A method of making a thermally stable polycrystalline super hard construction having a plurality of interbonded super hard grains and interstitial regions disposed therebetween to form a polycrystalline super hard construction having a first thermally stable region and a second region, the first thermally stable region forming at least part of a working surface of the construction, comprises treating the polycrystalline super hard material with a leaching mixture to remove non-super hard phase material from a number of interstitial regions in the first region. The step of treating comprises masking the polycrystalline super hard construction along at least a portion of the peripheral side surface up to and/or at the working surface to inhibit penetration of the leaching mixture into the super hard construction through a peripheral side surface of the super hard construction.

Methods for producing final bodies that contain a fine-grained refractory complex concentrated alloy (RCCA), as well as RCCAs, intermediate materials and final bodies containing the RCCAs, and high-temperature devices formed by such final bodies. Such a method includes providing a precursor with one or more precursor compounds containing elements of an RCCA, reducing the precursor compounds in the precursor via reaction with a reducing agent so as to generate the RCCA and a compound comprising a product of the reaction between the reducing agent and the precursor compounds, generating a solid material that contains at least the RCCA, forming with the solid material a porous intermediate body, and consolidating the porous intermediate body so as to partially or completely remove the pore volume from the porous intermediate body, and in doing so yield either a denser final body or a denser film.

Methods for producing final bodies that contain a fine-grained refractory complex concentrated alloy (RCCA), as well as RCCAs, intermediate materials and final bodies containing the RCCAs, and high-temperature devices formed by such final bodies. Such a method includes providing a precursor with one or more precursor compounds containing elements of an RCCA, reducing the precursor compounds in the precursor via reaction with a reducing agent so as to generate the RCCA and a compound comprising a product of the reaction between the reducing agent and the precursor compounds, generating a solid material that contains at least the RCCA, forming with the solid material a porous intermediate body, and consolidating the porous intermediate body so as to partially or completely remove the pore volume from the porous intermediate body, and in doing so yield either a denser final body or a denser film.

Provided is a method of manufacturing a machine part having a radial crushing strength of 120 MPa or more, including: a compression molding step of compressing raw material powder including, as a main component, metal powder that is capable of forming an oxide coating and has a pure iron powder content ratio of 95 mass % or more, to thereby obtain a green compact (10) having a predetermined shape; and a coating forming step of causing the metal powder to react with an oxidizing gas while heating the green compact (10) at a temperature lower than a sintering temperature of the metal powder in an oxidizing gas atmosphere, to thereby obtain a reinforced green compact (11) in which the oxide coating (5) is formed between particles of the metal powder.

Provided is a method of manufacturing a machine part having a radial crushing strength of 120 MPa or more, including: a compression molding step of compressing raw material powder including, as a main component, metal powder that is capable of forming an oxide coating and has a pure iron powder content ratio of 95 mass % or more, to thereby obtain a green compact (10) having a predetermined shape; and a coating forming step of causing the metal powder to react with an oxidizing gas while heating the green compact (10) at a temperature lower than a sintering temperature of the metal powder in an oxidizing gas atmosphere, to thereby obtain a reinforced green compact (11) in which the oxide coating (5) is formed between particles of the metal powder.

A protective mask for a part, the part including a plurality of openings in a surface thereof, is provided. The protective mask includes a mounting member at least partially within each of at least two of the plurality of openings. Each mounting member includes a water soluble material. A masking member couples the at least two mounting members. The masking member includes a non-water soluble material. Each mounting member includes a first plurality of integral layers of the water soluble material, and the masking member includes a second plurality of integral layers of the non-water soluble material. The protective mask can be made by a two material additive manufacturing system. A related method is also provided.

A protective mask for a part, the part including a plurality of openings in a surface thereof, is provided. The protective mask includes a mounting member at least partially within each of at least two of the plurality of openings. Each mounting member includes a water soluble material. A masking member couples the at least two mounting members. The masking member includes a non-water soluble material. Each mounting member includes a first plurality of integral layers of the water soluble material, and the masking member includes a second plurality of integral layers of the non-water soluble material. The protective mask can be made by a two material additive manufacturing system. A related method is also provided.

Techniques and compositions are disclosed for three-dimensional printing with powder/binder systems including, but not limited to, metal injection molding powder materials, highly-filled polymer composites, and any other materials suitable for handling with various additive manufacturing techniques, and further suitable for subsequent debinding and thermal processing into a final object.

Techniques and compositions are disclosed for three-dimensional printing with powder/binder systems including, but not limited to, metal injection molding powder materials, highly-filled polymer composites, and any other materials suitable for handling with various additive manufacturing techniques, and further suitable for subsequent debinding and thermal processing into a final object.

A method of making an article is disclosed. According to the method, an energy beam is directed to a build location on a substrate, and a first powder material is delivered to the build location on the substrate and melted with the energy beam. A second powder material is delivered to the build location on the substrate over the first material and melted with the energy beam. The direction of the energy beam and delivery and melting of the first and second powders is repeated at multiple build locations on the substrate to form a solid surface of the article of the second material. The solid surface comprising the second material is subjected to a finishing process.