Abstract:
A method for manufacturing a three-dimensional part (20). The method includes: performing partial densification processing on loose machining powder (142), to form a densified and sealed enclosure (24), where there is still loose machining powder accommodated inside the enclosure; and performing overall densification processing on the enclosure and the machining powder inside the enclosure, so as to implement metallurgical bonding between the machining powder inside the enclosure and the enclosure during the densification, thereby forming a target three-dimensional part.
Abstract:
A metallic alloy made of metallic constituent elements is fabricated and utilized by first furnishing (20) a mixture of nonmetallic precursor compounds of the metallic constituent elements, and thereafter chemically reducing (22) the mixture of nonmetallic precursor compounds to produce a metallic alloy as a metallic alloy powder, without melting the metallic alloy. The metallic alloy powder is applied (26) to a surface of a substrate article (24), preferably in a coating, joining, or deposition application.
Abstract:
A metallic article made of metallic constituent elements is fabricated from a mixture of nonmetallic precursor compounds of the metallic constituent elements. The mixture of nonmetallic precursor compounds contains more of a base-metal element, such as nickel, cobalt, iron, iron-nickel, and iron-nickel-cobalt than any other metallic element. The mixture of nonmetallic precursor compounds is chemically reduced to produce a metallic superalloy material, without melting the metallic superalloy material. The metallic superalloy material is consolidated to produce a consolidated metallic article, without melting the metallic superalloy material and without melting the consolidated metallic article.
Abstract:
An article (20) is prepared by furnishing a plurality of powder particle substrates (80) made of a substrate metal, providing a nonmetallic precursor of a metallic coating material, wherein the metallic coating material comprises an alloying element that is thermophysically melt incompatible with the substrate metal, contacting the powder particle substrates (80) with the nonmetallic precursor, chemically reducing the nonmetallic precursor to form coated powder particles (102) comprising the powder particle substrates (80) having a surface-enriched layer (120) of the metallic coating material thereon without melting the powder particle substrates (80), and processing the coated powder particles (102) to form the article (20), without melting the powder particle substrates (80).
Abstract:
A metallic article is produced by furnishing one or more nonmetallic precursor compound comprising the metallic base nickel, cobalt, iron, iron-nickel, or iron-nickel-cobalt, and at least one alloying element. The nonmetallic precursor compound(s) are chemically reduced to produce an initial metallic particle without melting the initial metallic particle. The initial metallic particle is thereafter melted and solidified to produce the metallic article. The melted-and-solidified metal may be used in the as-cast form, or it may be converted to billet and further worked to the final form.
Abstract:
A martensitic steel metallic article made of metallic constituent elements is fabricated from a mixture of nonmetallic precursor compounds of the metallic constituent elements. The mixture of nonmetallic precursor compounds is chemically reduced to produce a metallic martensitic steel, without melting the metallic martensitic steel. The metallic martensitic steel is consolidated to produce a consolidated metallic article, without melting the metallic martensitic steel and without melting the consolidated metallic article.
Abstract:
A metallic article made of metallic constituent elements is fabricated from a mixture of nonmetallic precursor compounds of the metallic constituent elements. The mixture of nonmetallic precursor compounds contains more of a base-metal element, such as nickel, cobalt, iron, iron-nickel, and iron-nickel-cobalt than any other metallic element. The mixture of nonmetallic precursor compounds is chemically reduced to produce a metallic superalloy material, without melting the metallic superalloy material. The metallic superalloy material is consolidated to produce a consolidated metallic article, without melting the metallic superalloy material and without melting the consolidated metallic article.
Abstract:
A method for manufacturing a three-dimensional part (20). The method includes: performing partial densification processing on loose machining powder (142), to form a densified and sealed enclosure (24), where there is still loose machining powder accommodated inside the enclosure; and performing overall densification processing on the enclosure and the machining powder inside the enclosure, so as to implement metallurgical bonding between the machining powder inside the enclosure and the enclosure during the densification, thereby forming a target three-dimensional part.
Abstract:
A method for preparing an article of a base metal alloyed with an alloying element includes the steps of preparing a compound mixture by the steps of providing (40) a chemically reducible nonmetallic base-metal precursor compound of a base metal, providing (42) a chemically reducible nonmetallic alloying-element precursor compound of an alloying element, and thereafter mixing (44) the base-metal precursor compound and the alloying-element precursor compound to form a compound mixture. The compound mixture is thereafter reduced (48) to a metallic alloy, without melting the metallic alloy. The step of preparing or the step of chemically reducing includes the step of adding an other additive constituent. The metallic alloy is thereafter consolidated to produce a consolidated (50) metallic article, without melting the metallic alloy and without melting the consolidated metallic article.