A metal composition, a method for additive manufacturing using such metal composition and the use of such metal composition is provided. The components of the metal composition are selected according to ranges and typically provide a more generic applicability in additive manufacturing.

Some variations provide a process for additive manufacturing of a nanofunctionalized metal alloy, comprising: providing a nanofunctionalized metal precursor containing metals and grain-refining nanoparticles; exposing a first amount of the nanofunctionalized metal precursor to an energy source for melting the precursor, thereby generating a first melt layer; solidifying the first melt layer, thereby generating a first solid layer; and repeating many times to generate a plurality of solid layers in an additive-manufacturing build direction. The additively manufactured, nanofunctionalized metal alloy has a microstructure with equiaxed grains. Other variations provide an additively manufactured, nanofunctionalized metal alloy comprising metals selected from aluminum, iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; and grain-refining nanoparticles selected from zirconium, tantalum, niobium, titanium, or oxides, nitrides, hydrides, carbides, or borides thereof, wherein the additively manufactured, nanofunctionalized metal alloy has a microstructure with equiaxed grains.

Some variations provide a method of making an additively manufactured metal component, comprising: providing a feedstock that includes a high-vapor-pressure metal; exposing a first amount of the feedstock to an energy source for melting; and solidifying the melt layer, thereby generating a solid layer of an additively manufactured metal component. The metal-containing feedstock is enriched with a higher concentration of the high-vapor-pressure metal compared to its concentration in the additively manufactured metal component. The high-vapor-pressure metal may be selected from Mg, Zn, Li, Al, Cd, Hg, K, Na, Rb, Cs, Mn, Be, Ca, Sr, or Ba, for example. Additively manufactured metal components are provided. Metal-containing feedstocks for additive manufacturing are also disclosed, wherein concentration of at least one high-vapor-pressure metal in the feedstock is selected based on a desired concentration of the high-vapor-pressure metal in an additively manufactured metal component derived from the metal-containing feedstock. Various feedstock compositions are disclosed.

A method for manufacturing a spherical metallic powder blend using a metallic starting material, the method including steps of grinding the metallic starting material to yield an intermediate powder, spheroidizing the intermediate powder to yield a first spherical powder component, and mixing the first spherical powder component with a second spherical powder component, wherein the first spherical powder component and the second spherical powder component have substantially the same chemical composition.

Some variations provide a process for additive manufacturing of a nanofunctionalized metal alloy, comprising: providing a nanofunctionalized metal precursor containing metals and grain-refining nanoparticles; exposing a first amount of the nanofunctionalized metal precursor to an energy source for melting the precursor, thereby generating a first melt layer; solidifying the first melt layer, thereby generating a first solid layer; and repeating many times to generate a plurality of solid layers in an additive-manufacturing build direction. The additively manufactured, nanofunctionalized metal alloy has a microstructure with equiaxed grains. Other variations provide an additively manufactured, nanofunctionalized metal alloy comprising metals selected from aluminum, iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; and grain-refining nanoparticles selected from zirconium, tantalum, niobium, titanium, or oxides, nitrides, hydrides, carbides, or borides thereof, wherein the additively manufactured, nanofunctionalized metal alloy has a microstructure with equiaxed grains.

A method for manufacturing a three-dimensional semi-finished product comprises the steps of applying a first raw material powder to a carrier, applying a second raw material powder to the carrier, selectively irradiating the first raw material powder applied to the carrier with electromagnetic radiation or particle radiation, in order to manufacture a workpiece produced from the first raw material powder on the carrier by a generative layer construction method, and selectively irradiating the second raw material powder applied to the carrier with electromagnetic radiation or particle radiation, in order to manufacture a support element produced from the second raw material powder on the carrier by a generative layer construction method, wherein the support element produced from the second raw material powder has a higher thermal conductivity than the workpiece produced from the first raw material powder and wherein the support element dissipates heat introduced during the irradiation of the first and the second raw material powder.

A method includes fabricating a part out of composite material including fiber reinforcement densified by a metal matrix.

Disclosed are titanium alloys for use in additive manufacturing that comprise a titanium material and a beta eutectoid stabilizer. The beta eutectoid stabilizer can be present in an effective amount to produce an equiaxed grain structure when the titanium alloy is melted or sintered during an additive manufacturing process. Also provided are methods of forming objects via additive manufacturing processes as well as methods of forming titanium alloys for use in additive manufacturing.

Some variations provide a method of making a nanofunctionalized metal powder, comprising: providing metal particles containing metals selected from iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; providing nanoparticles selected from zirconium, tantalum, niobium, or titanium; disposing the nanoparticles onto surfaces of the metal particles, in the presence of mixing media, thereby generating nanofunctionalized metal particles; and isolating and recovering the nanofunctionalized metal particles as a nanofunctionalized metal powder. Some variations provide a composition comprising a nanofunctionalized metal powder, the composition comprising metal particles and nanoparticles containing one or more elements selected from the group consisting of zirconium, tantalum, niobium, titanium, and oxides, nitrides, hydrides, carbides, or borides thereof, or combinations of the foregoing.

A process for manufacturing a part comprising a formation of successive metal layers, superimposed on one another, wherein each layer is formed by the deposition of a filler metal, the filler metal being subjected to an input of energy so as to melt and to constitute said layer by solidifying, the process being characterized in that the filler metal is an aluminium alloy comprising the following alloy elements (% by weight):—Fe: 2% to 8%, and preferably 2% to 6%, more preferentially 3% to 5%;—optionally Zr: 0.5% to 2.5% or 0.5% to 2% or 0.7% to 1.5%;—optionally Si: <1%, or even <0.5% or even <0.2% or even <0.05%;—optionally Cu: 0.5%, or even <0.2%, or even <0.05%;—optionally Mg: 0.2%, preferably 0.1%, preferably <0.05%;—optionally other alloy elements <0.1% individually and in total <0.5%;—impurities: <0.05%, or even <0.01% individually, and in total <0.15%; remainder aluminium.