Various embodiments relate to additive manufacturing in which the Langmuir equation can be used to predict composition in the processing. This equation can be integrated into a model with knowledge of elemental solubility and relative reactivity of relevant elements in the additive manufacturing processing. Use of thermodynamic principles can be programmed into a finite element modeling strategy integrating the Langmuir equation, coupling the thermal fields of additive manufacturing and the surrounding environments with the rules and/or equations to predict solute pickup and/or solute loss. The modeling strategy can be implemented to identify the elements in relative concentrations to be used in the additive manufacturing processing to provide for the controlled loss of certain elements to prevent absorption of unwanted elements into molten material, formed by additive manufacturing, from the atmosphere around the molten material. Additional systems and methods are disclosed.

A method of making a composite downhole article is disclosed. The method include forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; and disposing at least one outer member on the core member, the outer member comprising a second material that is removable in the wellbore fluid at a second removal rate, wherein the removable core member has a composition gradient or a density gradient, or a combination thereof, and wherein the first removal rate is substantially greater than the second removal rate. A method of using a composite downhole article is also disclosed. The method includes forming a composite downhole article as described above; using the article to perform a first wellbore operation; exposing the article to the wellbore fluid; and selectively removing the second removable member.

Methods of fabricating dental prostheses are provided that include the steps of providing a powder of a dental material, and then selectively melting the powder of the dental material to produce a functionally graded layer of the dental material. Additional layers of functionally graded dental material are then built on top of the initial layer of dental material to thereby produce a three-dimensional dental prosthesis having a functionally graded structure and a desired physical geometry. Dental prostheses produced by the foregoing methods are also provided.

A hybrid compressor blade having an airfoil portion and a root portion that includes an outer shell comprised of one or multiple types of material that are each located at a predesignated section on the compressor blade, having at least one transition region between two different sections. The transition region is comprised of one or multiple layers with a compositional gradient based upon materials in the neighboring sections to provide a gradual transition from one section to another.

A method of making dispersion-strengthened alloy particles involves melting an alloy having a corrosion and/or oxidation resistance-imparting alloying element, a dispersoid-forming element, and a matrix metal wherein the dispersoid-forming element exhibits a greater tendency to react with a reactive species acquired from an atomizing gas than does the alloying element. The melted alloy is atomized with the atomizing gas including the reactive species to form atomized particles so that the reactive species is (a) dissolved in solid solution to a depth below the surface of atomized particles and/or (b) reacted with the dispersoid-forming element to form dispersoids in the atomized particles to a depth below the surface of said atomized particles. The atomized alloy particles are solidified as solidified alloy particles or as a solidified deposit of alloy particles. Bodies made from the dispersion strengthened alloy particles, deposit thereof, exhibit enhanced fatigue and creep resistance and reduced wear as well as enhanced corrosion and/or oxidation resistance at high temperatures by virtue of the presence of the corrosion and/or oxidation resistance imparting alloying element in solid solution in the particle alloy matrix.

A method for ascertaining the concentration of at least one material in a powder mixture used as starting material for the production of a component in an additive production method, comprising: providing the powder mixture having at least two different materials; guiding a high-energy beam generated by a radiation source over the surface of the powder mixture; detecting by a detection unit at least one brightness value of at least one subregion of the surface irradiated by the high-energy beam during the irradiation; ascertaining by an analysis unit the concentration of at least one material in the powder mixture depending on the detected at least one brightness value and at least one predetermined reference brightness value for a concentration and/or a concentration range of the material.

A method for ascertaining the concentration of at least one material in a powder mixture used as starting material for the production of a component in an additive production method, comprising: providing the powder mixture having at least two different materials; guiding a high-energy beam generated by a radiation source over the surface of the powder mixture; detecting by a detection unit at least one brightness value of at least one subregion of the surface irradiated by the high-energy beam during the irradiation; ascertaining by an analysis unit the concentration of at least one material in the powder mixture depending on the detected at least one brightness value and at least one predetermined reference brightness value for a concentration and/or a concentration range of the material.

A hybrid compressor blade having an airfoil portion and a root portion that includes an outer shell comprised of one or multiple types of material that are each located at a predesignated section on the compressor blade, having at least one transition region between two different sections. The transition region is comprised of one or multiple layers with a compositional gradient based upon materials in the neighboring sections to provide a gradual transition from one section to another.