The present application describes an article having a first metal component joined to a second metal component by a metallurgic joint of presintered powdered metal interposed between contiguous surfaces of the first metal component and the second metal component. The present application also describes a composition for use in a brazing process comprising a presintered powdered metal. The present application also describes a process for brazing including the following steps: presintering a powdered metal; adding the presintered powdered metal to a first and second metal component; and heating the combination of the first and second metal components containing the presintered powdered metal until the powdered metal melts and joins the metal components to form a metallurgic joint.

A method of additive manufacture is disclosed. The method can include providing an enclosure surrounding a powder bed and having an atmosphere including helium gas. A high flux laser beam is directed at a defined two dimensional region of the powder bed. Powder is melted and fused within the defined two dimensional region, with less than 50% by weight of the powder particles being displaced into any defined two dimensional region that shares an edge or corner with the defined two dimensional region where powder melting and fusing occurs.

A method of additive manufacture is disclosed. The method can include providing an enclosure surrounding a powder bed and having an atmosphere including helium gas. A high flux laser beam is directed at a defined two dimensional region of the powder bed. Powder is melted and fused within the defined two dimensional region, with less than 50% by weight of the powder particles being displaced into any defined two dimensional region that shares an edge or corner with the defined two dimensional region where powder melting and fusing occurs.

The present application provides a combined additive manufacturing and machining system. The combined additive manufacturing and machining system may include an outer chamber, an additive manufacturing tool positioned within the outer chamber, a machining tool positioned within the outer chamber, and a cryogenic fluid source in communication with the machining tool.

The present application provides a combined additive manufacturing and machining system. The combined additive manufacturing and machining system may include an outer chamber, an additive manufacturing tool positioned within the outer chamber, a machining tool positioned within the outer chamber, and a cryogenic fluid source in communication with the machining tool.

Methods are provided for producing alloy forms from alloys containing one or more extremely reactive elements and for fabricating a component therefrom. The fabricating method comprises substantially removing a reactive gas from the fabrication environment. An alloy form of the alloy is formed. The alloy form is formed by melting the alloy or by melting one or more base elements of the alloy to produce a molten liquid and introducing the one or more extremely reactive elements into the molten liquid. The molten alloy is shaped into the alloy form. The component is formed from the alloy form. If the one or more extremely reactive elements are introduced into the molten liquid, such introduction occurs just prior to the shaping step.

Methods are provided for producing alloy forms from alloys containing one or more extremely reactive elements and for fabricating a component therefrom. The fabricating method comprises substantially removing a reactive gas from the fabrication environment. An alloy form of the alloy is formed. The alloy form is formed by melting the alloy or by melting one or more base elements of the alloy to produce a molten liquid and introducing the one or more extremely reactive elements into the molten liquid. The molten alloy is shaped into the alloy form. The component is formed from the alloy form. If the one or more extremely reactive elements are introduced into the molten liquid, such introduction occurs just prior to the shaping step.

A metal powder producing apparatus includes a molten metal supply unit, a cylinder body, and a cooling liquid introduction unit. The molten metal supply unit discharges a molten metal. The cylinder body is capable of being formed with a layer of a cooling liquid for cooling the molten metal on an inner circumference surface of the cylinder body. The cooling liquid introduction unit supplies the cooling liquid to an upper inside of the cylinder body. The inner circumference surface of the upper inside of the cylinder body has a substantially elliptical shape.

A metal powder producing apparatus includes a molten metal supply unit, a cylinder body, and a cooling liquid introduction unit. The molten metal supply unit discharges a molten metal. The cylinder body is capable of being formed with a layer of a cooling liquid for cooling the molten metal on an inner circumference surface of the cylinder body. The cooling liquid introduction unit supplies the cooling liquid to an upper inside of the cylinder body. The inner circumference surface of the upper inside of the cylinder body has a substantially elliptical shape.

There are provided reactive metal powder atomization manufacturing processes. For example, such processes include providing a heated metal source and contact the heated metal source with at least one additive gas while carrying out the atomization process. Such processes provide raw reactive metal powder having improved flowability. The at least one additive gas can be mixed together with an atomization gas to obtain an atomization mixture, and the heated metal source can be contacted with the atomization mixture while carrying out the atomization process. Reactive metal powder spheroidization manufacturing processes are also provided.