A method of forming an article includes producing a base powder including a plurality of base particles. Each base particle includes an external surface and a first material. The method further includes removing one or more oxides from the external surface of each base particle to form a cleaned powder including a plurality of cleaned particles. Each cleaned particle includes a cleaned external surface made of the first material. The method further includes coating the cleaned external surface of each cleaned particle with a second material having a greater oxidation resistance than the first material to form a coated powder including a plurality of coated particles. Each coated particle includes an external layer including the second material that fully covers the cleaned external surface made of the first material. The method further includes forming the article using the coated powder.

Systems and methods for real time, nondestructive inspection of an object being formed by additive manufacturing is provided. The disclosed systems and methods can be used with any additive manufacturing system and can detect defects introduced during fabrication. In operation, additive manufacturing of the object can be paused and the object rotated within the build chamber. An x-ray pulse can then be directed through a linear aperture towards the object being formed inside the build chamber. A linear x-ray detector array can detect the x-ray pulse and an x-ray image of the object being formed can be created. By rotating the object being formed during exposure to the x-ray pulse at least one half of one full rotation, the entire volume of the object can be inspected.

Systems and methods for real time, nondestructive inspection of an object being formed by additive manufacturing is provided. The disclosed systems and methods can be used with any additive manufacturing system and can detect defects introduced during fabrication. In operation, additive manufacturing of the object can be paused and the object rotated within the build chamber. An x-ray pulse can then be directed through a linear aperture towards the object being formed inside the build chamber. A linear x-ray detector array can detect the x-ray pulse and an x-ray image of the object being formed can be created. By rotating the object being formed during exposure to the x-ray pulse at least one half of one full rotation, the entire volume of the object can be inspected.

Selective laser solidification apparatus is described that includes a powder bed onto which a powder layer can be deposited and a gas flow unit for passing a flow of gas over the powder bed along a predefined gas flow direction. A laser scanning unit is provided for scanning a laser beam over the powder layer to selectively solidify at least part of the powder layer to form a required pattern. The required pattern is formed from a plurality of stripes or stripe segments that are formed by advancing the laser beam along the stripe or stripe segment in a stripe formation direction. The stripe formation direction is arranged so that it always at least partially opposes the predefined gas flow direction. A corresponding method is also described.

Selective laser solidification apparatus is described that includes a powder bed onto which a powder layer can be deposited and a gas flow unit for passing a flow of gas over the powder bed along a predefined gas flow direction. A laser scanning unit is provided for scanning a laser beam over the powder layer to selectively solidify at least part of the powder layer to form a required pattern. The required pattern is formed from a plurality of stripes or stripe segments that are formed by advancing the laser beam along the stripe or stripe segment in a stripe formation direction. The stripe formation direction is arranged so that it always at least partially opposes the predefined gas flow direction. A corresponding method is also described.

A three-dimensional (3D) metal object manufacturing apparatus is equipped with a movable directed energy source to melt hardened metal drops and form an oxidation layer. A metal support structure can be formed over the oxidation layer, an object feature can be formed over the oxidation layer, or both a metal support structure and an object feature can be formed over oxidation layers located at opposite sides of a metal support structure. The oxidation layers weakly attach the metal support structure to the object feature supported by the metal support structure so the support structure can be easily removed after manufacture of the object is complete.

A three-dimensional (3D) metal object manufacturing apparatus is equipped with a movable directed energy source to melt hardened metal drops and form an oxidation layer. A metal support structure can be formed over the oxidation layer, an object feature can be formed over the oxidation layer, or both a metal support structure and an object feature can be formed over oxidation layers located at opposite sides of a metal support structure. The oxidation layers weakly attach the metal support structure to the object feature supported by the metal support structure so the support structure can be easily removed after manufacture of the object is complete.

A laser-solid-forming manufacturing device includes a laser emitter, a magnetic field generator, and a forming platform. The laser emitter emits a laser beam which acts on a feedstock to form a molten pool. The magnetic field generator includes a spiral copper coil, a first electrode and a second electrode. The spiral copper coil is formed by spirally winding a copper tube. The first and second electrodes are arranged at respective ends of the copper tube and are used for loading a voltage to generate a magnetic field in the spiral copper coil. At any time, the spiral copper coil sleeves an action point of the laser beam and the feedstock. A corresponding laser-solid-forming manufacturing method is also presented.

A fiber with metal ions excited by luminous energy and a manufacturing method thereof are provided. The method includes: adding dry copper nanopowder with a particle size not more than 48 nm after mixing to a fiber slurry, to form a first mixed liquid; mixing and stirring the first mixed liquid and an additive, and performing an electrochemical reaction, to form a second mixed liquid, where the additive contains at least one of graphene, Ge ions, and Zr ions; performing energy exciting on the second mixed liquid, to form a mixed material; drying the mixed material, to remove moisture contained in the mixed material; extruding at least one fibril from the mixed material by using a spinning device; passing the at least one fibril through a plurality of rollers and performing stretching; and performing cooling and shaping on at least one stretched fibril, to form a final fiber product.

A fiber with metal ions excited by luminous energy and a manufacturing method thereof are provided. The method includes: adding dry copper nanopowder with a particle size not more than 48 nm after mixing to a fiber slurry, to form a first mixed liquid; mixing and stirring the first mixed liquid and an additive, and performing an electrochemical reaction, to form a second mixed liquid, where the additive contains at least one of graphene, Ge ions, and Zr ions; performing energy exciting on the second mixed liquid, to form a mixed material; drying the mixed material, to remove moisture contained in the mixed material; extruding at least one fibril from the mixed material by using a spinning device; passing the at least one fibril through a plurality of rollers and performing stretching; and performing cooling and shaping on at least one stretched fibril, to form a final fiber product.