Abstract: An additive manufacturing method of producing a metal alloy article may involve: Providing a supply of a metal alloy in powder form; providing a supply of a nucleant material, the nucleant material lowering the nucleation energy required to crystallize the metal alloy; blending the supply of metal alloy powder and nucleant material to form a blended mixture; forming the blended mixture into a first layer; subjecting at least a portion of the first layer to energy sufficient to raise the temperature of the first layer to at least the liquidus temperature of the metal alloy; allowing at least a portion of the first layer to cool to a temperature sufficient to allow the metal alloy to recrystallize; forming a second layer of the blended mixture on the first layer; and repeating the subjecting and allowing steps on the second layer to form an additional portion of the metal alloy article.

Abstract: An additive manufacturing method of producing a metal alloy article may involve: Providing a supply of a metal alloy in powder form; providing a supply of a nucleant material, the nucleant material lowering the nucleation energy required to crystallize the metal alloy; blending the supply of metal alloy powder and nucleant material to form a blended mixture; forming the blended mixture into a first layer; subjecting at least a portion of the first layer to energy sufficient to raise the temperature of the first layer to at least the liquidus temperature of the metal alloy; allowing at least a portion of the first layer to cool to a temperature sufficient to allow the metal alloy to recrystallize; forming a second layer of the blended mixture on the first layer; and repeating the subjecting and allowing steps on the second layer to form an additional portion of the metal alloy article.

Abstract: A composition of an exothermic mixture suitable for a cladding process, comprising at least one transition metal oxide and at least one fuel, wherein the fuel is at least a binary mixture selected from the group of aluminium, calcium, magnesium or silicon. The invention is furthermore directed to a process for producing corrosion resistant alloy clad metal pipes by loading and distributing the exothermic mixture to one or more pipes in a clad assembly, followed by igniting the exothermic mixture and applying a post cladding pipe procedure.

Abstract: The present invention relates to a process for producing corrosion resistant alloy-clad metal pipes by: (a) providing one or more pipes to be clad; (b) providing an exothermic mixture; 5 (c) loading and distributing the exothermic mixture into the one or more pipes in a cladding assembly at a rotational speed suitable to generate a centrifugal force of at most 10 times the gravitational force; (d) igniting the loaded exothermic mixture using an ignition system at a rotational speed generating a centrifugal force of at least 50 times the gravitational force; 10 and (e) applying a post cladding pipe procedure.

Abstract: An additive manufacturing method may involve: Providing a first material in powder form and a second material as a consumable electrode; forming the first material into a first layer on a base; placing an end of the second material in close proximity to a portion of the first layer; operating a power supply connected to the base and the second material to provide electrical energy sufficient to initiate a chemical reaction between the first and second materials and form a reaction product; feeding additional amounts of the second material while moving the end of the second material along a desired pattern adjacent the first layer, additional reaction products forming additional portions of the article; providing additional quantities of the first material over the first layer to form a subsequent layer; and operating the power supply to form additional portions of the article in the subsequent layer.

Abstract: An additive manufacturing method may involve: Providing a first material in powder form and a second material as a consumable electrode; forming the first material into a first layer on a base; placing an end of the second material in close proximity to a portion of the first layer; operating a power supply connected to the base and the second material to provide electrical energy sufficient to initiate a chemical reaction between the first and second materials and form a reaction product; feeding additional amounts of the second material while moving the end of the second material along a desired pattern adjacent the first layer, additional reaction products forming additional portions of the article; providing additional quantities of the first material over the first layer to form a subsequent layer; and operating the power supply form additional portions of the article in the subsequent layer.

Abstract: An additive manufacturing method may involve: Providing a first and a second material, the second material capable of reacting with the first material to form a reaction product; forming at least the first material into a first layer; subjecting at least a portion of the first layer to energy in the presence of the second material, the energy being sufficient to initiate a reaction between at least the first and second materials to form a portion of the article, the portion of the article comprising the reaction product; forming a second layer of at least the first material on the first layer; and subjecting at least a portion of the second layer to energy in the presence of the second material, the energy being sufficient to initiate a reaction between the first and second materials to form an additional portion of the article.

Abstract: An additive manufacturing method may involve: Providing a first and a second material, the second material capable of reacting with the first material to form a reaction product; forming at least the first material into a first layer; subjecting at least a portion of the first layer to energy in the presence of the second material, the energy being sufficient to initiate a reaction between at least the first and second materials to form a portion of the article, the portion of the article comprising the reaction product; forming a second layer of at least the first material on the first layer; and subjecting at least a portion of the second layer to energy in the presence of the second material, the energy being sufficient to initiate a reaction between the first and second materials to form an additional portion of the article.

Abstract: An additive manufacturing method may involve: Providing a first and a second material, the second material capable of reacting with the first material to form a reaction product; forming at least the first material into a first layer; subjecting at least a portion of the first layer to energy in the presence of the second material, the energy being sufficient to initiate a reaction between at least the first and second materials to form a portion of the article, the portion of the article comprising the reaction product; forming a second layer of at least the first material on the first layer; and subjecting at least a portion of the second layer to energy in the presence of the second material, the energy being sufficient to initiate a reaction between the first and second materials to form an additional portion of the article.

Abstract: An additively manufactured non-uniform porous material in-situ with dense material for the in situ additive manufacturing of both porous and dense material in the same part so that no secondary process is required. The additively manufactured non-uniform porous material in-situ with dense material generally includes additively manufactured porous material which can be tuned for porosity and density, has the ability to be built in situ with dense material, and can also be tuned for response to pressure waves. Also included are computer program products, methods and components and systems manufactured using the methods.

Abstract: An additive manufacturing method of producing a metal alloy article may involve: Providing a supply of a metal alloy in powder form; providing a supply of a nucleant material, the nucleant material lowering the nucleation energy required to crystallize the metal alloy; blending the supply of metal alloy powder and nucleant material to form a blended mixture; forming the blended mixture into a first layer; subjecting at least a portion of the first layer to energy sufficient to raise the temperature of the first layer to at least the liquidus temperature of the metal alloy; allowing at least a portion of the first layer to cool to a temperature sufficient to allow the metal alloy to recrystallize; forming a second layer of the blended mixture on the first layer; and repeating the subjecting and allowing steps on the second layer to form an additional portion of the metal alloy article.

Abstract: A method of forge welding includes placing at least two components for welding together, adjacent each other and with an exothermic flux mixture placed between the components. The exothermic flux mixture is heated to initiate an exothermic reaction and the faying surfaces of the two components are pressed together. The components being welded may be tubular, in particular pipes. Apparatus for the method of forge welding and exothermic flux mixtures for the method of forge welding are also provided.

Abstract: An additive manufacturing method may involve: Providing a first and a second material, the second material capable of reacting with the first material to form a reaction product; forming at least the first material into a first layer; subjecting at least a portion of the first layer to energy in the presence of the second material, the energy being sufficient to initiate a reaction between at least the first and second materials to form a portion of the article, the portion of the article comprising the reaction product; forming a second layer of at least the first material on the first layer; and subjecting at least a portion of the second layer to energy in the presence of the second material, the energy being sufficient to initiate a reaction between the first and second materials to form an additional portion of the article.

Abstract: A method of forge welding includes placing at least two components for welding together, adjacent each other and with an exothermic flux mixture placed between the components. The exothermic flux mixture is heated to initiate an exothermic reaction and the faying surfaces of the two components are pressed together. The components being welded may be tubular, in particular pipes. Apparatus for the method of forge welding and exothermic flux mixtures for the method of forge welding are also provided.