A multiple axis manufacturing platform for three-dimensional object fabrication in three dimensions and along at least two rotary axes. The platform includes one or more additive and one or more subtractive manufacturing tools. An automatic tool changer (ATS) holds the additive and the subtractive manufacturing tools and selects among them. A movable substrate platform supports a workpiece. A programmable control system has one or more programs for controlling the manufacturing tools, the automatic tool changer and the movable substrate platform, and includes machine code to control one or more relay switches to control the additive manufacturing tools. A machine vision system detects displacement between or features of deposited material. A vision camera mounting for the spindle housing allows viewing the manufacturing process. A laser displacement sensor extracts distance and position of the selected tool or the workpiece. A feedback system is used to dynamically control material flow from an additive manufacturing tool.

A multiple axis manufacturing platform for three-dimensional object fabrication in three dimensions and along at least two rotary axes. The platform includes one or more additive and one or more subtractive manufacturing tools. An automatic tool changer (ATS) holds the additive and the subtractive manufacturing tools and selects among them. A movable substrate platform supports a workpiece. A programmable control system has one or more programs for controlling the manufacturing tools, the automatic tool changer and the movable substrate platform, and includes machine code to control one or more relay switches to control the additive manufacturing tools. A machine vision system detects displacement between or features of deposited material. A vision camera mounting for the spindle housing allows viewing the manufacturing process. A laser displacement sensor extracts distance and position of the selected tool or the workpiece. A feedback system is used to dynamically control material flow from an additive manufacturing tool.

A component has a matrix phase composed of at least one material selected from the group molybdenum, a molybdenum-based alloy, tungsten, a tungsten-based alloy and a molybdenum-tungsten-based alloy. The component is manufactured using a laser or electron beam in an additive manufacturing process. The molybdenum content, the tungsten content or the total content of molybdenum and tungsten is more than 85 at %, and the component contains particulates having a melting point above the melting point of the matrix phase.

In various embodiments, metallic alloy powders are utilized as feedstock, or to fabricate feedstock, utilized in additive manufacturing processes to form three-dimensional metallic parts. Such three-dimensional parts are fabricated by providing a powder bed containing particles each comprising a mixture and/or alloy of constituent elemental metals, forming a first layer of the part by (i) dispersing a binder into the powder bed, and (ii) curing the binder, the first layer of the shaped part comprising particles bound together by cured binder, disposing a layer of the particles over the first layer of the part, forming subsequent layers of the part, and then sintering the part.

Method for manufacturing an aluminium alloy part by additive manufacturing comprising a step during which a layer of a mixture of powders is locally melted and then solidified, characterised in that the mixture of powders comprises: first particles comprising at least 80% by mass of aluminium and up to 20% by mass of one or more additional elements, and second yttria-stabilized zirconia particles, the mixture of powders comprising at least 1.5% by volume of second particles.

Method for manufacturing an aluminium alloy part by additive manufacturing comprising a step during which a layer of a mixture of powders is locally melted and then solidified, characterised in that the mixture of powders comprises: first particles comprising at least 80% by mass of aluminium and up to 20% by mass of one or more additional elements, and second yttria-stabilized zirconia particles, the mixture of powders comprising at least 1.5% by volume of second particles.

A mixture for forming a wear resistant layer on a substrate comprises particles of a first wear resistant particle type, particles of a second wear resistant particle type and a wear resistant layer binder for binding the first and the second wear resistant particles in the wear resistant layer when the layer is formed. As well, wear resistant particle size distributions for the first and second wear resistant particle types have a first mode and a second mode. The first particle type is associated with the first mode and the second particle type is associated with the second mode. Moreover, a number of first wear resistant particles associated with the first mode is larger than a number of second wear resistant particles associated with the second mode. Further, the second mode is larger than the first mode.

A mixture for forming a wear resistant layer on a substrate comprises particles of a first wear resistant particle type, particles of a second wear resistant particle type and a wear resistant layer binder for binding the first and the second wear resistant particles in the wear resistant layer when the layer is formed. As well, wear resistant particle size distributions for the first and second wear resistant particle types have a first mode and a second mode. The first particle type is associated with the first mode and the second particle type is associated with the second mode. Moreover, a number of first wear resistant particles associated with the first mode is larger than a number of second wear resistant particles associated with the second mode. Further, the second mode is larger than the first mode.

In various embodiments, metallic alloy powders are formed at least in part by spray drying to form agglomerate particles and/or plasma densification to form composite particles.

In various embodiments, metallic alloy powders are formed at least in part by spray drying to form agglomerate particles and/or plasma densification to form composite particles.