Abstract: A method may comprise: placing a probe in a molten metal melt comprising a thixotropic metal alloy; injecting a gas into the molten metal melt to form a saturated slurry, the saturated slurry being at a temperature above a liquidus temperature of the thixotropic metal alloy after injecting the gas; removing the probe from the molten metal melt; and depositing the molten metal melt through an extruder of an additive manufacturing system.

Abstract: A method is provided for producing ultra-fine-grained materials using additive manufacturing. The method includes commanding, by a controller, a laser device to produce a plurality of optical pulses to a base material to add an additive material to the base material. The method further includes commanding, by the controller, a vibration mechanism to vibrate the base material as the plurality of optical pulses are being applied to the base material forming fine equiaxed grains with random crystallographic texture in the base material.

Abstract: An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.

Abstract: A method may comprise: placing a probe in a molten metal melt comprising a thixotropic metal alloy; injecting a gas into the molten metal melt to form a saturated slurry, the saturated slurry being at a temperature above a liquidus temperature of the thixotropic metal alloy after injecting the gas; removing the probe from the molten metal melt; and depositing the molten metal melt through an extruder of an additive manufacturing system.

Abstract: An additive material manufacturing (AMM) system is provided to deposit powder to a build. The AMM system includes a powder supply, and a delivery mechanism. The powder supply receives a first electrical charge having first polarity. The delivery mechanism receives a second electrical charge having second polarity opposite first polarity. The build receives a third electrical charge having the first polarity. The third electrical charge of the build is greater than the second electrical charge of the delivery mechanism. The delivery mechanism receives the electrically charged powder where it is retained thereto based on electrostatic attraction generated between the first polarity of the electrically charged powder and the second polarity of the delivery mechanism. The electrocharged powder is from the delivery mechanism to the build based on electrostatic attraction generated between the first polarity of the electrically charged powder and the second polarity of the build.

Abstract: A method may comprise: placing a probe in a molten metal melt comprising a thixotropic metal alloy; injecting a gas into the molten metal melt to form a saturated slurry, the saturated slurry being at a temperature above a liquidus temperature of the thixotropic metal alloy after injecting the gas; removing the probe from the molten metal melt; and depositing the molten metal melt through an extruder of an additive manufacturing system.

Abstract: An additive manufacturing system includes an ultrasonic inspection system integrated in such a way as to minimize time needed for an inspection process. The inspection system may have an ultrasonic phased array integrated into a build table for detecting defects in each successive slice of a workpiece and such that each slice may be re-melted if and when defects are detected.

Abstract: A vacuum arc remelt apparatus comprising a crucible having a wall, said wall having an interior and an exterior opposite said interior; an electrode within the crucible proximate the interior; an ingot within the crucible and below the electrode, wherein said ingot includes a crown and shelf; and a vibration source at the exterior of the crucible proximate the crown and shelf.

Abstract: A method for making a component comprising a high entropy alloy (HEA) includes combining a reaction component with a powdered HEA precursor, igniting the combination of the reaction component and the powdered HEA precursor to induce a self-propagating high-temperature synthesis (SHS) reaction and to form a solid HEA feedstock, converting the solid HEA feedstock into a powder HEA feedstock, and additively manufacturing at least a portion of the powder feedstock into a HEA component or HEA preformed shape approximating a desired shape of the component.

Abstract: The present disclosure relates to a method of manufacturing a powder for additive manufacturing. The method comprises steps of: vaporising a precursor metal material to form a metal vapor, wherein the precursor material includes a metal alloy and inclusions, and vaporising the alloy includes heating the precursor material to a temperature above the boiling point of the metal alloy and below the boiling point of the inclusions; condensing the metal vapor to form a molten metal; and atomizing the molten metal to form a metal powder. The present disclosure also relates to an apparatus for carrying out the method.

Abstract: A method comprises discharging from a metal vaporization device a vapor of a metal or a metal precursor to a chemical vapor infiltration device where the chemical vapor infiltration device is in fluid communication with the metal vaporization device. The chemical vapor infiltration device contains a preform containing ceramic fibers. The preform is infiltrated with a metallic coating or a coating of a metallic precursor along with a ceramic precursor coating. The metallic coating and/or the metallic precursor coating and the ceramic precursor coating are applied sequentially or simultaneously.

Abstract: An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.

Abstract: An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.

Abstract: A nondestructive multispectral vibrothermography inspection system includes a fixture to retain a component, an ultrasonic excitation source directed toward the component retained within the fixture, a laser Doppler vibrometer directed toward the component retained within the fixture, and a multispectral thermography system directed toward the component retained within the fixture. A method for nondestructive multispectral vibrothermography inspection of a component, includes generating ultrasonic excitations in a component over a broad range of frequencies; determining a spectral signature in the component from the excitations; comparing the spectral energy signature against database 270 of correlations between vibrational frequencies of a multiple of components and the spectral energy distribution thereof, and classifying the component based on the database data.

Abstract: An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.

Abstract: A vacuum arc remelt apparatus comprising a crucible having a wall, said wall having an interior and an exterior opposite said interior; an electrode within the crucible proximate the interior; an ingot within the crucible and below the electrode, wherein said ingot includes a crown and shelf; and a vibration source at the exterior of the crucible proximate the crown and shelf.

Abstract: A method includes accessing a first model defining a shape of a part. The shape of the part is segregated into a plurality of predefined shapes selected from a library of predefined shapes. The predefined models for each of plurality of predefined shapes are assembled into a second model defining the shape of the part. The part is additively manufactured according to the second model.

Abstract: A feedstock for a cold spray process includes a plurality of globule bodies. The globule bodies include a plurality of discrete particles bonded to one another to define porous globule bodies. The bonds between the particles are of sufficient strength such that the globule bodies can retain both the body integrity as well as the body shape when the body experiences acceleration from a conveying gas in a cold spray technique. Methods of making the feedstock and globule bodies are also described.

Abstract: An example embodiment of a method is disclosed for making a component including a high entropy alloy (HEA). The method includes combining a reaction component with a powdered HEA precursor to form a solid HEA feedstock. The solid HEA feedstock is converted into a powder suitable for use as a powder feedstock in an additive manufacturing device and capable of sustaining a self-propagating high-temperature synthesis (SHS) reaction. At least a portion of the powder feedstock is additively manufactured into a preformed shape approximating a desired shape of the component. The preformed shape is filled with the HEA powder feedstock. The powdered HEA precursor in the preformed shape are ignited to induce the self-propagating high-temperature synthesis (SHS) reaction, thereby forming a stable HEA component approximating the desired shape.

Abstract: A build plate for an additive manufacturing system is disclosed. The build plate includes a support structure, a sub-plate, and one or more transducers. The support structure is configured to support a stack of sintered layers of a pulverant material. Further, the support structure extends orthogonally to a build direction. The sub-plate is arranged along the support structure, and defines a transducer cavity. One or more transducers are arranged in the transducer cavities. The one or more transducers are operable to cause vibration of the support structure and the stack parallel to the build direction. Such vibration relieves internal stresses caused by sintering of the stack.