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.

Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Transformation steps including drying are incorporated into a process of additive manufacturing of a part. Processes and devices for achieving a transformation are described. A cycle of manufacturing is begun by adding a feedstock such as a metal paste to form a partial part followed by a transformation of the added feedstock, such as removing solvent from a metal paste, to form a transformed part suitable for a manipulation step such as machining. Inclusion of a manipulation process such as machining comprises a single cycle of a manufacturing process. One or more said cycles comprise the process of producing a completed part suitable for further processing such as sintering in the case of a metal paste feedstock to form a finished part.

Transformation steps including drying are incorporated into a process of additive manufacturing of a part. Processes and devices for achieving a transformation are described. A cycle of manufacturing is begun by adding a feedstock such as a metal paste to form a partial part followed by a transformation of the added feedstock, such as removing solvent from a metal paste, to form a transformed part suitable for a manipulation step such as machining. Inclusion of a manipulation process such as machining comprises a single cycle of a manufacturing process. One or more said cycles comprise the process of producing a completed part suitable for further processing such as sintering in the case of a metal paste feedstock to form a finished part.

Disclosed herein is a method comprising disposing a container containing a metal and/or ferromagnetic solid and abrasive particles in a static magnetic field; where the container is surrounded by an induction coil; activating the induction coil with an electrical current, to heat up the metallic or ferromagnetic solid to form a fluid; generating sonic energy to produce acoustic cavitation and abrasion between the abrasive particles and the container; and producing nanoparticles that comprise elements from the container, the metal and/or the ferromagnetic solid and the abrasive particles. Disclosed herein too is a composition comprising first metal or a first ceramic; and particles comprising carbides and/or nitrides dispersed therein. Disclosed herein too is a composition comprising nanoparticles comprising chromium carbide, iron carbide, nickel carbide, γ-Fe and magnesium nitride.

A method for three-dimensional printing includes printing a three-dimensional part formed form a first material, the first material including induction sensitive particles and applying magnetic induction to the three-dimensional part during or after printing to heat the induction sensitive particles and melt the first material, allowing reflow thereof. The method also includes printing a support structure. The support structure may also include induction sensitive particles.

A method for three-dimensional printing includes printing a three-dimensional part formed form a first material, the first material including induction sensitive particles and applying magnetic induction to the three-dimensional part during or after printing to heat the induction sensitive particles and melt the first material, allowing reflow thereof. The method also includes printing a support structure. The support structure may also include induction sensitive particles.

An additive manufacturing system for building a product includes a base plate for mounting the product thereon, and at least one heating element shaped to at least partially conform to the product and configured to apply heat to at least a portion of the product as the product is additively manufactured to reduce thermal gradients in the product.

An additive manufacturing system for building a product includes a base plate for mounting the product thereon, and at least one heating element shaped to at least partially conform to the product and configured to apply heat to at least a portion of the product as the product is additively manufactured to reduce thermal gradients in the product.