This disclosure, and the exemplary embodiments provided herein, include 3D printed titanium composites and methods including 1 vol. % carbon nanotube reinforcements on selective laser melt printed Ti64. The interrelationships with laser energy density, laser power, and laser scan speed are demonstrated and discussed. Utilizing selective laser melting, according to one exemplary embodiment of this disclosure, a >99% dense Ti-CNT composite is disclosed with microhardness of 4.75 GPa—a 30% enhancement over its Ti64 counterpart.

A component for a gas turbine engine can be made via additive manufacturing. During the additive manufacturing process a powder can be used that comprises a superalloy material (12) and carbon nanostructures (14a, 14b). Components made using the powder can have preferred characteristics at certain locations through the use of the carbon nanostructure based additive manufacturing powder.

Disclosed are a method of manufacturing an aluminum alloy clad section, and an aluminum alloy clad section manufactured by the method. The method includes preparing a composite powder by ball-milling aluminum powder and carbon nanotubes, preparing a billet from the composite powder, and subjecting the billet to direct extrusion using an extrusion die. The method is simple in procedure and uses simple equipment because it is based on direct extrusion which is suitable for mass production. Thus, the method is capable of producing a lightweight high-strength functional aluminum alloy clad section having a competitive advantage in terms of price over conventional aluminum alloy clad sections.

A method of manufacturing a functional sheet according to an embodiment of the present invention, comprise powdering a filler with specific functional component and a binder, charging the filler and the binder with second polarity, spraying the binder and the filler onto an upper surface of an electrode plate charged with first polarity opposite to the second polarity, heat-treating the binder and filler, pressing an upper surface of the filler with a rolling roller, and separating the binder and the filler from the electrode plate. Therefore, the method can improve functionality while reducing harmfulness by manufacturing the functional sheet using a powdered filler and binder without using an organic solvent.

An aluminum-based composite material includes a plurality of coarse crystalline grains (3) of pure aluminum, and a plurality of fine crystalline grains (4) each having an aluminum matrix (1), and a dispersion material (2) dispersed inside the aluminum matrix and formed by reacting a portion or all of an additive with aluminum in the aluminum matrix. The fine crystalline grains exist among the coarse crystalline grains, and the fine crystalline grains have crystalline grain diameters smaller than crystalline grain diameters of the coarse crystalline grains.

Disclosed are a method of manufacturing an aluminum-based clad heat sink, and an aluminum-based clad heat sink manufactured by the method. The method includes ball-milling (i) aluminum or aluminum alloy powder and (ii) carbon nanotubes (CNT) to prepare a composite powder, preparing a multi-layered billet using the composite billet, and directly extruding the multi-layered billet using an extrusion die to produce a heat sink. The method has an advantage of producing a light high-strength high-conductivity aluminum-based clad heat sink having an competitive advantage in terms of price by using direct extrusion that is suitable for mass production due to its simplicity in process procedure and equipment required.

A carbon nanotube composite wire 2 includes: a carbon nanotube 6; and a sintered layer 8 attached to a surface of the carbon nanotube 6. The sintered layer 8 includes a large number of silver flakes 14. These silver flakes 14 are bonded to each other by sintering. Flat surfaces 16 of silver flakes 14 partly overlap, or are partly in contact with, flat surfaces 16 of other adjacent silver flakes 14. An electrically conductive network is formed by these silver flakes 14 being adjacent to each other.

A composition for making a composite polycrystalline diamond includes a plurality of diamond particles, a plurality of boron-doped diamond particles, and an additive which is selected from the group consisting of boron oxide powder, nano-carbon material and a combination thereof. Based on the total weight of the composition, the diamond particles are present in an amount that ranges from 0.5 wt % to 99.4 wt %, the boron-doped diamond particles are present in an amount that ranges from 0.5 wt % to 99.4 wt %, and the additive is present in an amount that ranges from 0.1 wt % to 20 wt %. A method for making the composite polycrystalline diamond and a composite polycrystalline diamond made thereby are also disclosed.

This disclosure, and the exemplary embodiments provided herein, disclose carbon nanotubes (CNT) integrated into 316L stainless steel (SS) powder feedstocks and 3D-printed using selective laser melting (SLM). Ball milling is used to disperse CNT clusters homogeneously onto the surface of 316L SS powders with minimal damage to the CNTs. Hardness increased by 35% and wear was reduced by 70% with the addition of 2 vol % CNT, relative to SLM 316L SS. The addition of CNTs increased the water contact angle and retained the desirable corrosion resistance of SLM 316L SS, demonstrating the potential of 3D-printed SS-CNT composites for use in structural marine applications.

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%.