An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

A 3DP preparation process of a high-strength rapid-dissolving magnesium alloy for an underground temporary plugging tool is disclosed by the present disclosure, comprising the following steps: 1) evenly mixing ingredients of material components; 2) importing the shape of a product needing to be printed into a computer control system, and printing alloy powder and glue in a 3D printer in an alternate spraying molding mode to obtain a blank with the needed shape; 3) drying the blank obtained in the step 2) and then carrying out degreasing and sintering in a protective atmosphere or vacuum; and 4) sintering the blank obtained in the step 3) at a high temperature of 570° C.-680° C. in the protective atmosphere or vacuum and then cooling to a room temperature.

A 3DP preparation process of a high-strength rapid-dissolving magnesium alloy for an underground temporary plugging tool is disclosed by the present disclosure, comprising the following steps: 1) evenly mixing ingredients of material components; 2) importing the shape of a product needing to be printed into a computer control system, and printing alloy powder and glue in a 3D printer in an alternate spraying molding mode to obtain a blank with the needed shape; 3) drying the blank obtained in the step 2) and then carrying out degreasing and sintering in a protective atmosphere or vacuum; and 4) sintering the blank obtained in the step 3) at a high temperature of 570° C.-680° C. in the protective atmosphere or vacuum and then cooling to a room temperature.

A blower (100) blows inert gas. A crusher (200) repeats vitrifying plural kinds of inorganic compounds (A1) by mechanical energy and blowing up the plural kinds of vitrified inorganic compounds (A1) by the inert gas blown from the blower (100). At least some of the plural kinds of inorganic compounds (A1) blown up by the inert gas enter into a first collector (300). The first collector (300) returns the at least some of the plural kinds of inorganic compounds to the crusher (200). A system (S) (for example, a pipe (Pa), a buffer tank (110), a pipe (Pb), a pipe (Pc), and a pipe (Pi) described below) circulates the inert gas from the blower (100) through the crusher (200) and the first collector (300) to the blower (100).

A caster assembly configured to process and store a material includes a reaction chamber, a storage assembly configured to store material processed in the reaction chamber, and a blower configured to process and store the material. The reaction chamber includes a vessel configured to hold the material in a melted state prior to processing and a powder generating assembly configured to receive the material from the melting vessel. The powder generating assembly includes a feeding chamber and a feeding device disposed at least partially within the feeding chamber. The feeding device includes at least one nozzle configured to inject inert fluid, where the fluid is a gas, liquid, or combination of the two into the feeding chamber and a material inlet through which the material is configured to flow into the feeding chamber to be exposed to the inert fluid, where the fluid is a gas, liquid, or combination of the two.

A caster assembly configured to process and store a material includes a reaction chamber, a storage assembly configured to store material processed in the reaction chamber, and a blower configured to process and store the material. The reaction chamber includes a vessel configured to hold the material in a melted state prior to processing and a powder generating assembly configured to receive the material from the melting vessel. The powder generating assembly includes a feeding chamber and a feeding device disposed at least partially within the feeding chamber. The feeding device includes at least one nozzle configured to inject inert fluid, where the fluid is a gas, liquid, or combination of the two into the feeding chamber and a material inlet through which the material is configured to flow into the feeding chamber to be exposed to the inert fluid, where the fluid is a gas, liquid, or combination of the two.

A method for manufacturing a porous metal body according to the present invention includes: a surface oxidizing step of heating a titanium-containing powder in an atmosphere containing oxygen at a temperature of 250° C. or more for 30 minutes or more to provide a surface-oxidized powder; and a sintering step of depositing the surface-oxidized powder in a dry process, and sintering the surface-oxidized powder by heating it in a reduced pressure atmosphere or an inert atmosphere at a temperature of 950° C. or more.

A method for manufacturing a porous metal body according to the present invention includes: a surface oxidizing step of heating a titanium-containing powder in an atmosphere containing oxygen at a temperature of 250° C. or more for 30 minutes or more to provide a surface-oxidized powder; and a sintering step of depositing the surface-oxidized powder in a dry process, and sintering the surface-oxidized powder by heating it in a reduced pressure atmosphere or an inert atmosphere at a temperature of 950° C. or more.

A method of fabricating a near net shape component includes forming a sacrificial shell from a pulverant material using an additive manufacturing process, the shell having an aperture. The method further includes filling the shell with a second pulverant material, subjecting the filled shell to a consolidation process, and removing the shell from the consolidated second pulverant material.