Abstract: A method for processing a powder material includes feeding a powder material through an additive processing machine to deposit multiple layers of the powder material onto one another and using an energy beam to thermally fuse selected portions of the layers to one another with reference to data relating to a particular cross-section of an article being formed. The powder material has spherical metal particles and a spaced-apart distribution of ceramic nanoparticles attached to the surfaces of the particles. The ceramic nanoparticles form a dispersion of reinforcement through the formed article.

Abstract: A process comprising providing a metallic first powder having a plurality of first particles. The process includes adding a second material to the first powder, the second material having a plurality of second particles. The process includes combining the first powder with the second material to form a modified powder including modified powder particles having an interior portion containing an interior composition, and an outer surface portion with an outer composition different from the interior composition.

Abstract: A system and methods are provided for electrochemical grinding a workpiece. In one embodiment, a method includes controlling potentials to grinding tool and the workpiece, controlling applying electrolyte, and controlling grinding of the workpiece by the grinding tool. The method may also include determining screen replacement when there is sufficient metal plated.

Abstract: A carrier gas recovery system for use in cold spray manufacturing recovers carrier gas utilized during the cold spray process and recycles the carrier gas for immediate use or stores the carrier gas for future use. The carrier gas recovery system includes an enclosure subsystem, a filtration subsystem, a reclamation subsystem, and a compensation subsystem. An article is placed in the enclosure and particulate matter is carried to the article on a carrier gas stream. Carrier gas in the enclosure is filtered through the filtration subsystem to remove particulate from the carrier gas, and the filtered carrier gas is fed to the reclamation subsystem. The carrier gas either flows to a gas separator, to increase the concentration of carrier gas, or to the compensation subsystem if the carrier gas concentration is sufficiently high. The carrier gas can be stored in the compensation subsystem or used in further cold spray manufacturing.

Abstract: A method for heat treating metal alloy powder includes (a) introducing metal alloy powder to a chamber having a floor and a sidewall; (b) flowing a fluidizing gas through the floor and into the chamber to fluidize the metal alloy powder in the chamber; (c) flowing an additional gas through the sidewall into the chamber; and (d) heating the chamber to heat treat the metal alloy powder in the chamber. A system for heat treating metal alloy powder includes an inner chamber having a porous floor and a porous sidewall; an outer chamber, the inner chamber being inside of the outer chamber and defining an annular space between the outer chamber and the inner chamber, wherein the outer chamber and the inner chamber are inside a furnace; a source of fluidizing gas connected to the porous floor through the annular space; and a source of additional gas communicated with the porous sidewall through the annular space.

Abstract: A system for treatment of atomized powder including a fluidized bed operable to treat feedstock alloy powders. A method of treating atomized powder including communicating an inert gas into a fluidized bed; communicating an atomized powder into the fluidized bed; and heating the atomized powder in the fluidized bed, eject the treated powders out of the fluidized bed to quench the powders.

Abstract: A method and system for coating metallic powder particles is provided. The method includes: disposing an amount of metallic powder particulates within a fluidizing reactor; removing moisture adhered to the powder particles disposed within the reactor using a working gas; coating the powder particles disposed within the reactor using a precursor gas; and purging the precursor gas from the reactor using the working gas.

Abstract: A method for processing a powder material includes cleaning surfaces of a powder material that has spherical metal particles, coating the cleaned surfaces with an organic bonding agent, mixing the coated particles with a dispersion that contains ceramic nanoparticles, drying the mixture to remove a carrier of the dispersion and deposit the ceramic nanoparticles with a spaced-apart distribution onto the organic bonding agent on the surfaces of the particles, and thermally removing the organic bonding agent to attach the ceramic nanoparticles to the surface of the particles.

Abstract: A method of coating metallic powder particles includes disposing an amount of metallic powder particles in a fluidizing reactor and removing moisture adhered to the powder particles within the reactor with a working gas at an elevated temperature for a predetermined time. The method further includes coating the powder particles in the reactor with silicon present within the precursor gas at an elevated temperature for a predetermined time and purging the precursor gas from the reactor using the working gas.

Abstract: A system and method for enhancing a diffusion limited CVI/CVD process is provided. The system may densify a porous structure by flowing a reactant gas around the porous structure. A mass flow controller may be configured to pulse the flow rate of the reactant gas around the porous structure. The mass flow controller may pulse the flow rate from a nominal flow rate to a first flow rate. The mass flow controller may pulse the first flow rate back to the nominal flow rate or to a second flow rate. The mass flow controller may pulse the flow rate between the nominal flow rate, the first flow rate, and the second flow rate, as desired.

Abstract: A process for densifying an annular porous structure comprising flowing a reactant gas into an inner diameter (ID) volume and through an ID surface of the annular porous structure, flowing the reactant gas through an outer diameter (OD) surface of the annular porous structure and into an OD volume, flowing the reactant gas from the OD volume through the OD surface of the annular porous structure, and flowing the reactant gas through an ID surface of the annular porous structure and into the ID volume.

Abstract: A method and system for coating metallic powder particles is provided. The method includes: disposing an amount of metallic powder particulates within a fluidizing reactor; removing moisture adhered to the powder particles disposed within the reactor using a working gas; coating the powder particles disposed within the reactor using a precursor gas; and purging the precursor gas from the reactor using the working gas.

Abstract: A fluidized powder heat treatment classification assembly includes a gas source. A fluidized bed is connected to the gas source via a metered connection. The fluidized bed includes a first output connected to a powder classifier via at least a first valve. The powder classifier includes a catch container operable to decelerate a gas flow from the output and operable to catch particles entrained in the gas flow.

Abstract: A particulate for an additive manufacturing technique includes metallic particulate bodies with exterior surfaces bearing a polymeric coating. The polymeric coating is conformally disposed over the exterior surface that prevents the underlying metallic body from oxidation upon exposure to the ambient environment by isolating the metallic particulate bodies from the ambient environment. Feedstock materials for additive manufacturing techniques, and methods of making such feedstock, are also disclosed.

Abstract: A particulate for an additive manufacturing technique includes a particulate body formed from a particulate material and a coating disposed over particulate body. The coating includes a carbonaceous material that has a reflectivity that is lower than a reflectivity of the particulate material to reduce an energy input requirement of the particulate such that less energy is necessary to fuse the particulate into a layer of an article fabricated using the additive manufacturing technique. A method of making particulate is also disclosed.

Abstract: Material is provided for forming a part using a manufacturing system. The material includes a plurality of discrete particles. Each of the particles includes a metal powder core encapsulated by a non-metal coating. At least the cores of the particles are adapted to be solidified together by the manufacturing system to form the part.

Abstract: A system comprises a furnace, a fluidized bed assembly and a powder bed. The fluidized bed assembly is positioned in the furnace and comprises an outer chamber having an outer chamber inlet for receiving gas, an inner chamber positioned inside of the outer chamber. The inner chamber comprises an inner chamber inlet in fluid communication with the outer chamber, and an outlet through which the gas may exit the inner chamber and the outer chamber. The powder bed is disposed in the inner chamber.

Abstract: A method of making a composite material includes disposing a carbon-based particulate material, such as graphene or carbon nanotubes, in an activation solution and activating surfaces of the carbon-based particulate material using the activation solution. Once the surfaces of the carbon-based particulate material have been activated a metallic coating is applied to the activated surfaces to form a composite material. The composite material is then recovered as a particulate material formed having carbon-based particulate material with a metallic coating that is suitable for fusing together for forming electrical conductors, such as with an additive manufacturing technique.

Abstract: A method includes providing a metallic first powder having a plurality of first particles with a first mean particle diameter. A second powder added to the first powder has a plurality of second particles with a second mean particle diameter less than the first mean particle diameter. Energy is applied to at least the second powder so as to selectively heat the second particles. The first powder is combined with the heated second powder to form a modified powder including modified powder particles. Modified powder particles have an interior portion containing an interior composition, and an outer surface portion with an outer composition different from the interior composition.

Abstract: A powder classification apparatus (10; 110; 210) includes a first chamber (12; 112; 212) that includes a fluidized bed and has an inlet (16; 116; 216A) and an outlet (18; 118; 218), the inlet (16; 116; 216A) configured to receive a gas (G) and distribute the gas 30 (G) in a uniform flow through the first chamber (12; 112; 212), the first chamber (12; 112; 212) configured to receive a powder (P) and the gas (G) and create a fluidization zone, the outlet (18; 118; 218) configured to allow at least a portion of the powder (P) to exit the first chamber (12; 112; 212); and a second chamber (14; 114; 214) having a powder inlet (24; 124; 224) configured to accept at least a portion of the powder (P) from the outlet (18; 118; 218) in the first chamber (12; 112; 212) caused by at least a portion of the powder (P) being ejected from the first chamber (12; 112; 212) by the gas (G).