Method of consolidating/molding near net-shaped components made from powders

A method for fabricating a component from powder, comprising:

• (a) cold compacting powder to create a pre-form;
• (b) placing the pre-form between smart susceptors of an induction tool assembly;
• (c) flooding a space inside the induction tool assembly with an oxygen-free gas;
• (d) heating the smart susceptors to their Curie temperature that is greater than a phase change temperature of the pre-form by supplying an alternating current to induction coils which produce a varying magnetic field having a peak strength less than 0.1 tesla and a magnetic flux that passes through surfaces of the smart susceptors;
• (e) applying consolidation pressure to the pre-form at least during a time period subsequent to the temperature of the smart susceptors reaching the Curie temperature;
• and
• (f) while consolidation pressure is being applied, intermittently supplying direct current to the induction coils to produce a pulsed magnetic field having a strength greater than or equal to 0.5 tesla and a magnetic flux that passes through a surface of the pre-form,
• wherein a pulse rate of the pulsed magnetic field is selected so that the crystallographic phase of the pre-form will oscillate, and the pulsed magnetic field is applied sufficiently long that superplasticity of the pre-form is attained during phase oscillation.

A method for consolidating a pre-form made of powder comprising ferromagnetic material, comprising:

• (a) placing the pre-form between smart susceptors;
• (b) heating the smart susceptors to their Curie temperature that is greater than a phase change temperature of the pre-form by supplying an alternating current to induction coils which produce a varying magnetic field having a peak strength less than 0.1 tesla and a magnetic flux that passes through surfaces of the smart susceptors;
• (c) applying consolidation pressure to the pre-form at least during a time period subsequent to the temperature of the smart susceptors reaching the Curie temperature;
• and
• (d) while consolidation pressure is being applied, intermittently supplying direct current to the induction coils to produce a pulsed magnetic field having a strength greater than or equal to 0.5 tesla and a magnetic flux that passes through a surface of the pre-form,
• wherein a pulse rate of the pulsed magnetic field is selected so that the crystallographic phase of the pre-form will oscillate, and the pulsed magnetic field is applied sufficiently long that superplasticity of the pre-form is attained during phase oscillation.