The present invention provides a producing method of a rare earth sintered magnet which is suitable as a producing method of a high performance rare earth sintered magnet which can reduce the number of steps for reusing defective molded bodies generated in a wet molding step of the rare earth sintered magnet, and which has a small content amount of oxygen. The invention also provides a slurry recycling method used for the producing method, and a slurry recycling apparatus. Each of the methods includes a crushing step of crushing, in mineral oil and/or synthetic fluid, a molded body in which slurry formed from alloy powder for a rare earth sintered magnet and mineral oil and/or synthetic fluid is wet molded in magnetic field, and recycling the crushed molded body into slurry.

The present invention provides a producing method of a rare earth sintered magnet which is suitable as a producing method of a high performance rare earth sintered magnet which can reduce the number of steps for reusing defective molded bodies generated in a wet molding step of the rare earth sintered magnet, and which has a small content amount of oxygen. The invention also provides a slurry recycling method used for the producing method, and a slurry recycling apparatus. Each of the methods includes a crushing step of crushing, in mineral oil and/or synthetic fluid, a molded body in which slurry formed from alloy powder for a rare earth sintered magnet and mineral oil and/or synthetic fluid is wet molded in magnetic field, and recycling the crushed molded body into slurry.

A powder recycling system includes a supply tank, a continuous loss-in-weight module, a pneumatic module, a transfer channel, a recycle module, and a refilling tank. The supply tank accommodates recycling powder. The continuous loss-in-weight module includes a storage tank receiving the recycling powder from the supply tank and a rotary output pipe connected to the storage tank to output the recycling powder. The continuous loss-in-weight module controls the mass flow rate of the output of the recycling powder according to the weight change of the storage tank. The pneumatic module enables the recycling powder to float and move in the transfer channel. The recycle module is connected to the transfer channel to receive the recycling powder, sieves the recycling powder, provides virgin powder, and mixes the virgin powder with the recycling powder. The refilling tank is connected to the recycle module to receive the recycling powder and the virgin powder.

A powder recycling system includes a supply tank, a continuous loss-in-weight module, a pneumatic module, a transfer channel, a recycle module, and a refilling tank. The supply tank accommodates recycling powder. The continuous loss-in-weight module includes a storage tank receiving the recycling powder from the supply tank and a rotary output pipe connected to the storage tank to output the recycling powder. The continuous loss-in-weight module controls the mass flow rate of the output of the recycling powder according to the weight change of the storage tank. The pneumatic module enables the recycling powder to float and move in the transfer channel. The recycle module is connected to the transfer channel to receive the recycling powder, sieves the recycling powder, provides virgin powder, and mixes the virgin powder with the recycling powder. The refilling tank is connected to the recycle module to receive the recycling powder and the virgin powder.

A method of additively manufacturing a part is provided. The method includes flowing masticated particles through a deposition nozzle of a directed energy deposition additive manufacturing apparatus. Each particle of the masticated particles includes a surface formed by at least angular facets. The method also includes melting the masticated particles exiting the deposition nozzle with a directed energy source of the directed energy deposition additive manufacturing apparatus so as to form the part.

An additive manufacturing system may include a controller operably coupled to a vision system and an additive manufacturing machine. The controller may be configured to determine a workpiece-interface of each of a plurality of workpieces from one or more digital representations of one or more fields of view having been captured by a vision system and determining one or more coordinates of the workpiece-interface of respective ones of the plurality of workpieces, and to transmit one or more print commands to an additive manufacturing machine so as to additively print a plurality of extension segments on the workpiece-interface of respective ones of the plurality of workpieces, with the one or more print commands having been generated based at least in part on the one or more digital representations of the one or more fields of view.

Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, and recycled used powder. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

A three-dimensional shaping apparatus coupled to a server includes a melting portion melting a material to form a shaping material, an ejection portion ejecting the shaping material supplied from the melting portion, a shaping stage where the shaping material ejected from the ejection portion is stacked, a moving mechanism changing a relative position of the ejection portion and the shaping stage, a shape data generation portion generating second shape data for representing a shape of a three-dimensional shaped article including a shape representing identification information for identifying the three-dimensional shaped article using first shape data and the identification information for identifying the three-dimensional shaped article, a controller controlling the melting portion and the moving mechanism according to the second shape data, thereby producing the three-dimensional shaped article, and a communication portion transmitting the identification information for identifying the three-dimensional shaped article and production information of the three-dimensional shaped article to the server.

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.

An expeditionary additive manufacturing (ExAM) system [10] for manufacturing metal parts [20] includes a mobile foundry system [12] configured to produce an alloy powder [14] from a feedstock [16], and an additive manufacturing system [18] configured to fabricate a part using the alloy powder [14]. The additive manufacturing system [18] includes a computer system [50] having parts data and machine learning programs in signal communication with a cloud service. The parts data [56] can include material specifications, drawings, process specifications, assembly instructions, and product verification requirements for the part [20]. An expeditionary additive manufacturing (ExAM) method for making metal parts [20] includes the steps of transporting the mobile foundry system [12] and the additive manufacturing system [18] to a desired location; making the alloy powder [14] at the location using the mobile foundry system; and building a part [20] at the location using the additive manufacturing system [18].