Abstract: A method for manufacturing metal components includes the steps of providing a waste feedstock having a selected chemical composition; producing an additive manufacturing (AM) grade alloy powder from the waste feedstock using a cold hearth mixing process; providing an additive manufacturing system; controlling the producing of the alloy powder such that the properties of the alloy powder optimize building of the components using the additive manufacturing system; and building the components using the alloy powder and the additive manufacturing system.

Abstract: A deployable manufacturing center (DMC) system includes a foundry module containing a metallurgical system configured to convert a raw material into an alloy powder, and an additive manufacturing (AM) module containing an additive manufacturing system configured to form the alloy powder into metal parts. The deployable manufacturing center (DMC) system can also include a machining module containing a machining system configured to machine the metal parts into machined metal parts, and a quality conformance (QC) module containing an inspection and evaluation system configured to inspect and evaluate the metal parts. A process for manufacturing metal parts includes the steps of providing the deployable manufacturing center (DMC) system; deploying the (DMC) system to a desired location; forming an alloy powder from a raw material using the deployable foundry module; and then forming the metal parts from the alloy powder using the additive manufacturing (AM) module.

Abstract: A method for recycling metal parts includes the steps of providing a metal part with a QR code linked to an online website or an application containing data on the metal part and information on recycling of the metal part. The method also includes the step of reading the QR code using a mobile communication device enabling access to the information on the website or the application by a user of the mobile communication device and access to the data on the metal part by a recycling entity associated with the website or the application. The method also includes the step of displaying selected information from the website or the application on the mobile communication device. The method also includes the step of recycling the metal part using at least some of the information on the website or the application and the data on the metal part.

Abstract: A method for manufacturing metal components includes the steps of providing a waste feedstock having a selected chemical composition; producing an additive manufacturing (AM) grade alloy powder from the waste feedstock using a cold hearth mixing process; providing an additive manufacturing system; controlling the producing of the alloy powder such that the properties of the alloy powder optimize building of the components using the additive manufacturing system; and building the components using the alloy powder and the additive manufacturing system.

Abstract: A metallurgical system for producing metals and metal alloys includes a fluid cooled mixing cold hearth having a melting cavity configured to hold a raw material for melting into a molten metal, and a mechanical drive configured to mount and move the mixing cold hearth for mixing the raw material. The system also includes a heat source configured to heat the raw material in the melting cavity, and a heat removal system configured to provide adjustable insulation for the molten metal. The mixing cold hearth can be configured as a removal element of an assembly of interchangeable mixing cold hearths, with each mixing cold hearth of the assembly configured for melting a specific category of raw materials. A process includes the steps of providing the mixing cold hearth, feeding the raw material into the melting cavity, heating the raw material, and moving the mixing cold hearth during the heating step.

Abstract: A deployable manufacturing center (DMC) system includes a foundry module containing a metallurgical system configured to convert a raw material into an alloy powder, and an additive manufacturing (AM) module containing an additive manufacturing system configured to form the alloy powder into metal parts. The deployable manufacturing center (DMC) system can also include a machining module containing a machining system configured to machine the metal parts into machined metal parts, and a quality conformance (QC) module containing an inspection and evaluation system configured to inspect and evaluate the metal parts. A process for manufacturing metal parts includes the steps of providing the deployable manufacturing center (DMC) system; deploying the (DMC) system to a desired location; forming an alloy powder from a raw material using the deployable foundry module; and then forming the metal parts from the alloy powder using the additive manufacturing (AM) module.

Abstract: A metallurgical system for producing metals and metal alloys includes a fluid cooled mixing cold hearth having a melting cavity configured to hold a raw material for melting into a molten metal, and a mechanical drive configured to mount and move the mixing cold hearth for mixing the raw material. The system also includes a heat source configured to heat the raw material in the melting cavity, and a heat removal system configured to provide adjustable insulation for the molten metal. The mixing cold hearth can be configured as a removal element of an assembly of interchangeable mixing cold hearths, with each mixing cold hearth of the assembly configured for melting a specific category of raw materials. A process includes the steps of providing the mixing cold hearth, feeding the raw material into the melting cavity, heating the raw material, and moving the mixing cold hearth during the heating step.

Abstract: A metallurgical system for producing metals and metal alloys includes a fluid cooled mixing cold hearth having a melting cavity configured to hold a raw material for melting into a molten metal, and a mechanical drive configured to mount and move the mixing cold hearth for mixing the raw material. The system also includes a heat source configured to heat the raw material in the melting cavity, and a heat removal system configured to provide adjustable insulation for the molten metal. The mixing cold hearth can be configured as a removal element of an assembly of interchangeable mixing cold hearths, with each mixing cold hearth of the assembly configured for melting a specific category of raw materials. A process includes the steps of providing the mixing cold hearth, feeding the raw material into the melting cavity, heating the raw material, and moving the mixing cold hearth during the heating step.

Abstract: A metallurgical system for producing metals and metal alloys includes a fluid cooled mixing cold hearth having a melting cavity configured to hold a raw material for melting into a molten metal, and a mechanical drive configured to mount and move the mixing cold hearth for mixing the raw material. The system also includes a heat source configured to heat the raw material in the melting cavity, and a heat removal system configured to provide adjustable insulation for the molten metal. The mixing cold hearth can be configured as a removal element of an assembly of interchangeable mixing cold hearths, with each mixing cold hearth of the assembly configured for melting a specific category of raw materials. A process includes the steps of providing the mixing cold hearth, feeding the raw material into the melting cavity, heating the raw material, and moving the mixing cold hearth during the heating step.