Infiltrated ferrous materials

A method for layer-by-layer formation of a free-standing metallic part comprising:

• (a) forming an article comprising at least a first layer and a second layer on the first layer, wherein:
• the first and second layers each comprise metallic alloy particles and a binder;
• the metallic alloy particles comprise, in weight percent:
• 17.0<Cr<22.0, 8.0<Mo<12.0, 2.0<B<5.0, 3.0<W<7.0, 0.5<C<2.0, 1.0<Mn<4.0, 1.0<Si<3.0, balance Fe;
• and
• forming the article comprises:
• forming the first layer via a binder jetting process;
• and
• forming the second layer on the first layer via a binder jetting process;
• (b) heating the article to produce a cured article having a porosity ranging from 20 to 60%, wherein the heating cures the binder;
• (c) sintering the cured article, wherein the sintering comprises heating the cured article to remove the binder and cooling at a rate of less than 5° C./minute to form a porous metallic skeleton;
• and
• (d) infiltrating the porous metallic skeleton with an infiltrant to form the free-standing metallic part, wherein the free-standing metallic part has a wear resistance with a volume loss of less than or equal to 130 mm3 as measured according to ASTM 065-04(2010) Procedure A.