A metal matrix nanocomposite includes: (1) a matrix including an aluminum alloy; and (2) nanostmctures dispersed in the matrix, wherein the matrix includes grains having aspect ratios of about 3 or less. Manufacturing processes include subjecting the nanocomposite to solidification processing, fusion welding, extrusion, thixocasting, additive manufacturing, and heat treatment.

Alloys comprised of a refined microstructure, ultrafine or nano scaled, that when reacted with water or any liquid containing water will spontaneously and rapidly produce hydrogen at ambient or elevated temperature are described. These metals, termed here as aluminum based nanogalvanic alloys will have applications that include but are not limited to energy generation on demand. The alloys may be composed of primarily aluminum and other metals e.g. tin bismuth, indium, gallium, lead, etc. and/or carbon, and mixtures and alloys thereof. The alloys may be processed by ball milling for the purpose of synthesizing powder feed stocks, in which each powder particle will have the above mentioned characteristics. These powders can be used in their inherent form or consolidated using commercially available techniques for the purpose of manufacturing useful functional components.

An Fe-based soft magnetic alloy is provided. The Fe-based soft magnetic alloy can be represented by empirical formula Fe.sub.aB.sub.bC.sub.cCu.sub.d, and in the empirical formula, a, b, c and d are atomic percent (at %) of the corresponding element and are respectively 78.5≤a≤86, 13.5≤b+c≤21 and 0.5≤d≤1.5. The alloy has a high saturated magnetic flux density, excellent high frequency characteristics and low coercivity, and thus greatly facilitates the development of use as high performance/high efficiency small/lightweight parts. Since manufacturing costs are very low and the components contained in an alloy are easily controlled in an alloy manufacturing process, thereby enabling mass production of the alloy, the present invention can be widely applied as magnetic parts of electric and electronic devices such as a high power laser, a high frequency power supply, a high-speed pulse generator, an SMPS, a high-pass filter, a low-loss high frequency transformer, a fast switch and wireless charging.

Provided herein are manufacturing methods of a metal matrix nanocomposite, comprising: providing a molten metal including a first reactant; providing a molten salt, including a second set of reactants and a diluting salt, over a surface of the molten metal; and maintaining the molten salt and the molten metal at a temperature sufficient to react the first reactant and the second set of reactants, such that nanostructures with controlled small sizes are formed adjacent to an interface between the molten salt and the molten metal, and are incorporated into the molten metal for mass manufacturing of metal matrix nanocomposite.

A soft magnetic metal powder that has low coercivity Hcj and high saturation magnetic flux density Bs, and has high powder resistivity and high insulating performance is obtained. The soft magnetic metal powder is soft magnetic metal powder containing Fe. The soft magnetic metal powder has particles each including a soft magnetic metal portion and a coating portion coating the soft magnetic metal portion. The coating portion includes a first coating portion and a second coating portion. The first coating portion is closer to the soft magnetic metal portion than the second coating portion. The first coating portion and the second coating portion have oxides containing at least one element selected from Si, Fe, and B as a main component. The first coating portion includes amorphous material, the second coating portion includes crystals, and the second coating portion has a higher crystal content ratio than the first coating portion.

A new lattice structure design or discrimination method inspired by the crystalline structure of high-entropy alloy is described. A method for providing a high-entropy lattice (HEL) having a pseudo-random lattice structure comprises fabricating a locally distorted lattice structure and generating a high-entropy lattice (HEL) having a macroscopically ordered configuration from the locally distorted lattice structure. An article of manufacture comprising a high-entropy lattice (HEL) having a pseudo-random lattice structure, wherein the pseudo-random lattice structure is a macroscopically ordered lattice structure that includes locally distorted lattice structures, may be provided.

A soft magnetic alloy including a compositional formula of ((Fe.sub.(1−(α+β))X1.sub.αX2.sub.β).sub.(1−(a+b+c+e))M.sub.aB.sub.bP.sub.cCu.sub.e).sub.1−fC.sub.f, wherein X1 is one or more selected from the group consisting Co and Ni, X2 is one or more selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Bi, N, O, and rare earth elements, “M” is one or more selected from the group consisting of Nb, Hf, Zr, Ta, Ti, Mo, W, and V, 0.030<a≤0.14, 0.028≤b≤0.20, 0≤c≤0.030, 0<e≤0.030, 0<f≤0.040, α≥0, β≥0, and 0≤α+β≤0.50 are satisfied.

An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.

The iron alloy particle is a particle including an iron alloy. The particle includes multiple mixed-phase particles, each including nanocrystals of 10 nm or more and 100 nm or less (i.e., from 10 nm to 100 nm) in crystallite size and an amorphous phase; and a grain boundary layer between the mixed-phase particles. Also, the iron alloy has a composition containing Fe, Si, P, B, C, and Cu.

A Fe-based nanocrystalline alloy powder having an alloy composition represented by the following Composition Formula (1) and having an alloy structure including nanocrystal particles:
Fe.sub.100-a-b-c-d-e-f-gCu.sub.aSi.sub.bB.sub.cMo.sub.dCr.sub.eC.sub.fNb.sub.g   Composition Formula (1), in which 100-a-b-c-d-e-f-g, a, b, c, d, e, f, and g each represent a percent (%) by atom of a relevant element, and a, b, c, d, e, f, and g satisfy 0.10≤a≤1.10, 13.00≤b≤16.00, 7.00≤c≤12.00, 0.50≤d≤5.00, 0.001≤e≤1.50, 0.05≤f≤0.40, and 0≤(g/(d+g))≤0.50, in Composition Formula (1).