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.
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 ≤0.08 wt.% phosphorus ≤0.03 wt.% sulfur ≤0.01 wt.% nickel <22 wt.% cobalt <0.10 wt.% silicon ≤0.75 wt.% niobium ≤0.80 wt.% copper ≤0.25 wt.% balance iron. The billet is annealed and cold worked to form article. Without annealing of the article, the article is subsequently case hardened at a single 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 method for producing an additively manufactured, graded composite transition joint (AM-GCTJ) (300) includes preparing a grating or lattice pattern (101) from a first alloy A (100); the grating or lattice pattern (101) includes pores (110) in the grating or lattice patterns (101). 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 (200) powder to the second end of grating or lattice pattern. The second alloy B (200) powder is filled towards the first end. A composite is formed of first alloy A (100) and second alloy B (200) powder in the AM-GCTJ (300). The composite is subjected to hot isotropic pressing (HIP) to densify the composite. The second alloy B (200) is graduated from the first end to the second end of AM-GCTJ (300).
B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
B22F 7/00 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
B23K 35/02 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
B23K 35/30 - Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
C22C 1/04 - Making non-ferrous alloys by powder metallurgy
C22C 33/02 - Making ferrous alloys by powder metallurgy
B22F 10/38 - Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
5.
SOFT MAGNETIC COMPOSITE MATERIALS AND METHODS AND POWDERS FOR PRODUCING THE SAME
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.
B22F 1/02 - Special treatment of metallic powder, e.g. to facilitate working, to improve properties; Metallic powders per se, e.g. mixtures of particles of different composition comprising coating of the powder
B33Y 70/00 - Materials specially adapted for additive manufacturing
B33Y 80/00 - Products made by additive manufacturing
C03C 10/00 - Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
H01F 1/24 - 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 metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
6.
INDIRECT ADDITIVE MANUFACTURING PROCESS FOR FABRICATING BONDED SOFT 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.
B28B 1/00 - Producing shaped articles from the material
B29C 67/00 - Shaping techniques not covered by groups , or
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
7.
DOUBLE-SHOULDERED CONNECTION FOR DRILLING TUBULARS WITH LARGE INSIDE DIAMETER
A threaded connection for drilling tubulars includes a tubular box section having a sidewall. The box section has a tapered box portion of an inner surface of the sidewall between a first end and a second end. The tapered box portion has internal threads, a first torque shoulder on a first side of the tapered box portion, and a second shoulder on a second side of the tapered box portion. A threaded collar having internal collar threads is positioned between the second end and the second shoulder. A threaded insert having a tubular body with an inner surface and an outer surface having external insert threads is configured for threadably connecting to the internal collar threads. A direction of the internal threads of the tapered box portion is opposite to a direction of the internal collar threads and the external insert threads.
A pressure generating device for use in downhole drilling operations includes a rotating valve portion having a first body with at least one first flow channel, and a stationary valve portion having a second body with at least one second flow channels and at least one bypass channel. A flow restrictor is positioned within the at least one bypass channel for adjusting a total flow area of the at least one bypass channel. During rotation of the rotating valve portion relative to the stationary valve portion, a total flow area of a passage defined by the first flow channel(s), the second flow channel(s), and the at least one bypass channel varies according to a uniform closure pattern to provide uniform pressure pulses within a single revolution of the rotating valve portion. A method of generating uniform pressure pulses in downhole drilling operations is also disclosed.
E21B 21/10 - Valves arrangements in drilling-fluid circulation systems
E21B 7/18 - Drilling by liquid or gas jets, with or without entrained pellets
E21B 7/24 - Drilling using vibrating or oscillating means, e.g. out-of-balance masses
E21B 21/08 - Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure
E21B 21/12 - Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor using drilling pipes with plural fluid passages, e.g. closed circulation systems
E21B 34/06 - Valve arrangements for boreholes or wells in wells
E21B 41/00 - Equipment or details not covered by groups
This disclosure relates to a new alloy and methods of making same. The new alloy is an enhanced strength Ti-6A1-4V Grade 23+ titanium alloy having the following composition by weight percent: Aluminum - 6.0 wt% to 6.5 wt%; Vanadium - 4.0 wt% to 4.5 wt%; Iron - 0.15 wt% to 0.25 wt%; Oxygen - 0.00 wt% to 0.10 wt%; Nitrogen - 0.01 wt% to 0.03 wt%; Carbon - 0.04 wt% to 0.08 wt%; Hydrogen - 0.0000 wt% to 0.0125 wt%; Other Elements, each - 0.0 wt% to 0.1 wt%; Other Elements, total - 0.0 wt% to 0.4 wt%; and Titanium - Balance.
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