Patent ID: 8551395

Claim:
A method for preparing a metal-based part, the method comprising: (i) applying a slurry to a surface of a temporary substrate to thereby form a slurry-coated temporary substrate, wherein the slurry comprises a metal-based material, a binder, and a solvent; (ii) drying the slurry-coated temporary substrate to remove the solvent and to thereby form a coating layer having green strength; (iii) heating the coating layer to remove the binder; (iv) heating the coating layer to sinter the metal-based material into a continuous metal alloy layer; and (v) separating the substrate from the coating layer; wherein the metal-based material is a Co-based alloy comprising between about 21 wt % and about 35 wt % Cr, between about 4 wt % and about 19 wt % W, up to about 3 wt % Ni, up to about 5 wt % Fe, between about 0.4 wt % and about 3.5 wt % C, up to about 1.5 wt % Mn, between about 0.1 wt % and about 1.5 wt % Si, and up to about 1.5 wt % Mo, and the balance Co, and wherein the sintering is performed at a temperature above the solidus and below the liquidus of the alloy.