Method of forming a sintered nickel-titanium-rare earth (Ni—Ti—RE) alloy

A method of forming a sintered nickel-titanium-rare earth (Ni—Ti-RE) alloy, the method comprising:

• adding one or more powders comprising Ni, Ti, and a rare earth element consisting of Er to a powder consolidation unit comprising an electrically conductive die and punch connectable to a power supply;
• heating the one or more powders at a ramp rate of about 35° C./min or less to a sintering temperature within a softening temperature range of the rare earth constituent, the softening temperature range being equal to between about 0.5·Tm and about 0.55·Tm, where Tm is an absolute melting temperature of the rare earth constituent in degrees Celsius;
• applying pressure to the powders at the sintering temperature;
• and
• forming a sintered Ni—Ti-RE alloy comprising the Ni at a concentration from about 34 at. % to about 60 at. %, comprising the Ti at a concentration from about 34 at. % to about 60 at. %, and comprising the Er at a concentration from about 0.1 at. % to about 15 at. %;
• and
• hot working the sintered Ni—Ti-RE alloy.