The invention relates to a method for manufacturing a part including a formation of successive solid metallic layers (20.sub.1 . . . 20.sub.n), superimposed on one another, each layer describing a pattern defined from a digital model (M), each layer being formed by the deposition of a metal (25), called filler metal, the filler metal being subjected to an energy input so as to melt and constitute, when solidifying, said layer, wherein the filler metal is in the form of a powder (25), whose exposure to an energy beam (32) results in melting followed by solidification so as to form a solid layer (20.sub.1 . . . 20.sub.n), the method being characterized in that the filler metal (25) is an aluminum alloy comprising at least the following alloy elements: Ni, according to a weight fraction from 1 to 8%, preferably from 2 to 7%; Zr, according to a weight fraction from 0.3 à 3%, preferably from 0.5 to 2.5%; optionally V, according to a weight fraction from 0 à 4%, preferably from 0.5 to 2%; optionally Cu, according to a weight fraction from 0 à 7%, preferably from 2 to 7%; optionally Fe, according to a weight fraction from 0 à 3%, preferably from 0.5 to 3%.

The invention also relates to a part obtained by this method. The alloy used in the additive manufacturing method according to the invention, allows obtaining parts with remarkable features.

The invention relates to a method for manufacturing a part including a formation of successive solid metallic layers (20.sub.1 . . . 20.sub.n), superimposed on one another, each layer describing a pattern defined from a digital model (M), each layer being formed by the deposition of a metal (25), called filler metal, the filler metal being subjected to an energy input so as to melt and constitute, when solidifying, said layer, wherein the filler metal is in the form of a powder (25), whose exposure to an energy beam (32) results in melting followed by solidification so as to form a solid layer (20.sub.1 . . . 20.sub.n), the method being characterized in that the filler metal (25) is an aluminum alloy comprising at least the following alloy elements: Ni, according to a weight fraction from 1 to 8%, preferably from 2 to 7%; Zr, according to a weight fraction from 0.3 à 3%, preferably from 0.5 to 2.5%; optionally V, according to a weight fraction from 0 à 4%, preferably from 0.5 to 2%; optionally Cu, according to a weight fraction from 0 à 7%, preferably from 2 to 7%; optionally Fe, according to a weight fraction from 0 à 3%, preferably from 0.5 to 3%.

The invention also relates to a part obtained by this method. The alloy used in the additive manufacturing method according to the invention, allows obtaining parts with remarkable features.

A device for producing a gear green compact from a powder includes a die, an upper stamp, and a lower stamp, wherein the die has at least one helical toothing on an inner lateral surface, which helical toothing extends only over a partial area of the circumference of the inner lateral surface, and which has a first helix angle, wherein, adjoining the first helical toothing in a circumferential direction, one toothed edge surface is formed on each side, both of which have a second helix angle, wherein at least one of the second helix angles of the die is unequal to the first helix angle of the helical toothing of the die.

A device for producing a gear green compact from a powder includes a die, an upper stamp, and a lower stamp, wherein the die has at least one helical toothing on an inner lateral surface, which helical toothing extends only over a partial area of the circumference of the inner lateral surface, and which has a first helix angle, wherein, adjoining the first helical toothing in a circumferential direction, one toothed edge surface is formed on each side, both of which have a second helix angle, wherein at least one of the second helix angles of the die is unequal to the first helix angle of the helical toothing of the die.

Provided is a method for manufacturing a sintered component, which can suppress occurrence of edge chipping when a through-hole is formed in a powder-compact green body and also has a good productivity. The method for manufacturing a sintered component includes a molding step of press-molding a raw material powder containing a metal powder and thus fabricating a powder-compact green body; a drilling step of forming a hole in the powder-compact green body using a drill; a sintering step of sintering the powder-compact green body after drilling, wherein the drill used for drilling has a circular-arc shaped cutting edge on a point portion thereof.

The present invention discloses a method for manufacturing a thin-walled metal component by three-dimensional (3D) printing and hot gas bulging. The present invention uses 3D printing to obtain a complex thin-walled preform, which reduces a deformation during subsequent hot gas bulging. The present invention avoids local bulging thinning and cracking, undercuts at the parting during die closing, and wrinkles due to the uneven distribution of cross-sectional materials, etc. The present invention obtains a high accuracy in the form and dimension through hot gas bulging. After a desired shape is obtained by hot gas bulging, a die is closed to keep the component under high temperature and high pressure for a period of time, so that a grain and a phase of the material are transformed to form a desired microstructure.

The present invention discloses a method for manufacturing a thin-walled metal component by three-dimensional (3D) printing and hot gas bulging. The present invention uses 3D printing to obtain a complex thin-walled preform, which reduces a deformation during subsequent hot gas bulging. The present invention avoids local bulging thinning and cracking, undercuts at the parting during die closing, and wrinkles due to the uneven distribution of cross-sectional materials, etc. The present invention obtains a high accuracy in the form and dimension through hot gas bulging. After a desired shape is obtained by hot gas bulging, a die is closed to keep the component under high temperature and high pressure for a period of time, so that a grain and a phase of the material are transformed to form a desired microstructure.

Provided is a heat sink that has a clad structure of a Cu—Mo composite material and a Cu material and has a low coefficient of thermal expansion and high thermal conductivity. The heat sink comprises a pair of Cu—Mo composite layers and a Cu layer stacked in a thickness direction so that the Cu layer is interposed between the Cu—Mo composite layers or comprises three or more Cu—Mo composite layers and two or more Cu layers alternately stacked in the thickness direction so that two of the Cu—Mo composite layers are outermost layers on both sides, wherein each of the Cu—Mo composite layers has a thickness section microstructure in which flat Mo phase is dispersed in a Cu matrix. Such a clad structure achieves high thermal conductivity together with a low coefficient of thermal expansion.

Provided is a heat sink that has a clad structure of a Cu—Mo composite material and a Cu material and has a low coefficient of thermal expansion and high thermal conductivity. The heat sink comprises a pair of Cu—Mo composite layers and a Cu layer stacked in a thickness direction so that the Cu layer is interposed between the Cu—Mo composite layers or comprises three or more Cu—Mo composite layers and two or more Cu layers alternately stacked in the thickness direction so that two of the Cu—Mo composite layers are outermost layers on both sides, wherein each of the Cu—Mo composite layers has a thickness section microstructure in which flat Mo phase is dispersed in a Cu matrix. Such a clad structure achieves high thermal conductivity together with a low coefficient of thermal expansion.

A treated additive manufactured article is disclosed. The article comprises a shaped metal alloy having a treated surface layer and a core. At least one of the average hardness of the treated surface layer is greater than the average hardness of the core, and the average corrosion resistance of the treated surface layer is greater than the average corrosion resistance of the core.