Abstract: A metal additive manufacturing machine includes a housing, a torch at least partially disposed within the housing, a media, a material, a sensor, and a control system. The media is granular and substantially similar to the material such that it can initiate and maintain an arc, if necessary, and be incorporated into the component. The media forms a flat or topographically featured structure. The material is positioned such that it is melted by the torch and forms a layer of material onto the media. The sensor is configured to measure a first data, where the first data is a distance between the torch and a layer of material. The control system is operably coupled to the sensor and configured to receive the first data and compare the first data to a first data threshold. The control system sends a command to move the torch in a z-direction.

Abstract: The invention is a system for and method of manufacturing metallic parts through weld arc additive manufacturing with conductive granular media as support, to manufacture parts which have overhangs, hollow sections, a plurality of openings, a geometry having a discontinuous structure when formed by additive manufacturing steps that is joined, or a combination of geometries known in the art of manufacturing that could heretofore only be produced by cutting and assembling a variety of different parts. The system and method of the invention contemplate use of conductive granular media support material which may become at least partially incorporated in, or part of, a final part produced using the system or method of the invention.

Abstract: An electrorefining cell permits increased electrolyte flow rates while maintaining the slime layer at the bottom of the cell and on the anode faces substantially intact. The cell includes an inlet manifold located near the bottom of the cell and having a plurality of discharge orifices for the electrolyte solution. An inlet baffle shrouds the discharge orifices to regulate and direct the flow of electrolyte solution within the cell. The inlet baffle and the cell wall form an elongated slot that resides beneath the surface of the electrolyte solution. An analogous configuration is employed for electrolyte discharge to enable relatively high electrolyte flow into and out of the cell. The specific shape, size, and location of the inlet baffle and an outlet baffle may be selected to optimize the electrolyte flow characteristics of the cell.