Detection and classification of anomalies for powder bed metal additive manufacturing. Anomalies, such as recoater blade impacts, binder deposition issues, spatter generation, and some porosities, are surface-visible at each layer of the building process. A multi-scaled parallel dynamic segmentation convolutional neural network architecture provides additive manufacturing machine and imaging system agnostic pixel-wise semantic segmentation of layer-wise powder bed image data. Learned knowledge is easily transferrable between different additive manufacturing machines. The anomaly detection can be conducted in real-time and provides accurate and generalizable results.

The manufacturing method comprises the following steps: —extracting a sub-batch (18) from a batch (16) of powder, the batch having a ratio X.sub.0 of a predetermined component, —manufacturing parts (22) using powder-bed based additive manufacturing until all of the sub-batch is used up (18); then—performing the following cycle a number n.sub.max of times: —recycling the powder and continuing manufacture until all of the recycled powder is used up; —determining a contact surface S.sub.n between the powder and a material fused into the parts (22), n designating the cycle number, and a mass M.sub.n of accumulated powder used since the start of the method, and—measuring a ratio X.sub.nmax of a predetermined component in at least one of the parts (22) or a test piece (24) manufactured during the last cycle, then—determining a quantity R such that: Formula (I); —performing the following cycle at least once: —recycling the powder and continuing manufacture until all of the recycled powder has been used up at least once, then—determining the contact surface S.sub.n, and the mass M.sub.n of accumulated powder, and—calculating, by means of S.sub.n, M.sub.n and R, a ratio X.sub.n of the component in one of the parts (22) manufactured during the cycle.

In various embodiments, metallic wires are fabricated by combining one or more powders of substantially spherical metal particles with one or more powders of non-spherical particles within one or more optional metallic tubes. The metal elements within the powders (and the one or more tubes, if present) collectively define a high entropy alloy of five or more metallic elements or a multi-principal element alloy of four or more metallic elements.

The present invention provides a metal powder-polymer matrix film for use in delivering metal powder to a three-dimensional printing process, the matrix comprising at least one metal powder and a polymer sheet, wherein the metal powder is incorporated within the polymer sheet architecture or on the polymer sheet surface, and wherein the polymer sheet has a thickness that is at least half that of the powder thickness.

Methods disclosed herein include using additive manufacturing to create a joint between a first metallic material and a second metallic material that is different from the first metallic material, wherein the porosity of the joint is less than about 0.1 percent by volume measured according to ASTM B-962. The additive manufacturing can be performed such that no intermetallic brittle phase forms between the first metallic material and the second metallic material.

Methods disclosed herein include using additive manufacturing to create a joint between a first metallic material and a second metallic material that is different from the first metallic material, wherein the porosity of the joint is less than about 0.1 percent by volume measured according to ASTM B-962. The additive manufacturing can be performed such that no intermetallic brittle phase forms between the first metallic material and the second metallic material.

Apparatus and methods for making metal-connected particle articles. A metal containing fluid is selectively applied to a layer of particles. The metal in the fluid is used to form metal connections between particles. The metal connections are formed at temperatures below the sintering temperature of the particles in the layer of particles.

The present disclosure discloses a nano-lanthanum oxide reinforced tungsten-based composite material and a preparation method thereof. A pure tungsten powder and a nano-lanthanum oxide powder are mixed to obtain a mixed powder, and in the mixed powder, the nano-lanthanum oxide powder accounts for 0.5-2% of the mixed powder by mass percent; and then, 3D printing forming is conducted on the mixed powder to obtain a bulk material of the nano-lanthanum oxide reinforced tungsten-based composite material. The nano-lanthanum oxide reinforced tungsten-based composite material of the present disclosure has excellent mechanical properties.

The present disclosure discloses a nano-lanthanum oxide reinforced tungsten-based composite material and a preparation method thereof. A pure tungsten powder and a nano-lanthanum oxide powder are mixed to obtain a mixed powder, and in the mixed powder, the nano-lanthanum oxide powder accounts for 0.5-2% of the mixed powder by mass percent; and then, 3D printing forming is conducted on the mixed powder to obtain a bulk material of the nano-lanthanum oxide reinforced tungsten-based composite material. The nano-lanthanum oxide reinforced tungsten-based composite material of the present disclosure has excellent mechanical properties.

In some examples, a build material recycling device of a three-dimensional (3D) printer can include an upper chamber including an inlet and a material separator coupled to the inlet, a classifier coupled to the upper chamber, and a lower chamber coupled to the classifier, where the classifier is located between the upper chamber and the lower chamber.