A method of manufacturing a piece of metal alloy or of metal matrix composite materials includes making a preform by additive manufacturing by adding material in successive layers, and subjecting the preform to a forging operation taking place in a single step and between two dies with a view to obtaining the final shape of the piece.

A method of preparing silicon carbide powder is provided, which includes mixing first silicon carbide powder with a liquid silicon carbide precursor, annealing the mixture at a first temperature and converting the silicon carbide precursor to a -phase silicon carbide particulate material, and annealing the material at a second temperature and grain-growing the first silicon carbide powder to second silicon carbide powder using the -phase silicon carbide particulate material.

A permanent magnetic alloy powder includes rare earth elements, iron, boron, aluminum, copper and carbides. The rare earth elements include neodymium, and account for 24 to 30 parts by weight. Iron accounts for 65 to 72 parts by weight. Boron accounts for 0.8 to 1.2 parts by weight. Cobalt accounts for 2.8 to 3.2 parts by weight. Aluminum accounts for 0.2 to 0.6 parts by weight. Copper accounts for 0.1 to 0.4 parts by weight. The carbides account for 0.1 to 0.4 parts by weight. The particle size of the permanent magnetic alloy powders is 10 m to 70 m, and the grain size of NdFeB phase in the permanent magnetic alloy powders is less than 5 m. Through the selection of alloy material ratio and manufacturing process, the processability and formability of permanent magnetic alloy materials can be effectively improved, suitable for metal injection molding and 3D printing production.

A powder metal composition providing a powder metal material to be compacted, sintered, and heat treated to be comparable to wrought 6013 aluminum alloy. The powder metal composition includes an aluminum base powder metal, an aluminum-silicon powder metal, an aluminum-copper powder metal, and an elemental magnesium powder metal. A weight percent of silicon in the powder metal composition is in a range of 0.6 to 1.0 wt % of the powder metal composition, a weight percent of copper in the powder metal composition is in a range of 0.7 to 1.1 wt % of the powder metal composition, and a weight percent of magnesium in the powder metal composition is in a range of 0.8 to 1.2 wt % of the powder metal composition. This powder metal is compactable to form a green compact which is further sinterable and heat treatable to provide a powder metal composition comparable to wrought 6013 aluminum alloy.

A method for manufacturing a metal bladed wheel of a turbomachine reinforced by an insert made of metal matrix composite material, includes winding the ceramic fibers around a mandrel in order to form the insert, the ceramic fibers being surrounded by a material constituting the matrix; and spark plasma sintering the insert with a powder of metal constituting the bladed wheel to be manufactured.

A thermal spray material feedstock is provided for flash-carbide coatings. Flash carbide coatings are thin, dense, and smooth thermal spray coatings that self-activate the substrate. Flash-carbide coatings form and peen the coating to impart compressive stress for good adhesion and corrosion resistance. To achieve this combination of properties and performance, a powder that includes fine, dense, and angular particles is used; however, this powder alone results in a poor deposition efficiency of typically less than 20%. The present disclosure mitigates the poor deposition efficiency of this powder alone by providing a composition having two or more different particles at a specific ratio to improve deposition efficiency with sufficient optimized stress and corrosion properties and, in some cases, an increase in coating performance.

A thixomolding material includes: a metal body that contains Mg as a main component; and a coating portion that is adhered to a surface of the metal body via a binder and contains SiC particles containing SiC as a main component. A mass fraction of the SiC particles in a total mass of the metal body and the SiC particles is 2.0 mass % or more and 40.0 mass % or less. The binder may contain waxes. A content of the binder may be 0.001 mass % or more and 0.200 mass % or less.

Metal matrix composites that include a base metal material and a ceramic additive to form composites strengthened by the additives to improve performance in extreme environments are disclosed. Typically the additive is about 2% of the total volume, up to about 10% of the total volume. The particle sizes are typically less than about 100 micrometers, and average about 40 micrometers, while maintaining a spherical shape of the same. The resulting composites can be used to print components for use in extreme environments, such as using additive manufacturing techniques like laser powder bed fusion. Techniques for formulating these composites, and for printing the resulting components using the composites, are also provided.