A method for manufacturing metal components includes the steps of providing a waste feedstock having a selected chemical composition; producing an additive manufacturing (AM) grade alloy powder from the waste feedstock using a cold hearth mixing process; providing an additive manufacturing system; controlling the producing of the alloy powder such that the properties of the alloy powder optimize building of the components using the additive manufacturing system; and building the components using the alloy powder and the additive manufacturing system.

The present invention is a method for treating an alloy, by which a solution that contains nickel and/or cobalt is obtained from an alloy that contains copper, zinc, and nickel and/or cobalt, said method comprising: a leaching process wherein a leachate is obtained by subjecting the alloy to a leaching treatment by means of an acid in the coexistence of a sulfurizing agent; a reduction process wherein the leachate is subjected to a reduction treatment with use of a reducing agent; and an ion exchanging process wherein a solution that contains nickel and/or cobalt is obtained by bringing a solution, which has been obtained in the reduction process, into contact with an amino phosphoric acid-based chelate resin, thereby having zinc adsorbed on the amino phosphoric acid-based chelate resin.

Aspects of the disclosure relate to apparatus and methods for producing a downhole electrical component, having steps of providing a non-conductive polymer substrate, establishing an active area on the non-conductive polymer substrate, patterning the active area on the non-conductive polymer substrate with a conductive material through an additive manufacturing process and incorporating the patterned non-conductive polymer substrate into a final arrangement.

An expeditionary additive manufacturing (ExAM) system for manufacturing metal parts includes a mobile foundry system configured to produce an alloy powder from a feedstock, and an additive manufacturing system configured to fabricate a part using the alloy powder. The additive manufacturing system includes a computer system having parts data and machine learning programs in signal communication with a cloud service. The parts data can include material specifications, drawings, process specifications, assembly instructions, and product verification requirements for the part. An expeditionary additive manufacturing (ExAM) method for making metal parts includes the steps of transporting the mobile foundry system and the additive manufacturing system to a desired location; making the alloy powder at the location using the mobile foundry system; and building a part at the location using the additive manufacturing system.

An expeditionary additive manufacturing (ExAM) system for manufacturing metal parts includes a mobile foundry system configured to produce an alloy powder from a feedstock, and an additive manufacturing system configured to fabricate a part using the alloy powder. The additive manufacturing system includes a computer system having parts data and machine learning programs in signal communication with a cloud service. The parts data can include material specifications, drawings, process specifications, assembly instructions, and product verification requirements for the part. An expeditionary additive manufacturing (ExAM) method for making metal parts includes the steps of transporting the mobile foundry system and the additive manufacturing system to a desired location; making the alloy powder at the location using the mobile foundry system; and building a part at the location using the additive manufacturing system.

A system and method for designing and manufacturing free-form objects made of composite material and optimised in their weight ratio and load capacity; a system for the design and manufacture of said objects, and the objects resulting from said method. Using three-dimensional (3D) design computer programs and computer calculation programs, the design of a composite material object is obtained, with a specific shape and orientation of its component fragments, optimised to be light and at the same time to meet a required specific mechanical and/or structural performance. Subsequently, a mould of at least two parts is obtained from this design and the parameters of said design are transformed into instructions so that one or more automated manufacturing machines deposit fragments of wood or another material onto the lower part of the mould in specific orientations, calculated to minimise the weight of the object and optimise its load capacity. Then, with the addition of one or more binders, the object is pressed between the parts of said mould. Finally, the new manufactured object is obtained by removing it from the mould.

A thixomolding material includes: a metal body that contains Mg as a main component; and a coating portion that is adhered to a surface of the metal body via a binder and contains C particles containing C as a main component. A mass fraction of the C particles in a total mass of the metal body and the C particles is 5.0 mass % or more and 40.0 mass % or less. The binder may contain waxes. The C particles may be graphite particles.

A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations. Methods for generation of different periodic and non-periodic structures and joints using the process-controlled solid-state additive manufacturing system are also disclosed.

A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations. Methods for generation of different periodic and non-periodic structures and joints using the process-controlled solid-state additive manufacturing system are also disclosed.

The present invention relates to a method of making a cemented carbide comprising mixing in a slurry a first powder fraction and a second powder fraction, subjecting the slurry to milling, drying, pressing and sintering. The first powder fraction is made from cemented carbide scrap recycled using the Zn recovery process, comprising the elements W, C, Co, and at least one or more of Ta, Ti, Nb, Cr, Zr, Hf and Mo, and the second powder fraction comprising virgin raw materials of WC and possibly carbides and/or carbonitrides of one or more of Cr, Zr, W, Ta, Ti, Hf and Nb. The first powder fraction is subjected to a pre-milling step, prior to the step of forming the slurry, to obtain an average grain size of between 0.2 to 1.5 μm.