Disclosed are titanium alloys for use in additive manufacturing that comprise a titanium material and a beta eutectoid stabilizer. The beta eutectoid stabilizer can be present in an effective amount to produce an equiaxed grain structure when the titanium alloy is melted or sintered during an additive manufacturing process. Also provided are methods of forming objects via additive manufacturing processes as well as methods of forming titanium alloys for use in additive manufacturing.

A gas turbine engine component may include a coating adapted to protect the component during use. The coating may be applied by sintering metallic particles to form a metallic matrix fused to the component.

A method of preparing a surface for diffusion bonding comprises contacting a binder material with a discontinuous surface comprising surface regions separated by gaps. The binder material is selectively deposited onto the surface regions and has a sufficient viscosity to form a self-supporting layer without flowing into the gaps. The self-supporting layer of binder material comprises a mass density in a range from about 0.001 g/in.sup.2 to about 0.050 g/in.sup.2. A braze powder is distributed over the self-supporting layer of binder material, and a predetermined amount of the braze powder is attached to the binder material. The discontinuous surface is then heated to remove the binder material and adhere the braze powder to the discontinuous surface. Thus, a prewet surface with a braze deposit thereon is formed.

A high quality porous aluminum body, which has excellent joint strength between the porous aluminum body and the aluminum bulk body, and a method of producing the porous aluminum complex, are provided. The porous aluminum complex (10) includes: a porous aluminum body (30) made of aluminum or aluminum alloy; and an aluminum bulk body (20) made of aluminum or aluminum alloy, the porous aluminum body (30) and the aluminum bulk body (20) being joined to each other. The junction (15) between the porous aluminum body (30) and the aluminum bulk body (20) includes a Ti—Al compound. It is preferable that pillar-shaped protrusions (32) projecting toward the outside are formed on outer surfaces of one of or both of the porous aluminum body (30) and the aluminum bulk body (20), and the pillar-shaped protrusions (32) include the junction (15).

A process for additive manufacture of an article including conjoined first and second metals, wherein the first metal includes one of steel and titanium and the second metal includes another of the steel and the titanium. The process comprises arranging an interface layer of a third metal on a substrate of the first metal, wherein the third metal is capable of forming an alloy with the first metal and capable of forming an alloy with the second metal. The process further comprises supplying a consumable form of the second metal to a locus of the interface layer and heating the locus of the interface layer in an non-reactive environment. In this process, the heating fuses the consumable form of the second metal to render a fused form of the second metal and joins the fused form of the second metal to the interface layer.

A method for producing a golf club head having a weight block includes providing a club head body formed of a titanium alloy. The club head body includes a surface having a coupling portion. A weight block formed of a tungsten-copper-nickel alloy is provided and includes 1-17 wt % of copper and 6-37 wt % of nickel, with the balance being tungsten. The tungsten-copper-nickel alloy has a specific weight of 12-17 g/cm.sup.3. The weight block is placed into the coupling portion of the club head body, and a welding heat source is applied to abutting portions of the weight block and the coupling portion to proceed with fusion welding, tightly engaging the weight block with the coupling portion of the club head body.

A universal approach is described to produce welding filler materials with enhanced grain refining, for making welded objects with hot-crack resistance. Some variations provide a welding filler material comprising a functionalized metal-containing powder, wherein the functionalized metal-containing powder comprises metal or metal alloy particles and a plurality of nanoparticles disposed on surfaces of the metal or metal alloy particles, and wherein the nanoparticles are consolidated in a three-dimensional architecture throughout the welding filler material. A welded object contains a welding filler material comprising the functionalized metal-containing powder, enabling the welded object to be free of hot cracks. Other variations provide methods of making a welding filler material. This approach has been successfully demonstrated by incorporating zirconium-based nanoparticle grain refiners within a welding precursor material for welding aluminum alloy Al 7075, as one non-limiting example.

A method of making a brazing foil includes flattening the brazing foil to a minimum thickness. Calculating a quantity of material to remove from the brazing foil. Cutting a plurality of perforations into the brazing foil to remove the quantity of material.

A suppressor having a body and a first connector half coupled to the body, wherein the first connector half includes a first component that includes at least one channel and a first surface; and wherein the body provides a second surface, wherein a gap between the first surface and the second surface defines at least one track; wherein the gun includes a second connector half comprising at least one protrusion, wherein the protrusion and channel have corresponding shapes that allow the protrusion to be inserted through the channel and into alignment with the track, wherein the first component may be rotated with respect to the protrusion and the body to bring the protrusion out of alignment with the channel so that the first and second surfaces clamp the protrusion to thereby secure the first connector half and second connector half with respect to each other.

A metallic part is disclosed. The part may comprise a functionally graded monolithic structure characterized by a variation between a first material composition of a first structural element and a second material composition of at least one of a second structural element. The first material composition may comprise an alpha-beta titanium alloy. The second material composition may comprise a beta titanium alloy.