An expeditionary additive manufacturing (ExAM) system for manufacturing metal parts includes a mobile foundry system configured to produce an alloy powder from a feedstock, and an additive manufacturing system configured to fabricate a part using the alloy powder. The additive manufacturing system includes a computer system having parts data and machine learning programs in signal communication with a cloud service. The parts data can include material specifications, drawings, process specifications, assembly instructions, and product verification requirements for the part. An expeditionary additive manufacturing (ExAM) method for making metal parts includes the steps of transporting the mobile foundry system and the additive manufacturing system to a desired location; making the alloy powder at the location using the mobile foundry system; and building a part at the location using the additive manufacturing system.

A fabricated object manufactured from powder contained in a container of a fabrication apparatus is provided. The fabricated object satisfies the following relationship d>d′, where d (μm) denotes a number average diameter of the powder contained in the container and d′ (μm) denotes a number average diameter of the powder included in the fabricated object.

A powder production method includes providing at least one elongated member including a ductile material; providing a rotating or vibrating cutter configured to repeatedly cut an end of the at least one elongated member to produce particles; and advancing the at least one elongated member or the cutter towards the other of the at least one elongated member or the cutter to cut the particles from the at least one elongated member to produce a powder comprising a plurality of the particles. The particles produced by the method can have a diameter ranging from about 10 μm to about 200 μm.

A powder production method includes providing at least one elongated member including a ductile material; providing a rotating or vibrating cutter configured to repeatedly cut an end of the at least one elongated member to produce particles; and advancing the at least one elongated member or the cutter towards the other of the at least one elongated member or the cutter to cut the particles from the at least one elongated member to produce a powder comprising a plurality of the particles. The particles produced by the method can have a diameter ranging from about 10 μm to about 200 μm.

An aluminum alloy powder for laser laminated manufacturing includes Si: 2.0-4.5 wt %; Mg: 0.1-1.3 wt %; Fe: 0.07-0.65 wt %; Cu: 0.35 wt % or less; Cr: 0.02-0.32 wt %; Zn: 0.23 wt % or less; Ti: 0.23 wt % or less; Mn: 0.13 wt % or less; and the rest is aluminum. The aluminum alloy powder further includes inevitable impurities.

The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

The invention relates to a method for producing precise components, preferably machining tools or cold forming tools, cold extrusion punches and dies, by laser melting or laser sintering or laser deposit welding or FDM or binder jetting of a powder material, which consists of a mixture of at least two powder elements, the powder mixture being formed by the primary component iron powder and additional powder alloying elements, which are present in elemental, pre-alloyed or partially pre-alloyed form, the powder elements each being added separately or in arbitrary combination in the following quantities according to the standard DIN EN 10027-2 no. 1.33XX or DIN EN 10027-2 no. 1.27XX, in particular according to the standard DIN EN 10027-2 no. 1.3343 with the short name HS6-5-2C or DIN EN 10027-2 no. 1.2709, a powder alloy being created from said powder elements over the course of the laser sintering process, wherein the following powder elements, present in elemental, alloyed or pre-alloyed form, are each additionally added to the alloy separately or in arbitrary combination: tungsten in the range of between 35, 10 and 0.7 mass%, preferably 10 mass%, titanium in the range of between 0.2, 3.2 to 10.7 mass%, preferably 3.2 mass%, carbon in the range of between 0.08, 1.23 up to 4.1 mass%, preferably 1.23 mass%, O in the range of between 0.00 up to 0.02 mass%, N in the range of between 0.00 up to 0.02 mass%, undefined residual substances at less than 0.1 mass%.

A process for producing a crack-free and dense three-dimensional article of a gamma-prime precipitation-strengthened nickel-base superalloy, with more than 6 wt. % of [2 Al (wt. %)+Ti (wt. %)], which involves: (a) preparing a powder layer of a gamma-prime precipitation-strengthened nickel-based alloy material, with uniform thickness on a SLM apparatus substrate plate, or on a previously processed powder layer; (b) melting the prepared powder layer by scanning with a focused laser beam an article cross section area according to a three-dimensional sliced model with calculated cross sections, stored in the SLM control unit; (c) lowering the substrate plate by one layer thickness; and (d) repeating (a) to (c) until reaching a final cross section according to the three-dimensional sliced model, wherein, for (b), the laser power, focus diameter of the focal spot, and scan speed of the focused laser beam are adjusted to obtain heat dissipation welding.

The present disclosure provides an aluminum alloy workpiece and a preparation method thereof. By optimizing a composition of the aluminum alloy workpiece, the aluminum alloy workpiece can be prepared by laser powder bed fusion (LPBF) in the preparation method, thereby forming a target metallographic phase. The preparation method overcomes the problem that the composition of a high temperature-resistant and high-strength aluminum alloy designed based on the traditional casting and forging process cannot be matched with the LPBF, and makes full use of rapid cooling of the LPBF to prepare an aluminum alloy composition of a target crystal phase. The preparation method combines the aluminum alloy composition with the LPBF to achieve mutual promotion, thereby forming a target workpiece, such that an aluminum alloy with high strength and toughness at room temperature/high temperature can be prepared by the LPBF.

The present disclosure provides an aluminum alloy workpiece and a preparation method thereof. By optimizing a composition of the aluminum alloy workpiece, the aluminum alloy workpiece can be prepared by laser powder bed fusion (LPBF) in the preparation method, thereby forming a target metallographic phase. The preparation method overcomes the problem that the composition of a high temperature-resistant and high-strength aluminum alloy designed based on the traditional casting and forging process cannot be matched with the LPBF, and makes full use of rapid cooling of the LPBF to prepare an aluminum alloy composition of a target crystal phase. The preparation method combines the aluminum alloy composition with the LPBF to achieve mutual promotion, thereby forming a target workpiece, such that an aluminum alloy with high strength and toughness at room temperature/high temperature can be prepared by the LPBF.