A deformation-driven solid-phase extrusion device and a one-step alloy bar preparation method by using the same are provided. The device includes a stir tool, an extrusion container and an ejector rod. The stir tool has an integral structure composed of an upper mounting part and a lower working part and having a hollow channel. The lower working part is disposed in a groove of the extrusion container, and the ejector rod is disposed in the hollow channel of the stir tool. The method includes adding alloy powder to the extrusion container, enabling the stir tool to exert a pressure and revolve at a high speed to cause large plastic deformation of the powder and generate heat by friction and deform among powder and the friction working surface of the working part, sintering the alloy powder and extruding the same through the hollow channel of the stir tool.

A deformation-driven solid-phase extrusion device and a one-step alloy bar preparation method by using the same are provided. The device includes a stir tool, an extrusion container and an ejector rod. The stir tool has an integral structure composed of an upper mounting part and a lower working part and having a hollow channel. The lower working part is disposed in a groove of the extrusion container, and the ejector rod is disposed in the hollow channel of the stir tool. The method includes adding alloy powder to the extrusion container, enabling the stir tool to exert a pressure and revolve at a high speed to cause large plastic deformation of the powder and generate heat by friction and deform among powder and the friction working surface of the working part, sintering the alloy powder and extruding the same through the hollow channel of the stir tool.

A deformation-driven solid-phase extrusion device and a one-step alloy bar preparation method by using the same are provided. The device includes a stir tool, an extrusion container and an ejector rod. The stir tool has an integral structure composed of an upper mounting part and a lower working part and having a hollow channel. The lower working part is disposed in a groove of the extrusion container, and the ejector rod is disposed in the hollow channel of the stir tool. The method includes adding alloy powder to the extrusion container, enabling the stir tool to exert a pressure and revolve at a high speed to cause large plastic deformation of the powder and generate heat by friction and deform among powder and the friction working surface of the working part, sintering the alloy powder and extruding the same through the hollow channel of the stir tool.

A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations. Methods for generation of different periodic and non-periodic structures and joints using the process-controlled solid-state additive manufacturing system are also disclosed.

A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations. Methods for generation of different periodic and non-periodic structures and joints using the process-controlled solid-state additive manufacturing system are also disclosed.

The present disclosure generally relates to powder packing for additive manufacturing (AM) methods and systems. Conventional powder packing methods are manual and non-standardized, and they result in operator fatigue and potentially product inconsistencies. Powder packing according to the present disclosure improves standardization and reduces turnaround time, with the potential to lower the cost of AM.

The present disclosure generally relates to powder packing for additive manufacturing (AM) methods and systems. Conventional powder packing methods are manual and non-standardized, and they result in operator fatigue and potentially product inconsistencies. Powder packing according to the present disclosure improves standardization and reduces turnaround time, with the potential to lower the cost of AM.

A method to reduce the number and type of processing steps to achieve conductive lines in the planes of a substrate concurrently interconnecting conductor through the substrate, by forming structures in the planes of a substrate. These structures may include interconnect lines, bond pads, and other structures, and improve the performance of subsequent unique processing while simultaneously reducing the manufacturing complexity to reduce time and cost. These structures are formed by selective etching using chemical mechanical polishing, and then completed using a single fill step with a conductive material.

A method to reduce the number and type of processing steps to achieve conductive lines in the planes of a substrate concurrently interconnecting conductor through the substrate, by forming structures in the planes of a substrate. These structures may include interconnect lines, bond pads, and other structures, and improve the performance of subsequent unique processing while simultaneously reducing the manufacturing complexity to reduce time and cost. These structures are formed by selective etching using chemical mechanical polishing, and then completed using a single fill step with a conductive material.

Disclosed are an apparatus and method for densifying or compacting powder material in the supply bin of an additive manufacture machine to improve the quality of the object being made. For example, a removable or portable apparatus can be applied to the surface of the supply bin once the bin has been filled. The apparatus can include a vibrational component that agitates the underlying powder to compact the material. The apparatus can then be removed during the remainder of the additive manufacturing process, which then follows in its normal course. A vacuum can also be used the remove of air or other gases that are emitted during the compaction process, for example, as voids are filled during densification.