Embodiments disclosed are systems and methods for fabricating microchannels in metal. In an embodiments, a method includes providing a first metallic plate having a first surface with an elongated slot recessed therein, providing a second metallic plate having a second surface, interfacing the first surface of the first metallic plate with the second surface of the second metallic plate with the second surface covering the elongated slot to form a microchannel between the first metallic plate and the second metallic plate, thermal bonding the first metallic plate to the second metallic plate to form a metallic body having the microchannel extending therethrough, and infiltrating the metallic body with an infiltrant.

Embodiments disclosed are systems and methods for fabricating microchannels in metal. In an embodiments, a method includes providing a first metallic plate having a first surface with an elongated slot recessed therein, providing a second metallic plate having a second surface, interfacing the first surface of the first metallic plate with the second surface of the second metallic plate with the second surface covering the elongated slot to form a microchannel between the first metallic plate and the second metallic plate, thermal bonding the first metallic plate to the second metallic plate to form a metallic body having the microchannel extending therethrough, and infiltrating the metallic body with an infiltrant.

The present disclosure relates to a wear part made in a foundry. The wear part has a reinforced portion comprising a ferrous alloy reinforced with metal carbides, nitrides, borides, or intermetallic alloys. The reinforced portion includes inserts of metal carbides, nitrides, metal, or intermetallic compounds manufactured beforehand with a defined geometry and inserted into an infiltrable structure of agglomerated grains including the reagents needed for the formation of metal or intermetallic carbides, nitrides, borides according to an in situ self-propagating thermal reaction initiated during the casting of the ferrous alloy.

A method for producing an additively manufactured, graded composite transition joint (AM-GCTJ) includes preparing a grating or lattice pattern from a first alloy A; the grating or lattice pattern includes pores in the grating or lattice patterns. The grating pattern is built from a first end to a second end being denser on the first end than on second end, and gradually reduces density by increasing the pore size and/or reducing density of the grating or lattice pattern; adding a second alloy B powder to the second end of grating or lattice pattern. The second alloy B powder is filled towards the first end. A composite is formed of first alloy A and second alloy B powder in the AM-GCTJ. The composite is subjected to hot isotropic pressing (HIP) to densify the composite. The second alloy B is graduated from the first end to the second end O of AM-GCTJ.

A method for producing an additively manufactured, graded composite transition joint (AM-GCTJ) includes preparing a grating or lattice pattern from a first alloy A; the grating or lattice pattern includes pores in the grating or lattice patterns. The grating pattern is built from a first end to a second end being denser on the first end than on second end, and gradually reduces density by increasing the pore size and/or reducing density of the grating or lattice pattern; adding a second alloy B powder to the second end of grating or lattice pattern. The second alloy B powder is filled towards the first end. A composite is formed of first alloy A and second alloy B powder in the AM-GCTJ. The composite is subjected to hot isotropic pressing (HIP) to densify the composite. The second alloy B is graduated from the first end to the second end O of AM-GCTJ.

A powder admixture useful for making a sintered valve seat insert includes a first iron-base powder and second iron-base powder wherein the first iron-base powder has a higher hardness than the second iron-base powder, the first iron-base powder including, in weight percent, 1-2% C, 10-25% Cr, 5-20% Mo, 15-25% Co, and 30-60 wt. % Fe, and the second iron-base powder including, in weight %, 1-1.5% C, 3-15% Cr, 5-7% Mo, 3-6% W, 1-1.7% V, and 60-85% Fe. The powder admixture can be sintered to form a sintered valve seat insert optionally infiltrated with copper.

A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.

A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.

The present disclosure relates to a hierarchical wear part including a reinforced portion comprising zirconia or an alumina-zirconia alloy. The reinforced portion also includes centimetric inserts with a predefined geometry. The inserts include micrometric particles of metal carbides, nitrides, borides, or intermetallic compounds bonded by a first metal matrix. The inserts are inserted into a reinforcement structure infiltrated by a second metal matrix, the reinforcement structure having a periodic alternation of millimetric areas of high and low concentration of micrometric particles of zirconia or alumina-zirconia alloy. The second metal matrix is different from the first metal matrix.

A composite wear pad includes a substrate that is selected from the group of iron based alloys, steel, nickel based alloys, and cobalt based alloys. A hard particle-matrix alloy layer is bonded at a surface to the substrate. The hard particle-matrix alloy layer has a plurality of hard particles dispersed in a matrix alloy. The hard particle-matrix alloy layer has a thickness ranging between greater than about 13 millimeters and about 20 millimeters.