Provided is a soft magnetic alloy having a composition of a compositional formula (Fe.sub.(1−(α+β))X1.sub.αX2.sub.β).sub.(1−(a+b+c+d+e))P.sub.aC.sub.bSi.sub.cCu.sub.dM.sub.e. X1 is one or more selected from a group consisting of Co and Ni, X2 is one or more selected from a group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Bi, N, 0, and rare earth elements, and M is one or more selected from the group consisting of Nb, Hf, Zr, Ta, Ti, Mo, W and V. 0.050≤a≤0.17, 0<b<0.050, 0.030<c≤0.10, 0<d≤0.020, 0≤e≤0.030, α≥0, β≥0, and 0≤α+β≤0.50.

Provided is a soft magnetic alloy having a composition of a compositional formula (Fe.sub.(1−(α+β))X1.sub.αX2.sub.β).sub.(1−(a+b+c+d+e))P.sub.aC.sub.bSi.sub.cCu.sub.dM.sub.e. X1 is one or more selected from a group consisting of Co and Ni, X2 is one or more selected from a group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Bi, N, 0, and rare earth elements, and M is one or more selected from the group consisting of Nb, Hf, Zr, Ta, Ti, Mo, W and V. 0.050≤a≤0.17, 0<b<0.050, 0.030<c≤0.10, 0<d≤0.020, 0≤e≤0.030, α≥0, β≥0, and 0≤α+β≤0.50.

Nickel-cobalt alloy for powder, wherein the contents (in wt %) are defined as follows: C>0-max. 0.1% S max. 0.015% Cr 13-23% Ni the rest (>30%) Mn max. 1.0% Si max. 1.0% Mo 1-6% Ti>0-3% Nb+Ta 3-8% Cu max. 0.5% Fe>0-max. 10% Al>0-<4.0% V up to 4% Zr>0-max. 0.1% Co>12-<35% W up to 4% Hf up to 3.0% O max. 0.1% N>0-max. 0.1% Mg>0-max. 0.01% B>0-max. 0.02% P>0-max. 0.03% Ar 0-max. 0.08% Se max. 0.0005% Bi max. 0.00005% Pb max. 0.002%

The metal powder production apparatus includes: a spray tank; and a plurality of spray nozzles each including a molten metal nozzle that lets molten metal flow down into the spray tank and a gas injection nozzle that injects gas from a plurality of injection holes to the molten metal flowing down from the molten metal nozzle. The sectional area A1 [mm.sup.2] of the spray tank has a value obtained by multiplying the number n (n is an integer equal to or greater than 2) of the spray nozzles by a predetermined area value c1.

There is provided a cobalt-based alloy material comprising: in mass %, 0.08-0.25% C; 0.003-0.2% N, the total amount of C and N being 0.083-0.28%; 0.1% or less B; 10-30% Cr; 5% or less Fe and 30% or less Ni, the total amount of Fe and Ni being 30% or less; W and/or Mo, the total amount of W and Mo being 5-12%; Al and/or Si, at least one of Al and Si being more than 0.5% and 3% or less, and the total amount of Al and Si being more than 0.5% and 4% or less; 0.5% or less Mn; 0.5-4% of an M component being a transition metal other than W and Mo and having an atomic radius of more than 130 pm; and the balance being Co and impurities. There is also provided a product formed from the cobalt-based alloy material.

There is provided a cobalt-based alloy material comprising: in mass %, 0.08-0.25% C; 0.003-0.2% N, the total amount of C and N being 0.083-0.28%; 0.1% or less B; 10-30% Cr; 5% or less Fe and 30% or less Ni, the total amount of Fe and Ni being 30% or less; W and/or Mo, the total amount of W and Mo being 5-12%; Al and/or Si, at least one of Al and Si being more than 0.5% and 3% or less, and the total amount of Al and Si being more than 0.5% and 4% or less; 0.5% or less Mn; 0.5-4% of an M component being a transition metal other than W and Mo and having an atomic radius of more than 130 pm; and the balance being Co and impurities. There is also provided a product formed from the cobalt-based alloy material.

To provide Ti—Cu alloy formulations and additive manufacturing process configurations for fabrication of a bulk metallic glass (BMG) product that is biocompatible and antimicrobial, compositions of Ti-based metal alloy powder, comprising: Ti; Cu within a range of 5-30 atomic percent; transition metal within a range of 0-50 atomic percent, wherein such transition metal is one or a plurality of Zr, Nb, Ta, Pd, and Co, are disclosed. Moreover, additive manufacturing processes disclosed herein are capable of fabricating a bulk metallic glass of one or a combination of following phasic structures: fully amorphous microstructure; amorphous beta titanium phase; amorphous copper phase; and amorphous (Ti,M).sub.2Cu phase. The resulting biocompatible metal alloy product may be a medical device, particularly but not limited to a medical implant.

To provide Ti—Cu alloy formulations and additive manufacturing process configurations for fabrication of a bulk metallic glass (BMG) product that is biocompatible and antimicrobial, compositions of Ti-based metal alloy powder, comprising: Ti; Cu within a range of 5-30 atomic percent; transition metal within a range of 0-50 atomic percent, wherein such transition metal is one or a plurality of Zr, Nb, Ta, Pd, and Co, are disclosed. Moreover, additive manufacturing processes disclosed herein are capable of fabricating a bulk metallic glass of one or a combination of following phasic structures: fully amorphous microstructure; amorphous beta titanium phase; amorphous copper phase; and amorphous (Ti,M).sub.2Cu phase. The resulting biocompatible metal alloy product may be a medical device, particularly but not limited to a medical implant.

A nickel alloy includes (in wt. %) Ni 50-55%, Cr 17-21%, Mo>0-9%, W 0-9%, Nb 1-5.7%, Ta>0-4.7%, Ti 0.1-3.0%, Al 0.4-4.0%, Co max. 3.0%, Mn max. 0.35%, Si max. 0.35%, Cu max. 0.23%, C 0.001-0.045%, S max. 0.01%, P 0.001-0.02%, B 0.001-0.01%, the remainder Fe and the conventional process-related impurities, wherein the following relations are provided: Nb+Ta 1-5.7% (1), Al+Ti>1.2-5% (2), Mo+W 3-9% (3), where Nb, Ta, Al and Ti are the concentration of the elements in question in wt. %.

A nickel-based superalloy for three-dimension (3D) printing and a powder preparation method thereof are provided. The method of preparing the nickel-based superalloy and its powder includes: RE microalloying combined with vacuum melting, degassing, refining, atomization with reasonable parameters, and a sieving process. The new method significantly reduces the cracking sensitivity of the “non-weldable” PM nickel-based superalloys, and broadens the 3D printing process window. The as-printed part has no cracks, and good mechanical properties. In addition, the powder prepared by the new method has higher sphericity and better flowability, and less irregular powders. The yield of fine powders with a particle size of 15-53 μm and medium-sized powders with a particle size of 53-106 μm that are required for 3D printing is greatly improved, which meet the requirements for 3D printing of high-quality, low-cost nickel-based superalloy powder.