A manufacturing method includes providing a material that includes a plurality of particles and a binder that is uncured. The method also includes forming a first article from the material including curing the binder to bind a collection of the particles together into the first article. Furthermore, the method includes encasing at least a portion of the first article with an outer member. The outer member defines an internal cavity that corresponds to the first article. Additionally, the method includes heating the outer member and the first article to melt the collection of particles into a molten mass within the internal cavity of the outer member. Moreover, the method includes solidifying the molten mass within the outer member to form a second article. The second article corresponds to at least a portion of the internal cavity of the outer member.

A manufacturing method includes providing a material that includes a plurality of particles and a binder that is uncured. The method also includes forming a first article from the material including curing the binder to bind a collection of the particles together into the first article. Furthermore, the method includes encasing at least a portion of the first article with an outer member. The outer member defines an internal cavity that corresponds to the first article. Additionally, the method includes heating the outer member and the first article to melt the collection of particles into a molten mass within the internal cavity of the outer member. Moreover, the method includes solidifying the molten mass within the outer member to form a second article. The second article corresponds to at least a portion of the internal cavity of the outer member.

In one aspect, methods of making freestanding metal matrix composite articles and alloy articles are described. A method of making a freestanding composite article described herein comprises disposing over a surface of the temporary substrate a layered assembly comprising a layer of infiltration metal or alloy and a hard particle layer formed of a flexible sheet comprising organic binder and the hard particles. The layered assembly is heated to infiltrate the hard particle layer with metal or alloy providing a metal matrix composite, and the metal matrix composite is separated from the temporary substrate. Further, a method of making a freestanding alloy article described herein comprises disposing over the surface of a temporary substrate a flexible sheet comprising organic binder and powder alloy and heating the sheet to provide a sintered alloy article. The sintered alloy article is then separated from the temporary substrate.

Provided is a heat sink that has a clad structure of a CuMo 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 CuMo composite layers and a Cu layer stacked in a thickness direction so that the Cu layer is interposed between the CuMo composite layers or comprises three or more CuMo composite layers and two or more Cu layers alternately stacked in the thickness direction so that two of the CuMo composite layers are outermost layers on both sides, wherein each of the CuMo 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 blade for a gas turbine includes a removed portion space, and further includes an airfoil portion defining the removed portion space, the airfoil portion formed from a base material, and a replacement component formed to fill the removed portion space. The replacement component is formed from a material that includes 50%-80% base material, 0%-30% braze material, and 0%-8% aluminum. A braze joint is formed between the airfoil portion and the replacement component to attach the replacement component to the airfoil portion and fill the removed portion space.

A blade for a gas turbine includes a removed portion space, and further includes an airfoil portion defining the removed portion space, the airfoil portion formed from a base material, and a replacement component formed to fill the removed portion space. The replacement component is formed from a material that includes 50%-80% base material, 0%-30% braze material, and 0%-8% aluminum. A braze joint is formed between the airfoil portion and the replacement component to attach the replacement component to the airfoil portion and fill the removed portion space.

A joined part comprises a first portion and a second portion. The first portion comprises a guide slot at least partially defined by a porous structure. A joint material is disposed within the porous structure. The second portion is disposed within the guide slot and contacts the porous structure and the joint material disposed therein to form an interfacial joint between the first portion and the second portion. A method of manufacturing the joined part includes disposing a joint material into a porous structure of a guide slot of a first portion, inserting a second portion into the guide slot, and contacting the porous structure and the joint material disposed therein to form an interfacial joint between the first portion and the second portion.

An apparatus for dispensing build powder and support powder, in a sequence of layers, and having a frame and a container. Also, a build powder pourer is at least partially filled with build powder and a support powder pourer at least partially filled with support powder, each of the pourers having a dispensing opening and a dispensing plug, controllably covering the dispensing opening. Further, a pourer-movement and dispensing plug-actuating assembly is supported by the frame over the container and includes a movement element that is selectively attachable to the build powder pourer and alternately to the support powder pourer and also capable to controllably move an attached pourer in three orthogonal dimensions and to control the dispensing plug. In addition, at least one docking station for holding a first one of the pourers; and a computing assembly controls the pourer-movement and dispensing plug-actuating assembly to create a target shape.

An apparatus for dispensing build powder and support powder, in a sequence of layers, and having a frame and a container. Also, a build powder pourer is at least partially filled with build powder and a support powder pourer at least partially filled with support powder, each of the pourers having a dispensing opening and a dispensing plug, controllably covering the dispensing opening. Further, a pourer-movement and dispensing plug-actuating assembly is supported by the frame over the container and includes a movement element that is selectively attachable to the build powder pourer and alternately to the support powder pourer and also capable to controllably move an attached pourer in three orthogonal dimensions and to control the dispensing plug. In addition, at least one docking station for holding a first one of the pourers; and a computing assembly controls the pourer-movement and dispensing plug-actuating assembly to create a target shape.

The present disclosure relates to a polycrystalline diamond compact (PDC) with a fiber-reinforces substrate. The disclosure further relates to method of forming such a PDC.