A heterogeneous composition is disclosed, including an alloy mixture and a ceramic additive. The alloy mixture includes a first alloy having a first melting point of at least a first threshold temperature, and a second alloy having a second melting point of less than a second threshold temperature. The second threshold temperature is lower than the first threshold temperature. The first alloy, the second alloy, and the ceramic additive are intermixed with one another as distinct phases. An article is disclosed including a first portion including a material composition, and a second portion including the heterogeneous composition. A method for forming the article is disclosing, including applying the second portion to the first portion.

A method for producing a bonded permanent magnet, comprising: (i) incorporating a solid precursor material comprising a thermoplastic crosslinkable polymer and magnetic particles into an additive manufacturing device, wherein the crosslinkable polymer has a delayed crosslinking ability; (ii) melting the precursor material by heating it to a temperature of at least and no more than 10 C. above its glass transition temperature; (iii) extruding the melt through the additive manufacturing device and, as the extrudate exits from the nozzle and is deposited on a substrate as a solidified preform of a desired shape, exposing the resultant extrudate to a directional magnetic field of sufficient strength to align the magnetic particles; and (iv) curing the solidified preform by subjecting it to conditions that result in crosslinking of the thermoplastic crosslinkable polymer to convert it to a crosslinked thermoset. The resulting bonded permanent magnet and articles made thereof are also described.

A variable stiffness engineered degradable ball or seal having a degradable phase and a stiffener material. The variable stiffness engineered degradable ball or seal can optionally be in the form of a degradable diverter ball or sealing element which can be made neutrally buoyant.

The invention is directed to the interventionless activation of wellbore devices using dissolving and/or degrading and/or expanding structural materials. Engineered response materials, such as those that dissolve and/or degrade or expand upon exposure to specific environment, can be used to centralize a device in a wellbore.

A castable, moldable, or extrudable structure using a metallic base metal or base metal alloy. One or more insoluble additives are added to the metallic base metal or base metal alloy so that the grain boundaries of the castable, moldable, or extrudable structure includes a composition and morphology to achieve a specific galvanic corrosion rates partially or throughout the structure or along the grain boundaries of the structure. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The insoluble particles generally have a submicron particle size. 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.

A metal matrix composite comprising nanotubes; a method of producing the same; and a composition, for example a metal alloy, used in such composites and methods, are disclosed. A method for continuously infiltrating nanotube yarns, tapes or other nanotube preforms with metal alloys using a continuous process or a multistep process, which results in a metal matrix composite wire, cable, tape, sheet, tube, or other continuous shape, and the microstructure of these infiltrated yarns or fibers, are disclosed. The nanotube yarns comprise a multiplicity of spun nanotubes of carbon (CNT), boron nitride (BNNT), boron (BNT), or other types of nanotubes. The element that infiltrates the nanotube yarns or fibers can, for example, be alloyed with a concentration of one or more elements chosen such that the resulting alloy, in its molten state, will exhibit improved wetting of the nanotube material.

A metal matrix composite comprising nanotubes; a method of producing the same; and a composition, for example a metal alloy, used in such composites and methods, are disclosed. A method for continuously infiltrating nanotube yarns, tapes or other nanotube preforms with metal alloys using a continuous process or a multistep process, which results in a metal matrix composite wire, cable, tape, sheet, tube, or other continuous shape, and the microstructure of these infiltrated yarns or fibers, are disclosed. The nanotube yarns comprise a multiplicity of spun nanotubes of carbon (CNT), boron nitride (BNNT), boron (BNT), or other types of nanotubes. The element that infiltrates the nanotube yarns or fibers can, for example, be alloyed with a concentration of one or more elements chosen such that the resulting alloy, in its molten state, will exhibit improved wetting of the nanotube material.

A method of making dispersion-strengthened alloy particles involves melting an alloy having a corrosion and/or oxidation resistance-imparting alloying element, a dispersoid-forming element, and a matrix metal wherein the dispersoid-forming element exhibits a greater tendency to react with a reactive species acquired from an atomizing gas than does the alloying element. The melted alloy is atomized with the atomizing gas including the reactive species to form atomized particles so that the reactive species is (a) dissolved in solid solution to a depth below the surface of atomized particles and/or (b) reacted with the dispersoid-forming element to form dispersoids in the atomized particles to a depth below the surface of said atomized particles. The atomized alloy particles are solidified as solidified alloy particles or as a solidified deposit of alloy particles. Bodies made from the dispersion strengthened alloy particles, deposit thereof, exhibit enhanced fatigue and creep resistance and reduced wear as well as enhanced corrosion and/or oxidation resistance at high temperatures by virtue of the presence of the corrosion and/or oxidation resistance imparting alloying element in solid solution in the particle alloy matrix.

A method of making dispersion-strengthened alloy particles involves melting an alloy having a corrosion and/or oxidation resistance-imparting alloying element, a dispersoid-forming element, and a matrix metal wherein the dispersoid-forming element exhibits a greater tendency to react with a reactive species acquired from an atomizing gas than does the alloying element. The melted alloy is atomized with the atomizing gas including the reactive species to form atomized particles so that the reactive species is (a) dissolved in solid solution to a depth below the surface of atomized particles and/or (b) reacted with the dispersoid-forming element to form dispersoids in the atomized particles to a depth below the surface of said atomized particles. The atomized alloy particles are solidified as solidified alloy particles or as a solidified deposit of alloy particles. Bodies made from the dispersion strengthened alloy particles, deposit thereof, exhibit enhanced fatigue and creep resistance and reduced wear as well as enhanced corrosion and/or oxidation resistance at high temperatures by virtue of the presence of the corrosion and/or oxidation resistance imparting alloying element in solid solution in the particle alloy matrix.

A castable, moldable, or extrudable structure using a metallic base metal or base metal alloy. One or more insoluble additives are added to the metallic base metal or base metal alloy so that the grain boundaries of the castable, moldable, or extrudable structure includes a composition and morphology to achieve a specific galvanic corrosion rates partially or throughout the structure or along the grain boundaries of the structure. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The insoluble particles generally have a submicron particle size. 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.