Apparatuses, systems and methods of providing heat to enable an FDM additive manufacturing nozzle having refined print control and enhanced printing speed. The heating element may include at least one sheath sized to fittedly engage around an outer circumference of the FDM printer nozzle; at least one wire coil at least partially contacting an inner diameter of the sheath; and at least one energy receiver associated with the at least one wire coil.

An ejector for an additive manufacturing printing system is disclosed, including an ejector body having a nozzle, a heating element to heat a solid printing material in the ejector, causing the solid printing material to change to a liquid printing material, and a piston disposed within the ejector body capable of translational motion. The ejector may include a segmented solenoid coil wrapped at least partially around the ejector body, which may be powered to cause the piston to translate along a longitudinal axis of the ejector thereby causing one or more drops of the liquid printing material to be jetted out of the nozzle. A method of ejecting liquid from an ejector is also disclosed, including melting a printing material within an ejector to form a liquid printing material, and moving a piston towards an ejector nozzle, and ejecting a drop of liquid printing material from the ejector nozzle.

An ejector for an additive manufacturing printing system is disclosed, including an ejector body having a nozzle, a heating element to heat a solid printing material in the ejector, causing the solid printing material to change to a liquid printing material, and a piston disposed within the ejector body capable of translational motion. The ejector may include a segmented solenoid coil wrapped at least partially around the ejector body, which may be powered to cause the piston to translate along a longitudinal axis of the ejector thereby causing one or more drops of the liquid printing material to be jetted out of the nozzle. A method of ejecting liquid from an ejector is also disclosed, including melting a printing material within an ejector to form a liquid printing material, and moving a piston towards an ejector nozzle, and ejecting a drop of liquid printing material from the ejector nozzle.

A device for atomizing a metallic, intermetallic or ceramic melt stream by means of a gas to form a spherical powder, comprising a melt chamber, a powder chamber, an induction coil in the melt chamber, a melt material, preferably melt rod in the induction coil and an atomizer nozzle interconnecting the melt and powder chambers and being arranged in a nozzle plate, for the melt stream melted off from the melt material by the induction coil, wherein the atomizer nozzle has an exclusively convergent nozzle profile having nozzle flanks which have a circular-arc-shaped cross-section, and therefore both the atomizing gas and the melt stream and the droplets generated therefrom reach a velocity which is at most equal to, preferably below the acoustic velocity of the atomizing gas.

A device for atomizing a metallic, intermetallic or ceramic melt stream by means of a gas to form a spherical powder, comprising a melt chamber, a powder chamber, an induction coil in the melt chamber, a melt material, preferably melt rod in the induction coil and an atomizer nozzle interconnecting the melt and powder chambers and being arranged in a nozzle plate, for the melt stream melted off from the melt material by the induction coil, wherein the atomizer nozzle has an exclusively convergent nozzle profile having nozzle flanks which have a circular-arc-shaped cross-section, and therefore both the atomizing gas and the melt stream and the droplets generated therefrom reach a velocity which is at most equal to, preferably below the acoustic velocity of the atomizing gas.

This invention discloses a boron-containing titanium-based composite powder for 3D printing, consisting of 0.5%-2% by weight of titanium diboride and 98%-99.5% by weight of titanium sponge. The invention further discloses a method of preparing such composite powder, where the element boron is introduced to the titanium powder through rapid solidification, which significantly improves the solid solubility of boron in Ti, enabling the introduction of part of the boron into the titanium matrix to form supersaturated solid solutions. The reinforcement phase TiB in the boron-containing titanium-based composite powder prepared herein can be precisely controlled in grain size ranging from the nanometer scale to the micrometer scale through temperature or energy density, thereby preparing the titanium-based composite materials with different sizes of reinforcement phases to meet different mechanical requirements.

This invention discloses a boron-containing titanium-based composite powder for 3D printing, consisting of 0.5%-2% by weight of titanium diboride and 98%-99.5% by weight of titanium sponge. The invention further discloses a method of preparing such composite powder, where the element boron is introduced to the titanium powder through rapid solidification, which significantly improves the solid solubility of boron in Ti, enabling the introduction of part of the boron into the titanium matrix to form supersaturated solid solutions. The reinforcement phase TiB in the boron-containing titanium-based composite powder prepared herein can be precisely controlled in grain size ranging from the nanometer scale to the micrometer scale through temperature or energy density, thereby preparing the titanium-based composite materials with different sizes of reinforcement phases to meet different mechanical requirements.

Provided are an alloy powder having excellent environmental resistance even in an environment where corrosion and wear are active simultaneously, and an alloy coating using the powder. A Ni—Fe base alloy powder comprising Cr of 15% by mass or more and 35% by mass or less, Fe of 10% by mass or more and 50% by mass or less, Mo of 0% by mass or more and 5% by mass or less, Si of 0.3% by mass or more and 2% by mass or less, C of 0.3% by mass or more and 0.9% by mass or less, B of 4% by mass or more and 7% by mass or less, and a balance of Ni and incidental impurities.

Provided are an alloy powder having excellent environmental resistance even in an environment where corrosion and wear are active simultaneously, and an alloy coating using the powder. A Ni—Fe base alloy powder comprising Cr of 15% by mass or more and 35% by mass or less, Fe of 10% by mass or more and 50% by mass or less, Mo of 0% by mass or more and 5% by mass or less, Si of 0.3% by mass or more and 2% by mass or less, C of 0.3% by mass or more and 0.9% by mass or less, B of 4% by mass or more and 7% by mass or less, and a balance of Ni and incidental impurities.

An inspection system for in situ evaluation of an additive manufacturing (AM) build part is provided. The inspection system comprises a build plane induction coil sensor configured and positionable so that during construction of the build part, the sensor's magnetization and sensor coils surround at least the last-produced layer of the AM build part in the build plane. The inspection system further comprises an energization circuit and a central processing system. The central processing system comprises a communication processor configured for sending command signals to the energization circuit and receiving impedance data from the build plane induction coil sensor, and energization controller configured for determining energization commands for transmission to the energization circuit, and an induction data analyzer configured for processing build part impedance data using complex impedance plane analysis and for identifying anomalies in the AM build part.