Thermoplastic-encapsulated functionalized metal or metal alloy powders

A method of forming and using a functionalized composite material, said method comprising:

• (a) providing a plurality of discrete metal or metal alloy particles and a plurality of discrete particulates fully or partially assembled on surfaces of said discrete metal or metal alloy particles, thereby establishing surface-functionalized discrete metal or metal alloy particles, wherein said discrete metal or metal alloy particles comprise an element selected from the group consisting of aluminum, iron, titanium, nickel, and alloys or intermetallics thereof, wherein said discrete particulates comprise a material selected from the group consisting of metals, ceramics, polymers, carbon, and nitrides, hydrides, carbides, oxides, or alloys thereof, and combinations of any of the foregoing, wherein said discrete particulates are smaller than said discrete metal or metal alloy particles in at least one dimension, and wherein said discrete particulates are compositionally different than said discrete metal or metal alloy particles;
• (b) disposing said surface-functionalized discrete metal or metal alloy particles in a thermoplastic polymer binder matrix having a distinct volume, wherein said discrete particulates are in contact with said thermoplastic polymer binder matrix;
• (c) recovering a functionalized composite material containing said thermoplastic polymer binder matrix and said surface-functionalized discrete metal or metal alloy particles;
• and
• (d) debinding said thermoplastic polymer binder matrix from said functionalized composite material, thereby forming a partially dense brown body containing said discrete metal or metal alloy particles and said discrete particulates fully or partially assembled on surfaces of said discrete metal or metal alloy particles,
• wherein said discrete particulates occupy from about 1 vol % to about 25 vol % of said distinct volume.

A method of forming and using a functionalized composite material, said method comprising:

• (a) providing a plurality of discrete metal or metal alloy particles and a plurality of discrete particulates fully or partially assembled on surfaces of said discrete metal or metal alloy particles, thereby establishing surface-functionalized discrete metal or metal alloy particles, wherein said discrete metal or metal alloy particles comprise an element selected from the group consisting of aluminum, iron, titanium, nickel, and alloys or intermetallics thereof, wherein said discrete particulates comprise a material selected from the group consisting of metals, ceramics, polymers, carbon, and nitrides, hydrides, carbides, oxides, or alloys thereof, and combinations of any of the foregoing, wherein said discrete particulates are smaller than said discrete metal or metal alloy particles in at least one dimension, and wherein said discrete particulates are compositionally different than said discrete metal or metal alloy particles;
• (b) disposing said surface-functionalized discrete metal or metal alloy particles in a thermoplastic polymer binder matrix having a distinct volume, wherein said discrete particulates are in contact with said thermoplastic polymer binder matrix;
• (c) recovering a functionalized composite material containing said thermoplastic polymer binder matrix and said surface-functionalized discrete metal or metal alloy particles;
• and
• (d) simultaneously sintering and debinding said functionalized composite material to form a dense body,
• wherein said discrete particulates occupy from about 1 vol % to about 25 vol % of said distinct volume.