The present disclosure provides an aluminum alloy workpiece and a preparation method thereof. By optimizing a composition of the aluminum alloy workpiece, the aluminum alloy workpiece can be prepared by laser powder bed fusion (LPBF) in the preparation method, thereby forming a target metallographic phase. The preparation method overcomes the problem that the composition of a high temperature-resistant and high-strength aluminum alloy designed based on the traditional casting and forging process cannot be matched with the LPBF, and makes full use of rapid cooling of the LPBF to prepare an aluminum alloy composition of a target crystal phase. The preparation method combines the aluminum alloy composition with the LPBF to achieve mutual promotion, thereby forming a target workpiece, such that an aluminum alloy with high strength and toughness at room temperature/high temperature can be prepared by the LPBF.

A method for fabricating an article includes forming a billet consisting essentially of a stainless steel composition of manganese 2.00 wt. %-24.00 wt. % chromium 19.00 wt. %-30 wt. % molybdenum 0.50 wt. %-4.0 wt. % nitrogen 0.25 wt. %-1.10 wt. % carbon ≤1 wt. % phosphorus ≤0.03 wt. % sulfur ≤1 wt. % nickel <22 wt. % cobalt <0.10 wt. % silicon ≤1 wt. % niobium ≤0.80 wt. % oxygen ≤1 wt. % copper ≤0.25 wt. % balance iron.
The billet is annealed and cold worked to form an article. Without annealing of the article, the article is subsequently case hardened at a single case hardening temperature to form a surface layer on a top surface thereof. Articles formed with the indicated stainless steel composition with case hardened surface layers are also provided.

Provided is a stainless steel powder composition, which comprises Cr, Cu, Mn, Mo, Ni and Fe; wherein, based on a total weight of the stainless steel powder composition, a content of Cr is 20 wt% to 24 wt%, and a content of Cu is more than 0 wt% and less than or equal to 0.5 wt%, a content of Mn is more than 0 wt% and less than or equal to 2 wt%, a content of Mo is 2.25 wt% to 3 wt% and a content of Ni is 10 wt% to 15 wt%. When applying the stainless steel powder composition of the present invention to laser additive manufacturing (LAM), the produced stainless steel workpiece has enhanced tensile strength, thereby expanding the follow-up applications and increasing the commercial value.

The present invention is to provide powder made of iron-based metallic glass, the corrosion resistance of which is improved over the conventional powder made of iron-based metallic glass. The basic composition includes a group of iron-based metallic elements that predominantly has Fe, a group of metalloid elements that consists of Si, B, P, and C, and a little amount of a group of elements for improving the degree of supercooling that consists of either or both of Nb and Mo. The powder made of the iron-based metallic glass is obtained by adding to the basic composition an element for improving the corrosion resistance. The obtained powder made of the iron-based metallic glass has an excellent corrosion resistance, an excellent magnetic property, and an excellent insulating property.

A deployable manufacturing center (DMC) system includes a foundry module containing a metallurgical system configured to convert a raw material into an alloy powder, and an additive manufacturing (AM) module containing an additive manufacturing system configured to form the alloy powder into metal parts. The deployable manufacturing center (DMC) system can also include a machining module containing a machining system configured to machine the metal parts into machined metal parts, and a quality conformance (QC) module containing an inspection and evaluation system configured to inspect and evaluate the metal parts. A process for manufacturing metal parts includes the steps of providing the deployable manufacturing center (DMC) system; deploying the (DMC) system to a desired location; forming an alloy powder from a raw material using the deployable foundry module; and then forming the metal parts from the alloy powder using the additive manufacturing (AM) module.

A deployable manufacturing center (DMC) system includes a foundry module containing a metallurgical system configured to convert a raw material into an alloy powder, and an additive manufacturing (AM) module containing an additive manufacturing system configured to form the alloy powder into metal parts. The deployable manufacturing center (DMC) system can also include a machining module containing a machining system configured to machine the metal parts into machined metal parts, and a quality conformance (QC) module containing an inspection and evaluation system configured to inspect and evaluate the metal parts. A process for manufacturing metal parts includes the steps of providing the deployable manufacturing center (DMC) system; deploying the (DMC) system to a desired location; forming an alloy powder from a raw material using the deployable foundry module; and then forming the metal parts from the alloy powder using the additive manufacturing (AM) module.

The present disclosure is directed and formulations and methods to provide alloys having relative high strength and ductility. The alloys may be provided in seamless tubular form and characterized by their particular alloy chemistries and identifiable crystalline grain size morphology. The alloys are such that they include boride pinning phases. In what is termed a Class 1 Steel the alloys indicate tensile strengths of 700 MPa to 1400 MPa and elongations of 10-70%. Class 2 Steel indicates tensile strengths of 800 MPa to 1800 MPa and elongations of 5-65%. Class 3 Steel indicates tensile strengths of 1000 MPa to 2000 MPa and elongations of 0.5-15%.

The present disclosure is directed and formulations and methods to provide alloys having relative high strength and ductility. The alloys may be provided in seamless tubular form and characterized by their particular alloy chemistries and identifiable crystalline grain size morphology. The alloys are such that they include boride pinning phases. In what is termed a Class 1 Steel the alloys indicate tensile strengths of 700 MPa to 1400 MPa and elongations of 10-70%. Class 2 Steel indicates tensile strengths of 800 MPa to 1800 MPa and elongations of 5-65%. Class 3 Steel indicates tensile strengths of 1000 MPa to 2000 MPa and elongations of 0.5-15%.

A method for gas atomization of a titanium alloy, nickel alloy, or other alumina (Al.sub.2O.sub.3)-forming alloy wherein the atomized particles are exposed as they solidify and cool in a very short time to multiple gaseous reactive agents for the in-situ formation of a passivation reaction film on the atomized particles wherein the reaction film retains a precursor halogen alloying element that is subsequently introduced into a microstructure formed by subsequent thermally processing of the atomized particles to improve oxidation resistance.

A method for gas atomization of a titanium alloy, nickel alloy, or other alumina (Al.sub.2O.sub.3)-forming alloy wherein the atomized particles are exposed as they solidify and cool in a very short time to multiple gaseous reactive agents for the in-situ formation of a passivation reaction film on the atomized particles wherein the reaction film retains a precursor halogen alloying element that is subsequently introduced into a microstructure formed by subsequent thermally processing of the atomized particles to improve oxidation resistance.