A method and apparatus for surface densification of powder metal annular preforms is described. A forming tool has external helical teeth corresponding to internal helical teeth of the preform. A die correspondingly configured to the external splines of the preform circumferentially surrounds the forming tool. The forming tool, die and lower punch(es) collectively define an aperture dimensioned to receive the preform. Upper punch(es) encase the preform in the aperture. Surface densification of the internal surface of the preform is achieved by movement of the preform axially over the forming tool. External splines of the preform and corresponding die splines direct the preform axially while internal helical teeth and corresponding forming teeth direct the forming tool to rotate as the preform moves. The forming teeth have varying dimensions in the circumferential and radial directions to apply compression and relaxation to densify the surface of the preform helical teeth.

The present invention provides an alloy, an alloy powder, an alloy member, and a composite member which are excellent in corrosion resistance and wear resistance, have crack resistance, and are suitable for an additive manufacturing method and the like. An alloy and an alloy powder include, by mass %, Cr: 18 to 22%, Mo: 18 to 28%, Ta: 1.5 to 57%, C: 1.0 to 2.5%, Nb: 0 to 42%, Ti: 0 to 15%, V: 0 to 27%, Zr: 0 to 29%, and a remainder consisting of Ni and unavoidable impurities, where a molar ratio of (Ta+0.7Nb+Ti+0.6V+Zr)/C=0.5 to 1.5 is satisfied. An alloy member is an additively manufactured product or a cast having such a solidification structure, and the solidification structure is a dendrite-like crystal structure having a metal phase having a face-centered cubic structure and carbides.

A helical sector gear having a body and a gear segment having a plurality of helical teeth. The gear segment has a toothed sector, on which all of the helical teeth are formed, and spacing segments on the opposite circumferential ends of the toothed sector. Each of the spacing segments has a circumferential surface, which is longer than a pitch of the helical teeth, and a radial surface that is formed in a helical manner that conforms to the helix angle of helical teeth. A die set for forming the helical sector gear and a related method are also provided.

Provided is an insert adapter for direct ink writing printers (DIW) and methods of fiber alignment in direct ink writing. The insert adapter is sized to fit snugly inside a print barrel DIW 3D printer. The adapter includes channels. The DIW printer with insert adapter, can be used in a passive method for microfiber alignment in DIW printing. The method includes feeding a non-Newtonian ink including microfibers through the print barrel such that the ink flows into the channels of the insert adapter before exiting through a print nozzle, causing the microfibers to align along the direction of ink flow.

Provided is an insert adapter for direct ink writing printers (DIW) and methods of fiber alignment in direct ink writing. The insert adapter is sized to fit snugly inside a print barrel DIW 3D printer. The adapter includes channels. The DIW printer with insert adapter, can be used in a passive method for microfiber alignment in DIW printing. The method includes feeding a non-Newtonian ink including microfibers through the print barrel such that the ink flows into the channels of the insert adapter before exiting through a print nozzle, causing the microfibers to align along the direction of ink flow.

According to a method for pressing a green compact from a sintering powder for producing a gear having a first track and a second track, wherein a first helical toothing with a first helix angle and a first diameter is produced as the first track and a second helical toothing with a second helix angle and a second diameter is produced as the second track, the sintering powder is filled into a mold cavity of a die, and then the sintering powder is pressed to form the green compact with an upper stamp and a lower stamp, and wherein the first and the second helical toothings are produced having the same pitch height.

Embodiments of the invention relate to methods of making articles having portions of polycrystalline diamond bonded to a surface of a substrate and polycrystalline diamond compacts made using the same. In an embodiment, a molding technique is disclosed for forming cutting tools comprising polycrystalline diamond portions bonded to the outer surface of a substrate.

A method for producing and reinforcing a composite gear includes providing a base material comprising a polymer and forming a composite gear from the base material, the composite gear having a gear body and at least one gear tooth extending from the gear body, the at least one gear tooth having a tooth face, a tooth flank, a tooth fillet, a tooth root, and a tooth tip. The method includes depositing a first metallic material to a first area of the at least one gear tooth of the composite gear, the first area including the tooth root of the at least one gear tooth and depositing a second metallic material to a second area of the at least one gear tooth of the composite gear. The first metallic material is applied in a first thickness and the second metallic material is applied in a second thickness.

An actuator includes a first ball-ramp plate, a second ball-ramp plate, and a plurality of balls. The first ball-ramp plate is formed of compressed powdered metal with ramps having a higher density than at least part of a remainder of the ball-ramp component. A method of manufacturing the actuator includes compacting a metal powder to form a blank of the first ball-ramp plate including an annular body disposed about an axis and a plurality of ramps fixedly coupled to the annular body and spaced circumferentially about the axis, and locally densifying the ramps of the blank by applying force to a ramped surface of each ramp.

A screw conveyor comprises a shaft, a screw flight arranged to extend helically around, and connected to the shaft at the outer circumference of the shaft, and extending in axial direction along at least a portion of the shaft, wherein the screw flight has an outer edge at the outer circumference of the screw flight, and at least one recess for receiving fibrous material is arranged in the outer edge of the screw flight. The screw flight has a cross-sectional profile with a width in the region of the outer circumference of the screw flight greater than the width in the region of the inner circumference of the screw flight. Furthermore, the invention relates to a separator device for dewatering moist masses, including liquid manure residues and/or digestates, as well as a method for additively manufacturing a screw conveyor and a use of a screw conveyor.