A compressor blade of a gas turbine includes a compressor blade portion including a plurality of layers; and a carbon fiber reinforcement embedded in the plurality of layers of the compressor blade portion and oriented in a direction of stress fields of the compressor blade when in operation. A method of manufacturing the compressor blade includes preparing a composite material including fiber-reinforced layers; forming a first layer of the composite material to extend in a radial direction of the compressor blade; and stacking a second layer of the composite material on the first layer in an axial direction of the compressor blade. The compressor blade is 3D-printed by forming each composite material layer in a radial direction, which layers are stacked in an axial direction. Fiber reinforcement in the composite compressor blade is oriented in line with the stress fields inherent in the operation of the compressor blade.

Disclosed herein are structures comprising a titanium, zirconium, or hafnium powder particle with titanium carbide, zirconium carbide, or hafnium carbide (respectively) nano-whiskers grown directly from and anchored to the powder particle. Also disclosed are methods for fabrication of such structures, involving heating the powder particles and exposing the particles to an organic gas.

Disclosed herein are structures comprising a titanium, zirconium, or hafnium powder particle with titanium carbide, zirconium carbide, or hafnium carbide (respectively) nano-whiskers grown directly from and anchored to the powder particle. Also disclosed are methods for fabrication of such structures, involving heating the powder particles and exposing the particles to an organic gas.

A method is disclosed for forming extrudate filament, which consist essentially of fiber, organic binder, and metal and/or ceramic. The extrudate filament can be spooled, or used to form preforms, and/or assemblages of preforms. In further methods, the extrudate filament and/or preforms can be used to fabricate fiber-reinforced metal-matrix or ceramic-matrix or metal and ceramic matrix composite parts, which consist essentially of fiber in a matrix of metal, or ceramic, or metal and ceramic, respectively.

A method is disclosed for forming extrudate filament, which consist essentially of fiber, organic binder, and metal and/or ceramic. The extrudate filament can be spooled, or used to form preforms, and/or assemblages of preforms. In further methods, the extrudate filament and/or preforms can be used to fabricate fiber-reinforced metal-matrix or ceramic-matrix or metal and ceramic matrix composite parts, which consist essentially of fiber in a matrix of metal, or ceramic, or metal and ceramic, respectively.

Carbon fiber reinforced metal matrix composite turbine rotors include a planar carbon fiber structure encapsulated within a metal matrix formed of sintered metal nanoparticles. The metal nanoparticles can include a metal having a high sintering temperature that would ordinarily destroy the carbon fiber. Novel techniques for making small uniform nanoparticles for sintering lowers the sintering temperature to a level that can accommodate carbon fiber. The composite rotors possess high strength to weight ratio.

Carbon fiber reinforced metal matrix composite gears include a planar carbon fiber structure fully encapsulated within a metal matrix formed of sintered metal nanoparticles. The metal nanoparticles can be composed of a metal having a high sintering temperature that would ordinarily destroy the carbon fiber. Novel techniques for making small uniform nanoparticles for sintering lowers the sintering temperature to a level that can accommodate carbon fiber. The composite gears possess high strength to weight ratio.

A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

A sintered friction material, in which a content of a copper component is 0.5 mass % or less, is provided. The sintered friction material includes a titanate and a metal material other than copper, as a matrix. A content of the metal material other than copper is 10.0 volume % to 34.0 volume %. A method for manufacturing a sintered friction material is provided. The method includes a mixing step of mixing raw materials containing a titanate and a metal material other than copper, a molding step of molding the raw materials mixed in the mixing step, and a sintering step of sintering, at 900° C. to 1300° C., a molded product molded in the molding step. In the sintered friction material, the titanate and the metal material other than copper form a matrix, and a content of the metal material other than copper is 10.0 volume % to 34.0 volume %.