Abstract: Methods of modeling metal alloys and forming those alloys are provided. The method involves comparing the strain accommodation and cleavage energies of a base alloy comprising a first metal and a chemical element different from the first metal. If a predetermined difference between those energies would be achieved, the base alloy will be sufficiently ductile. If that predetermined difference would not be achieved, the base alloy will not be sufficiently ductile, and the base alloy is modified (e.g., by adding a ductility component) until the predetermined difference in energies would be achieved, at which point, the alloy can be formed using conventional methods or further modified to achieve the desired degree of ductility.

Abstract: An apparatus and method for additive manufacturing a metal part having portions with varying microstructures. The method may include depositing an additive manufacturing powder on a surface and melting or sintering a first portion of the additive manufacturing powder while it is covered with a first type of cover gas. Next, the method may include melting or sintering a second portion of the additive manufacturing powder while it is covered with a second type of cover gas. The first portion may be a first layer of the additive manufacturing powder and the second portion may be a second layer of the additive manufacturing powder deposited after melting or sintering of the first layer. Additionally or alternatively, the first portion and the second portion may both include distinct portions of a single layer of the additive manufacturing powder.

Abstract: An apparatus and method for additive manufacturing a metal part having portions with varying microstructures. The method may include depositing an additive manufacturing powder on a surface and melting or sintering a first portion of the additive manufacturing powder while it is covered with a first type of cover gas. Next, the method may include melting or sintering a second portion of the additive manufacturing powder while it is covered with to second type of cover gas. The first portion may be a first layer of the additive manufacturing powder and the second portion may be a second layer of the additive manufacturing powder deposited after melting or sintering of the first layer. Additionally or alternatively, the first portion and the second portion may both include distinct portions of a single layer of the additive manufacturing powder.