An aluminium based alloy, and a method for production of components by additive manufacturing (AM) or other rapid solidification process with the alloy, is based on the alloy having a composition with from 2.01 wt % to 15.0 wt % manganese, from 0.3 wt % to 2.0 wt % scandium, with a balance apart from minor alloy elements and incidental impurities of aluminium.

An aluminium based alloy, and a method for production of components by additive manufacturing (AM) or other rapid solidification process with the alloy, is based on the alloy having a composition with from 2.01 wt % to 15.0 wt % manganese, from 0.3 wt % to 2.0 wt % scandium, with a balance apart from minor alloy elements and incidental impurities of aluminium.

An aluminium based alloy, and a method for production of components by additive manufacturing (AM) or other rapid solidification process with the alloy, is based on the alloy having a composition with from 2.01 wt % to 15.0 wt % manganese, from 0.3 wt % to 2.0 wt % scandium, with a balance apart from minor alloy elements and incidental impurities of aluminium.

An aluminium based alloy, and a method for production of components by additive manufacturing (AM) or other rapid solidification process with the alloy, is based on the alloy having a composition with from 2.01 wt % to 15.0 wt % manganese, from 0.3 wt % to 2.0 wt % scandium, with a balance apart from minor alloy elements and incidental impurities of aluminium.

Some variations provide a method of making an additively manufactured single-crystal metallic component, comprising: providing a feedstock comprising a first metal or metal alloy; providing a build plate comprising a single crystal of a second metal or metal alloy; exposing the feedstock to an energy source for melting the feedstock, generating a melt layer on the build plate; and solidifying the melt layer, generating a solid layer (on the build plate) of a metal component. The solid layer is also a single crystal of the first metal or metal alloy. The method may be repeated many times to build the part. Some variations provide a single-crystal metallic component comprising a plurality of solid layers in an additive-manufacturing build direction, wherein the plurality of solid layers forms a single crystal of a metal or metal alloy with a continuous crystallographic texture. The crystal orientation may vary along the additive-manufacturing build direction.

Embodiments disclosed are systems and methods for interfacing a metallic capillary in a microchannel of a metallic body. A method may include inserting a portion of the metallic capillary into a portion the microchannel of the metallic body, sintering the portion of the metallic capillary to the portion of the microchannel of the metallic body, disposing a sacrificial powder at least proximate to the metallic capillary and the metallic body after sintering the portion of the metallic capillary and the portion of the microchannel of the metallic body, and infiltrating at least the portion of the metallic capillary sintered to the portion of the microchannel of the metallic body with an infiltrant in the presence of the sacrificial powder disposed at least proximate to the metallic capillary and the metallic body.

Embodiments disclosed are systems and methods for interfacing a metallic capillary in a microchannel of a metallic body. A method may include inserting a portion of the metallic capillary into a portion the microchannel of the metallic body, sintering the portion of the metallic capillary to the portion of the microchannel of the metallic body, disposing a sacrificial powder at least proximate to the metallic capillary and the metallic body after sintering the portion of the metallic capillary and the portion of the microchannel of the metallic body, and infiltrating at least the portion of the metallic capillary sintered to the portion of the microchannel of the metallic body with an infiltrant in the presence of the sacrificial powder disposed at least proximate to the metallic capillary and the metallic body.

Disclosed herein are surface-functionalized powders which alter the solidification of the melted powders. Some variations provide a powdered material comprising a plurality of particles fabricated from a first material, wherein each of the particles has a particle surface area that is continuously or intermittently surface-functionalized with nanoparticles and/or microparticles selected to control solidification of the powdered material from a liquid state to a solid state. Other variations provide a method of controlling solidification of a powdered material, comprising melting at least a portion of the powdered material to a liquid state, and semi-passively controlling solidification of the powdered material from the liquid state to a solid state. Several techniques for semi-passive control are described in detail. The methods may further include creating a structure through one or more techniques selected from additive manufacturing, injection molding, pressing and sintering, capacitive discharge sintering, or spark plasma sintering.

Disclosed herein are surface-functionalized powders which alter the solidification of the melted powders. Some variations provide a powdered material comprising a plurality of particles fabricated from a first material, wherein each of the particles has a particle surface area that is continuously or intermittently surface-functionalized with nanoparticles and/or microparticles selected to control solidification of the powdered material from a liquid state to a solid state. Other variations provide a method of controlling solidification of a powdered material, comprising melting at least a portion of the powdered material to a liquid state, and semi-passively controlling solidification of the powdered material from the liquid state to a solid state. Several techniques for semi-passive control are described in detail. The methods may further include creating a structure through one or more techniques selected from additive manufacturing, injection molding, pressing and sintering, capacitive discharge sintering, or spark plasma sintering.

Disclosed herein are surface-functionalized powders which alter the solidification of the melted powders. Some variations provide a powdered material comprising a plurality of particles fabricated from a first material, wherein each of the particles has a particle surface area that is continuously or intermittently surface-functionalized with nanoparticles and/or microparticles selected to control solidification of the powdered material from a liquid state to a solid state. Other variations provide a method of controlling solidification of a powdered material, comprising melting at least a portion of the powdered material to a liquid state, and semi-passively controlling solidification of the powdered material from the liquid state to a solid state. Several techniques for semi-passive control are described in detail. The methods may further include creating a structure through one or more techniques selected from additive manufacturing, injection molding, pressing and sintering, capacitive discharge sintering, or spark plasma sintering.