A method for densifying a surface of a powder metal part, includes blending a plurality of powdered metals to form a powder metal blend, actuating an upper punch and a lower punch to apply pressure to the powder metal blend to compact the powder metal blend, sintering the compacted powder metal blend in an oven, forming the compacted powdered metal blend into the powder metal part, heating a portion of the surface of the powder metal part, and densifying the portion of the surface of the powder metal part for a predetermined period of time after the portion of the powder metal part is heated to a predetermined temperature.

A method of sintering electrically conducting powders in an air atmosphere for obtaining a sintered product includes the following step sequence: placing the powders in an electrically isolating mold, applying a pressure to the powders between 100 and 500 MPa, and applying to the powders a sintering current at a sintering voltage during a sintering time, for sintering the powders. Before applying the sintering current density to the powders, an activation current density is lower than the sintering current density at an activation voltage greater than the sintering voltage during an activation time lower than the sintering time, to reduce the electrical resistance of the powders.

Aspects are provided for additively manufacturing a component based on direct energy deposition (DED). An apparatus may include a DED system configured to additively manufacture a part. The apparatus may further include a forging tool configured to forge a region of the part during the additive manufacturing. In various embodiments, a solid body is used opposite to the forging tool during the forgery. For example, the solid body may include a mandrel against which the region of the part is forged.

Aspects are provided for additively manufacturing a component based on direct energy deposition (DED). An apparatus may include a DED system configured to additively manufacture a part. The apparatus may further include a forging tool configured to forge a region of the part during the additive manufacturing. In various embodiments, a solid body is used opposite to the forging tool during the forgery. For example, the solid body may include a mandrel against which the region of the part is forged.

An actuator includes a first ball-ramp plate, a second ball-ramp plate, and a plurality of balls. The first ball-ramp plate is formed of compressed powdered metal with ramps having a higher density than at least part of a remainder of the ball-ramp component. A method of manufacturing the actuator includes compacting a metal powder to form a blank of the first ball-ramp plate including an annular body disposed about an axis and a plurality of ramps fixedly coupled to the annular body and spaced circumferentially about the axis, and locally densifying the ramps of the blank by applying force to a ramped surface of each ramp.

Embossing of metallic glass supercooled liquids into templates is emerging as a precision net-shaping and surface patterning technique for metals. Here, the effect of thickness of metallic glass on template-based embossing is disclosed. The results show that the existing embossing theory developed for thick samples fails to describe the process when the thickness of metallic glass becomes comparable to the template cavity diameter. Increased flow resistance at the cavity entrance results in viscous buckling of supercooled liquid instead of filling. A new phenomenological equation is proposed to describe the thickness dependent filling of template cavities. The buckling phenomenon is analyzed based on the folding model of multilayer viscous media. Controlled buckling can be harnessed in fabrication of metal microtubes, which are desirable for many emerging applications.

Embossing of metallic glass supercooled liquids into templates is emerging as a precision net-shaping and surface patterning technique for metals. Here, the effect of thickness of metallic glass on template-based embossing is disclosed. The results show that the existing embossing theory developed for thick samples fails to describe the process when the thickness of metallic glass becomes comparable to the template cavity diameter. Increased flow resistance at the cavity entrance results in viscous buckling of supercooled liquid instead of filling. A new phenomenological equation is proposed to describe the thickness dependent filling of template cavities. The buckling phenomenon is analyzed based on the folding model of multilayer viscous media. Controlled buckling can be harnessed in fabrication of metal microtubes, which are desirable for many emerging applications.

Method for building up and/or finalizing a PVD target whereas the method comprises a process step where target material is added using an additive method.

The present invention relates to a coated cutting tool including a Cr-containing cemented carbide substrate having WC, a binder phase and a gamma phase. The cemented carbide includes a gradient surface zone with a thickness of between 2 to 100 μm, which is binder phase enriched and depleted of gamma phase. The cemented carbide includes M.sub.7C.sub.3 carbides in an amount of between 0.5 to 7 area % measured in the bulk, where M is elements being Cr, W and at least one binder metal. The coated cutting inserts shows an improved edge line toughness.

A method of manufacturing a part includes additively manufacturing, with an additive manufacturing machine, at least one wall of the part having a first thickness from powder in a powder bed, and peening, with a peening system, at least a portion of the wall of the part. The peening induces plastic deformation in the portion of the wall. The portion of the wall that is peened has a second thickness less than the first thickness of the wall prior to peening. The second thickness of the portion of the wall may be less than a minimum thickness limit achievable by the additive manufacturing machine.