Multi-material tooling and methods of making multi-material tooling are provided. The multi-material tooling includes a core formed of a first material having a hardness (Rockwell C scale) of up to 30 HRC, and a shell layer adjacent to the core. The shell layer is formed of a second material having a hardness of 33 HRC to 70 HRC. The method of making multi-material includes depositing a first layer of a first material using an additive manufacturing technique to form a core. The first material that forms the core has a hardness of up to 30 HRC. The method also includes depositing a second layer of a second material to form a shell layer adjacent to the core. The second material that forms the shell layer has a hardness of 33 HRC to 70 HRC.

The microstructure of braze joints in polycrystalline diamond compact (PDC) cutters may be tailored to increase the shear strength of the braze joint, for example, by increasing the amount of a dispersed particulate microstructure therein. A method for forming a dispersed particulate microstructure may include brazing a polycrystalline diamond table to a hard composite substrate with a braze alloy at a braze temperature between 5 C. above a solidus temperature of the braze alloy and 200 C. above a liquidus temperature of the braze alloy; and forming a braze joint between the polycrystalline diamond table and the hard composite substrate that comprises at least 40% by volume of the dispersed particulate microstructure composed of a particulate inter-metallic phase having a diameter of 0.5 m to 2.0 m and an aspect ratio of 1 to 5 dispersed in a ductile matrix.

The exposed metal tip of the strike end of an SMAW welding electrode is covered with a protective coating formed from a binder and metal particles. Because metal particles rather than graphite particles are used to provide electrical conductivity to this protective coating, flare-up of the arc when initially struck is eliminated substantially completely. In addition, the potential for weld porosity problems is also eliminated, because the metal particles of the inventive electrode do not produce CO.sub.2 as a reaction by-product which can ultimately lead to improper welding technique.

A system for producing chemicals, such as, ethylene or gasoline, at high temperature (above 1100 degrees C.) having a feedstock source. The system includes a chemical conversion portion connected with the feedstock source to receive feedstock and convert the feedstock to ethylene or gasoline. The conversion portion includes a coil array and a furnace that heats the feedstock to temperatures in excess of 1100 C. or 1200 C. or even 1250 C. or even 1300 C. or even 1400 C. A method for producing chemicals, such as ethylene or gasoline, at high temperature.

An orthopedic implant in the form of a hip joint endoprosthesis consists of a head, which is set onto an anchoring shaft, which itself is insertable into a bone and anchorable therein. The head comprises an inner blind-hole-type recess, and the anchoring shaft is provided with a tenon for inserting into this recess. A sleeve provided with an approximately central through-bore is soldered into the recess of the head, via which sleeve the head is setable or mountable on the tenon. The head consists of a ceramic based on zirconium dioxide, aluminum oxide or a mixed ceramic, while the sleeve consists of a high strength titanium material. The connection between the head and the sleeve is produced by a silicate ceramic solder that solidifies or hardens in a ceramic firing, as well as by a subsequently applied glass solder, of which the excess can exit via the through-bore into a hollow space existing between the sleeve and the tenon. Both the recess of the head as well as the metallic sleeve are embodied approximately cylinder-shaped.

Embodiments of hardfacing layers in which wear resistant particles are substantially uniformly distributed in a matrix material are provided. The composition and microstructure of the matrix material and the amount, size and distribution of the wear resistant particles can be such that the hardfacing is wear resistant but still retains some toughness. The matrix material may include two components, a first component including iron, chromium and nickel and a second component including chromium and a substantial amount of carbon. The combination of the two components provides hardness and toughness to the matrix material. In embodiments of the disclosure, the wear resistant particles include tungsten. A hardfaced article, in one embodiment, may be formed by fusion welding an austenitic stainless steel filler metal to the surface of a base metal, thereby generating a weld pool; and adding a plurality of particles including tungsten carbide to the weld pool.

A braze alloy composition for sealing a ceramic component to a metal component in an electrochemical cell is presented. The braze alloy composition includes copper, nickel, and an active metal element. The braze alloy includes nickel in an amount less than about 30 weight percent, and the active metal element in an amount less than about 10 weight percent. An electrochemical cell using the braze alloy for sealing a ceramic component to a metal component in the cell is also provided.

A method of hardfacing a component includes generating a laser beam and directing the laser beam to an area of a wear surface of the component. The method includes feeding a flexible cord of a cladding material into the laser beam to melt the flexible cord and produce a bead of the cladding material on the wear surface. The flexible cord includes an inner metal wire surrounded by an agglomerate of abrasion and wear-resistant material that contains diamond particles. The method further includes moving the laser beam and the flexible cord along the wear surface to produce a cladding layer over the wear surface of the component.

A composite hard-surface material preparation method and a composite hard-surface material prepared thereby, the preparation method comprising: dispersedly fixing a plurality of cemented carbide sheets (2) to a surface of a metal substrate (1); and surfacing the cemented carbide sheets (2) and the metal substrate (1) with a solder (3) to obtain a composite hard-surface material, the solder (3) comprising nickel-based alloy powder, tungsten carbide particles and boron nitride powder. The solder (3) used in the preparation of the composite hard-surface material comprises nickel-based alloy powder, tungsten carbide particles and boron nitride powder, wherein the nickel-based alloy powder can increase fluidity and corrosion resistance, the tungsten carbide particle can improve hardness, and the boron nitride powder can effectively reduce friction coefficient. The present solder has good fluidity, high hardness and good solderability, using said solder, the obtained composite hard-surface material may enjoy good wear resistance.

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.