body. The consolidated body can be at least partially sintered to form a sintered article. The method can also include deoxygenating at least one of the composite metal powder, the consolidated body, or the sintered article at a deoxygenation temperature under a hydrogen-containing atmosphere to reduce an oxygen content.

Systems, methods, and compositions disclosed herein provide for low-oxygen metal powders. These metal powders, such as very-fine powders and spherical powders of titanium and titanium alloys, can be effectively deoxidized through use of vapor deoxidation without requiring the powder to undergo re-sizing or re-shaping subsequent to the deoxidation. Systems, methods, and compositions in accordance with the present disclosure can produce low-cost, low-oxygen, metal powders, such as very-fine powders and spherical powders of, for example, titanium and titanium alloys. Moreover, systems, methods, and compositions in accordance with the present disclosure can provide for reducing the number of processes or cost of processes required to produce these low-oxygen metal powders.

Methods and alloy systems for non-Be BMG matrix composite materials that can be used to additively manufacturing parts with superior mechanical properties, especially high toughness and strength, are provided. Alloys are directed to BMGMC materials comprising a high strength BMG matrix reinforced with properly scaled, soft, crystalline metal dendrite inclusions dispersed throughout the matrix in a sufficient concentration to resist fracture.

A process for producing a coating source for physical vapour deposition provides the coating source with a target layer formed of an at least two-phase composite which contains a metallic phase and at least one further phase and a mechanical stabilizing layer which is joined to the target layer on one side of the target layer. A first powder mixture which corresponds in terms of its composition to the at least two-phase composite and a second powder mixture which corresponds in terms of its composition to the mechanical stabilizing layer are densified hot in superposed layers. A coating source for physical vapour deposition is also provided.

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.

A method for producing a substantially spherical metal powder is described. A particulate source metal includes a primary particulate and has an average starting particle size. The particulate source metal is optionally ball milled and mixed with a binder in a solvent to form a slurry. The slurry is granulated to form substantially spherical granules, wherein each granule comprises an agglomeration of particulate source metal in the binder. The granules are debinded at a debinding temperature to remove the binder from the granules forming debinded granules. The debinded granules are at least partially sintered at a sintering temperature such that particles within each granule fuse together to form partially or fully sintered solid granules. The granules can then be optionally recovered to form a substantially spherical metal powder.

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.

Crack-free powder-based, near net shaped parts are fabricated using a die assembly and cold isostatic pressing. Soft materials are introduced on both sides of die components in order to balance compression loads applied to the die component, and thereby avoid deformation of the die component.

An nitrogen solid solution titanium sintered compact includes a matrix made of a titanium component having an -phase, nitrogen atoms dissolved as a solute of solid solution in a crystal lattice of the titanium component, and metal atoms dissolved as a solute of solid solution in the crystal lattice of the titanium component.