A solid-state additive manufacturing additive manufacturing system applicable to building up 3D structures, coating and functionalizing surfaces, joining structures, adding customized features to objects, compounding proprietary compositions and repairing various structures is disclosed. The solid-state additive manufacturing system enables deposition of different fillers, viz. metals, metal alloys, MMCs, polymers, plastics, composites, hybrids and gradient compositions, as well as controls the resulting deposit structures, e.g. specific nano-/micro-, gradient- and porous-material structures. The system accommodates various feeding-, spindle- and tool-designs for depositing different forms of filler materials, viz. rods, wires, granules, powders, powder-filled-tubes, scrap pieces or their combination, and a working platform with multiple access points. One or multiple motors, driving and monitoring units control the movement of the workpiece, spindle and tool and move the filler through the feeding system, which passageway is in communication with the passageways of the spindle and the tool.

A low carbon footprint material is used to decrease the carbon dioxide emission for production of a high carbon footprint substance. A method of forming composite materials comprises providing a first high carbon footprint substance; providing a carbon nanomaterial produced with a carbon-footprint of less than 10 unit weight of carbon dioxide (CO.sub.2) emission during production of 1 unit weight of the carbon nanomaterial; and forming a composite comprising the high carbon footprint substance and from 0.001 wt % to 25 wt % of the carbon nanomaterial, wherein the carbon nanomaterial is homogeneously dispersed in the composite to reduce the carbon dioxide emission for producing the composite material relative to the high carbon footprint substance.

A consolidated material formed by powder metallurgy is provided. The consolidated material includes particles of a first component consolidated with particles of a second component. The first component is a transition metal selected from group 4, group 5, group 6, or group 7 of the periodic table of the elements, or an alloy thereof. The second component is a solid lubricant. Also provided is a method of making the consolidated material and articles made from the consolidated material.

A consolidated material formed by powder metallurgy is provided. The consolidated material includes particles of a first component consolidated with particles of a second component. The first component is a transition metal selected from group 4, group 5, group 6, or group 7 of the periodic table of the elements, or an alloy thereof. The second component is a solid lubricant. Also provided is a method of making the consolidated material and articles made from the consolidated material.

Processes produce a compound material structure by producing a composite material which extends along an axis of elongation from carbon nanostructures anchored in a matrix of a first metal extending along the axis of elongation of the composite material. The processes comprise dividing the composite material into segments of the composite material, arranging the segments in a plane of a die matrix, filling free spaces in the die matrix with a filler material and subsequently sintering in the die matrix to form a compound material structure or squeeze casting in the die matrix, and exposing the carbon nanostructures of the composite material on at least one surface of the compound material structure such that the carbon nanostructures protrude out of this surface. Compound material structures and uses thereof as a heat conductor and/or a heat exchanger are also provided.

A castable, moldable, or extrudable magnesium-based alloy that includes one or more insoluble additives. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The final structure can be enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final structure as compared to the non-enhanced structure. The magnesium-based composite has improved thermal and mechanical properties by the modification of grain boundary properties through the addition of insoluble nanoparticles to the magnesium alloys. The magnesium-based composite can have a thermal conductivity that is greater than 180 W/m-K, and/or ductility exceeding 15-20% elongation to failure.

A castable, moldable, or extrudable magnesium-based alloy that includes one or more insoluble additives. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The final structure can be enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final structure as compared to the non-enhanced structure. The magnesium-based composite has improved thermal and mechanical properties by the modification of grain boundary properties through the addition of insoluble nanoparticles to the magnesium alloys. The magnesium-based composite can have a thermal conductivity that is greater than 180 W/m-K, and/or ductility exceeding 15-20% elongation to failure.

A castable, moldable, or extrudable magnesium-based alloy that includes one or more insoluble additives. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The final structure can be enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final structure as compared to the non-enhanced structure. The magnesium-based composite has improved thermal and mechanical properties by the modification of grain boundary properties through the addition of insoluble nanoparticles to the magnesium alloys. The magnesium-based composite can have a thermal conductivity that is greater than 180 W/m-K, and/or ductility exceeding 15-20% elongation to failure.

A castable, moldable, or extrudable magnesium-based alloy that includes one or more insoluble additives. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The final structure can be enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final structure as compared to the non-enhanced structure. The magnesium-based composite has improved thermal and mechanical properties by the modification of grain boundary properties through the addition of insoluble nanoparticles to the magnesium alloys. The magnesium-based composite can have a thermal conductivity that is greater than 180 W/m-K, and/or ductility exceeding 15-20% elongation to failure.

An electrically conductive, flexible, strain resilient product is produced by mixing metal coated carbon nanotube networks with a liquid polymeric resin to produce a liquid mixture, and the mixture is cured to produce the product. The networks may include welded junctions between nanotubes formed by depositing and melting metal nanoparticles on the nanotubes to form the metal coating. After the mixing step the liquid mixture may be deposited on a flexible substrate in the form of an electrical circuit. The mixing step may further include mixing the composite with a volatile solvent to produce a selected viscosity. Then, a three-dimensional printer may be used to print the product, such as an electrical circuit, on a substrate. The product is cured in an atmosphere that absorbs the solvent. The conductivity of the mixture may be adjusted by adjusting the weight percentage of the metal coated carbon nanotube networks from 50% to 90%, but a preferred range is between 75% and 85%.