Disclosed are a method of manufacturing a rare-earth permanent magnet capable of offsetting a partially uneven demagnetization by varying the amount of heavy rare-earth element diffused to a grain boundary for each region and a Nd—Fe—B-based permanent magnet manufactured by the same.

The method includes: preparing a base material including a plurality of regions by using a sintered magnet including an Nd—Fe—B-based alloy; preparing a coating material including a heavy rare-earth element; applying the coating material to a surface of the base material; and diffusing the heavy rare-earth element to a grain boundary of the base material by heat-treating the base material to which the coating material is applied. In the applying the coating material, an amount of the coating material applied to each region of the base material may vary.

The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

Various embodiment related to methods for coating a metal substrate with a silicon nitride ceramic coating are disclosed herein. The metal substrate may be a biomedical implant with a laser-cladded silicon nitride coating for promoting osteogenesis.

Molybdenum is alloyed into stainless steel surface by electro-spark deposition technique. Shielding gas is used during electro-spark deposition process to minimize the oxidation of materials. Control of electro-spark voltage, frequency, capacitance, time can determine the alloying depth of Molybdenum. The alloyed surface thickness varies from 5 μm to 80 μm depending on the electro-spark deposition parameters. The alloyed surface comprises, by weight, 15 to 40% of Molybdenum, 8 to 22% of Cr, 0-15% of other alloy elements and impurities. The molybdenum alloyed stainless steel surface exhibits improvement in micro-hardness, wear resistance, and especially corrosion resistance in sodium chloride solutions. Thus, the present invention would be utilized in marine and handling of brines application, as well as in other applications which better corrosion resistance of stainless steel is desired.

Molybdenum is alloyed into stainless steel surface by electro-spark deposition technique. Shielding gas is used during electro-spark deposition process to minimize the oxidation of materials. Control of electro-spark voltage, frequency, capacitance, time can determine the alloying depth of Molybdenum. The alloyed surface thickness varies from 5 μm to 80 μm depending on the electro-spark deposition parameters. The alloyed surface comprises, by weight, 15 to 40% of Molybdenum, 8 to 22% of Cr, 0-15% of other alloy elements and impurities. The molybdenum alloyed stainless steel surface exhibits improvement in micro-hardness, wear resistance, and especially corrosion resistance in sodium chloride solutions. Thus, the present invention would be utilized in marine and handling of brines application, as well as in other applications which better corrosion resistance of stainless steel is desired.

This disclosure relates to a method of producing a tool comprising a substrate and a hard-face coating metallurgically bonded to the substrate. The method comprises the steps of: providing a steel substrate; providing a composition of fully sintered granulate grains; and then applying the fully sintered granulate grains onto the substrate. The resultant cemented carbide material on the steel substrate comprises a specific composition and includes a metastable phase having a nanohardness of at least 12 GPa and a Palmqvist fracture toughness of below 7 MPa m½. The method includes heat-treating the hard-face coating to at least partially decompose the metastable phase, to increase the Palmqvist fracture toughness.

A method for depositing a coating on a continuous carbon or ceramic fiber from a precursor of the coating, the method including at least the heating of at least one segment of the fiber in the presence of a liquid or supercritical phase of the coating precursor by a laser beam so as to bring the surface of the segment to a temperature allowing the formation of the coating on the segment from the coating precursor.

A patterned diamond and methods of making such patterned diamond are disclosed. The patterned diamond may include: a single crystal diamond or a polycrystal diamond; and a metallic pattern embedded in the single crystal diamond or the polycrystal diamond such that, the single crystal diamond or the polycrystal diamond encapsulates the metallic pattern from at least 4 sides. The disclosed method may include providing a first portion of a single crystal diamond or a polycrystal diamond; introducing a metallic pattern to at least one surface of the first portion of the single crystal or a first portion of the polycrystal diamond; and growing, using a CVD process or HTHP process, a second portion of the single crystal diamond or the second portion of the polycrystal diamond on the first portion, such that the single crystal diamond or the polycrystal diamond at least partially encapsulates the metallic pattern.

A method of forming a pattern of metallic material on a substrate includes providing a plurality of void regions on a surface of the substrate. At a first temperature, a first layer of a first metallic material of a eutectic-forming pair of metallic materials is deposited on the substrate to form a conformal metallic film over the substrate and over the surfaces of the plurality of void regions. The substrate and conformal metallic film are warmed to a second temperature greater than a eutectic-liquid-formation temperature of the eutectic pair of metallic materials. At the second temperature, the second metallic material of the eutectic-forming pair of metallic materials is deposited on the conformal metallic film to initiate a eutectic-liquid-forming reaction, such that the plurality of void regions are filled with a mixture of the first and second metallic materials of the eutectic-forming pair of metallic materials.