An alloy powder contains greater than or equal to 3% by mass and less than or equal to 30% by mass of tungsten, greater than or equal to 2% by mass and less than or equal to 30% by mass of aluminum, greater than or equal to 0.2% by mass and less than or equal to 15% by mass of oxygen, and at least one of cobalt and nickel as the balance. The alloy powder has an average particle diameter of greater than or equal to 0.1 μm and less than or equal to 10 μm.

According to examples, a brown body has from about 0.02 wt. % to about 10 wt. % of a metal nanoparticle binder, in which the metal nanoparticle binder is selectively located within an area of the brown body to impart a strength greater than about 1 kPa to the area.

According to an aspect of the present invention, a method for producing an oxide-dispersed strengthened alloy using organic-inorganic kneaded composition is provided. The method, comprises: a feedstock preparing step of preparing the organic-inorganic kneaded composition prepared by kneading, pulverizing and granulating ODS mixed powders and a polymer binder; a molding step of forming a semi-finished product having a predetermined shape using the organic-inorganic kneaded composition; a debinding step of removing the polymeric binder from the semi-finished product molded in the molding step; and a sintering step of extracting a final product having a predetermined shape by sintering and cooling the semi-finished product in which the polymeric binder has been removed in the debinding step.

A method for manufacturing a powder magnetic core using a soft magnetic material powder, wherein the method has: a first step of mixing the soft magnetic material powder with a binder, a second step of subjecting a mixture obtained through the first step to pressure forming, and a third step of subjecting a formed body obtained through the second step to heat treatment. The soft magnetic material powder is an Fe—Cr—Al based alloy powder comprising Fe, Cr and Al. An oxide layer is formed on a surface of the soft magnetic material powder by the heat treatment. The oxide layer has a higher ratio by mass of Al to the sum of Fe, Cr and Al than an alloy phase inside the powder.

A micro-nano composite powder dedicated for laser repair of tiny crack on stainless steel surface, includes 3 wt %-7 wt % of nano-WC, 0.5 wt %-2 wt % of nano-Al.sub.2O.sub.3, 0.2 wt %-0.8 wt % of micro-V powder and the balance of micro stainless steel powder. The stainless steel powder includes 0.08 wt % of C, 0.5 wt % of Si, 1.46 wt % of Mn, 0.03 wt % of P, 0.005 wt % of S, 19 wt % of Cr, 9.5 wt % of Ni, 0.5 wt % of Mo and the balance of Fe. The micro and nano powders are mixed through ball milling and mixed with anhydrous ethanol. The composite powder is suitable for laser repair of tiny crack on the surface of stainless steel part with high toughness requirement. After laser repair, the composite powder can be fused with the substrate, the repaired layer and the substrate are metallurgically bonded at the interface, the repaired layer contains fine grains, and therefore the compatibility and fracture property of the repaired layer are improved.

Various embodiments of the present disclosure provide an additive manufacturing method. The method includes forming a first layer of a first ceramic material and forming a second layer of a second ceramic material. The method further includes contacting the first layer of the first ceramic material, the second layer of the second ceramic material, or both with a saturant. The method further includes heating the first layer of the first ceramic material, the second layer of the second ceramic material, or both to a temperature in a range of from about 50° C. to about 300° C. The method further includes applying pressure to the first layer of the first ceramic material, the second layer of the second ceramic material, or both. The pressure can be in a range of from about 10 kPa to about 800 MPa. The method further includes at least partially dissolving a portion of an external surface of a ceramic particle of the first layer of the first ceramic material, the second layer of the second ceramic material, or both. The method further includes fusing a portion of the dissolved portion of the external surface of the ceramic particle to from a product having a density in a range of from about 65% to about 100% relative to a corresponding fully densified product and optionally containing no organic binder.

Implementations provide gas atomized metal matrix composite (“GAMMC”)-based feedstock for cold spray additive manufacturing (“CSAM”) enabling complex structural repairs. The feedstock is prepared by arranging a metal matrix composite (MMC) material in a gas atomization system, wherein the MMC material includes metal particles and ceramic particles. The feedstock is further prepared by performing gas atomization of the MMC material using the gas atomization system to atomize the MMC material, and producing a feedstock powder comprised of metal particles that are embedded with the ceramic particles from the atomized MMC material. The GAMMC-based feedstock comprises metallic (for binding to the substrate of the damaged part) and ceramic (for reinforcement) particles bonded together such that the ceramic particles bond directly to and within the metallic particles. GAMMC-based feedstock strengthens the repaired part and prevents degradation of the mechanical properties of the repaired part below stock specifications.

A method for manufacturing a planet gear or a sun gear of a gearbox of a wind turbine includes forming a base of the planet gear via at least one of casting or forging. The base of the planet gear includes an inner circumferential surface and an outer circumferential surface. Therefore, at least one of the inner circumferential surface or the outer circumferential surface of the planet gear includes a plurality of net or near-net gear teeth. The method also includes applying a coating material to at least a portion of the base of the gear and at least a portion of the plurality of gear teeth of the gear via an additive manufacturing process so as to increase a hardness of the portions of the base and the plurality of gear teeth that includes the coating material.

According to examples, a brown body has from about 0.02 wt. % to about 10 wt. % of a metal nanoparticle binder, in which the metal nanoparticle binder is selectively located within an area of the brown body to impart a strength greater than about 1 kPa to the area.

The sheath (3) is a material, which includes an aluminium (Al) matrix, in which nanometric aluminium oxide particles (Al.sub.2O.sub.3) are homogenously dispersed, the content of Al.sub.2O.sub.3 is 0.25 to 5 vol. % and the balance is Al. It is preferred that Al.sub.2O.sub.3 originates from the surface layer present on Al powder used as feedstock material for consolidation. The superconductor based on magnesium diboride (MgB.sub.2) core (1) is fabricated by powder-in-tube or internal magnesium diffusion to boron technology, while the tube is the Al+Al.sub.2O.sub.3 composite, which is a product of powder metallurgy. A loose Al powder is pressed by cold isostatic pressing, and then the powder billet is degassed at elevated temperature and under vacuum, and then is hot extruded into a tube. A thin diffusion barrier (2) tube filled up with a mixture of Mg and B powders or Mg wire surrounded with B powder is placed into the Al+Al.sub.2O.sub.3 composite tube under inert gas or vacuum. Such composite unit is cold worked into a thin wire and then annealed at 625-655 C. for 8-90 min, what results in a formation superconducting MgB.sub.2 in a wire's core (1).