Disclosed herein are duplex stainless steel alloys comprising 40 wt %-60 wt % ferrite and 60 wt %-40 wt % austenite and methods of formation thereof, the alloys including or consisting essentially of
from 10 wt % to 20 wt % chromium (Cr);
from 6 wt % to 13 wt % molybdenum (Mo);
from 0.5 wt % to 6.5 wt % nickel (Ni);
from 2.25 wt % to 12 wt % manganese (Mn);
from 0.05 wt % to 5 wt % copper (Cu);
from 0.05 wt % to 0.4 wt % nitrogen (N);
from 0.05 wt % to 0.35 wt % carbon (C);
from 0.01 wt % to 3.5 wt % cobalt (Co);
less than 2 wt % silicon (Si);
less than 2 wt % tungsten (W); and
iron (Fe) balance.
The duplex stainless steel alloy may include cast or wrought steel, or it may be in powder form.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
C21D 8/00 - Modifying the physical properties by deformation combined with, or followed by, heat treatment
A method for fabricating an article includes forming a billet consisting essentially of a stainless steel composition of
manganese 2.00 wt. %-24.00 wt. %
chromium 19.00 wt. %-30 wt. %
molybdenum 0.50 wt. %-4.0 wt. %
nitrogen 0.25 wt. %-1.10 wt. %
carbon ≤1 wt. %
phosphorus ≤0.03 wt. %
sulfur ≤1 wt. %
nickel <22 wt. %
cobalt <0.10 wt. %
silicon ≤1 wt. %
niobium ≤0.80 wt. %
oxygen ≤1 wt. %
copper ≤0.25 wt. %
balance iron.
The billet is annealed and cold worked to form an article. Without annealing of the article, the article is subsequently case hardened at a single case hardening temperature to form a surface layer on a top surface thereof. Articles formed with the indicated stainless steel composition with case hardened surface layers are also provided.
Closed-loop metal powder management methods for additive manufacturing. Virgin metal powder is provided in a closed powder container comprising at least one sensor, tracker, or optical device. The metal powder is transferred to an additive manufacturing system, a portion of a metal powder layer is consolidated, and excess metal powder is transferred from the additive manufacturing system to the powder container, a second powder container, or an internal powder container. Virgin metal powder or a second metal powder are added to the excess metal powder, a quality of the mixed powder is validated, the process is repeated at least once, and powder physical transfer data associated with at least one of the steps is collected and stored in a data repository. Powder material parameters may be measured and assessed, and may be also be stored in the data repository.
A powder including a plurality of particulates, each particulate including a soft magnetic metallic core coated with a continuous dielectric coating having a thickness selected from a range of 100 nanometers to 100 micrometers. The particulates have a mean particle size selected from a range of 100 nanometers to 250 micrometers. Methods for forming the powder are disclosed. A soft magnetic composite component includes a soft magnetic material in a dielectric matrix, wherein (i) the soft magnetic material comprises a plurality of particulates comprising metallic cores, (ii) each metallic core is coated by a continuous dielectric coating covering >90% of a surface area of the metallic core, (iii) the metallic cores are electrically isolated from each other, and (iv) the dielectric coatings of adjacent metallic cores are consolidated together. Methods for formation of the soft magnetic component by additive manufacturing and hot isostatic pressing are disclosed.
H01F 1/147 - Alloys characterised by their composition
H01F 41/02 - Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils or magnets
A bonded soft magnet object comprising bonded soft magnetic particles of an iron-containing alloy having a soft magnet characteristic, wherein the bonded soft magnetic particles have a particle size of at least 200 nm and up to 100 microns. Also described herein is a method for producing the bonded soft magnet by indirect additive manufacturing (IAM), such as by: (i) producing a soft magnet preform by bonding soft magnetic particles with an organic binder, wherein the magnetic particles have an iron-containing alloy composition with a soft magnet characteristic, and wherein the particles of the soft magnet material have a particle size of at least 200 nm and up to 100 microns; (ii) subjecting the preform to an elevated temperature sufficient to remove the organic binder to produce a binder-free preform; and (iii) sintering the binder-free preform at a further elevated temperature to produce the bonded soft magnet.
H01F 41/02 - Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils or magnets
H01F 1/147 - Alloys characterised by their composition
H01F 1/33 - Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metallic particles having oxide skin
C22C 38/02 - Ferrous alloys, e.g. steel alloys containing silicon
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
A magnetic iron alloy and process of making the same. The alloy includes iron, approximately 2 wt. % to approximately 8 wt. % cobalt, approximately 0.05 wt. % to approximately 5 wt. % manganese, and approximately 0.05 wt. % to approximately 5 wt. % silicon. The alloy may also include up to approximately 0.3 wt. % chromium, up to approximately 2 wt. % vanadium, up to approximately 1 wt. % nickel, up to approximately 0.05 wt. % niobium, and up to approximately 0.02 wt. % carbon.
A method and apparatus for producing titanium metal powder from a melt. The apparatus includes an atomization chamber having an inner wall that is coated with or formed entirely of a titanium alloy that is the same as the titanium metal powder to prevent contamination of titanium metal powder therein. The inner surfaces of some or all components of the apparatus in a flow path following the atomization chamber may also be coated with or formed entirely of the titanium alloy or CP-Ti.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
C22C 1/04 - Making non-ferrous alloys by powder metallurgy
8.
Method of hardening articles and articles comprising the same
Disclosed herein is a method comprising disposing on a base article a nickel-titanium alloy; where the nickel is in an amount of about 58 to about 62 weight percent and titanium in an amount of about 38 to about 42 wt %, based on the total weight of the nickel-titanium alloy; and applying a pressure of 12 to 20 kilopounds per square inch at a temperature of 1400 to 2100° F. for a period of 1 to 8 hours to form a nickel-titanium alloy coating on the base article. Disclosed is an article comprising a base article; and a nickel-titanium alloy; where the nickel-titanium alloy is disposed on the base article; where the nickel is in an amount of about 58 to about 62 weight percent and titanium in an amount of about 38 to about 42 wt %, based on the total weight of the nickel-titanium alloy.
C22C 19/03 - Alloys based on nickel or cobalt based on nickel
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 37/10 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using direct action of vacuum or fluid pressure
B32B 37/06 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
B32B 15/01 - Layered products essentially comprising metal all layers being exclusively metallic
B05D 7/24 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
B05D 3/02 - Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
B05D 7/14 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
B23K 20/02 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press
C23C 28/02 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of metallic material
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
A method and apparatus for producing titanium metal powder from a melt. The apparatus includes an atomization chamber having an inner wall that is coated with or formed entirely of CP-Ti to prevent contamination of titanium metal powder therein. The inner surfaces of all components of the apparatus in a flow path following the atomization chamber may also be coated with or formed entirely of CP-Ti.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
A method of producing a high strength, high stiffness and high ductility titanium alloy, comprising combining the titanium alloy with boron so that the boron concentration in the boron-modified titanium alloy does not exceed the eutectic limit. The carbon concentration of the boron-modified titanium alloy is maintained below a predetermined limit to avoid embrittlement. The boron-modified alloy is heated to a temperature above the beta transus temperature to eliminate any supersaturated excess boron. The boron-modified titanium alloy is deformed at a speed slow enough to prevent microstructural damage and reduced ductility.
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