A tantalum-titanium alloy powder that is highly spherical is described. The alloy powder can be useful in additive manufacturing and other uses. Methods to make the alloy powder are further described as well as methods to utilize the alloy powder in additive manufacturing processes. Resulting products and articles using the alloy powder are further described.

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 small adaptive engines uses a battlefield repository having cloud services that is configured to enable additive manufacturing (AM) of engine parts and assemblies. The method also uses a compilation of recipes/signatures for building the engine parts and the assemblies using additive manufacturing (AM) processes and machine learning programs. An additive manufacturing system and an alloy powder suitable for performing the additive manufacturing (AM) processes can be provided. In addition, the engine parts can be built using the additive manufacturing (AM) system, the alloy powder, the battlefield repository and the compilation of recipes/signatures. A system for manufacturing small adaptive engines includes the battlefield repository, the compilation of recipes/signatures, a foundry system for providing the alloy powder and an additive manufacturing (AM) system configured to perform the additive manufacturing (AM) processes.

A method for manufacturing a three-dimensional object includes: a modeling step of modeling an intermediate object by applying a binding fluid to a metal powder containing titanium; and a sintering step of sintering the intermediate object to produce a three-dimensional object. The modeling step is performed in a vacuum or inert gas atmosphere. When the modeling step is performed in a modeling area and the method includes a curing step of curing the binding fluid included in the intermediate object in a curing area different from the modeling area after the modeling step and before the sintering step, the curing step is performed in a vacuum or inert gas atmosphere. A moving path for moving the intermediate object having gone through the modeling step from the modeling area to the curing area is in a vacuum or inert gas atmosphere.

A shaping composition for controlling deformation of a green body object can include from about 10 wt % to about 80 wt % liquid vehicle, and from about 10 wt % to about 90 wt % metal particulates. The metal particulates can include from about 35 wt % to about 90 wt % high melting point metal particles, from about 10 wt % to about 65 wt % aluminum alloy particles, and from about 0.1 wt % to about 10 wt % metal complex selected from an inorganic metal salt, an organic metal salt, or a metal oxide. The metal of the metal complex can include copper, iron, aluminum, chromium, titanium, cobalt, silver, gold, nickel, tin, or zinc.

An nitrogen solid solution titanium sintered compact includes a matrix made of a titanium component having an -phase, nitrogen atoms dissolved as a solute of solid solution in a crystal lattice of the titanium component, and metal atoms dissolved as a solute of solid solution in the crystal lattice of the titanium component.

A method based on fluidizing for modifying and preparing low-cost titanium powders for 3D printing includes: using hydrogenated-dehydrogenated irregularly-shaped titanium powders as the raw material, adding the titanium powders to a fluidized bed reactor, and introducing Ar or H.sub.2 at the flow rate of 0.5-1.5 L/min, heating the reactor to 300-700 C., and fluidizing for 5-90 min to modify the titanium powders. When filled with high-purity argon gas and heated at high temperature, the sharp edges and corners of irregularly-shaped titanium powders are ground collision of the particles due to the friction among powder particles.

The present invention relates to a powder for additive manufacturing, having a composition consisting of, in mass %: 0.25<C<0.40, 0.001Si0.15, 0.30Mn0.45, 5.0Cr5.5, 1.0Mo1.5, 0.35V0.45, 0.01N0.05, 0.01O0.04, and optionally, P<0.10, Cu<0.20, Ni<0.20, Al<0.05, Zr<0.05, S<0.20, Pb<0.20, Bi<0.20, Nb<0.20, Ti<0.20, B<0.10, and Co<0.20, with the balance being Fe and unavoidable impurities, in which a surface of the powder for additive manufacturing is coated with an oxide film, and the oxide film has a thickness of 3 nm or more and 30 nm or less.

In one aspect, methods of making freestanding metal matrix composite articles and alloy articles are described. A method of making a freestanding composite article described herein comprises disposing over a surface of the temporary substrate a layered assembly comprising a layer of infiltration metal or alloy and a hard particle layer formed of a flexible sheet comprising organic binder and the hard particles. The layered assembly is heated to infiltrate the hard particle layer with metal or alloy providing a metal matrix composite, and the metal matrix composite is separated from the temporary substrate. Further, a method of making a freestanding alloy article described herein comprises disposing over the surface of a temporary substrate a flexible sheet comprising organic binder and powder alloy and heating the sheet to provide a sintered alloy article. The sintered alloy article is then separated from the temporary substrate.

A metallic part is disclosed. The part may comprise a functionally graded monolithic structure characterized by a variation between a first material composition of a first structural element and a second material composition of at least one of a second structural element. The first material composition may comprise an alpha-beta titanium alloy. The second material composition may comprise a beta titanium alloy.