Systems and methods for direct deposition of thixotropic alloys

1. A method, comprising:

placing a probe in a molten metal melt comprising a thixotropic metal alloy;

injecting a gas composition including an inert gas and an interstitial gas into the molten metal melt to form a saturated slurry, the saturated slurry being at a temperature above a liquidus temperature of the thixotropic metal alloy after injecting the gas composition;

removing the probe from the molten metal melt;

depositing the molten metal melt through an extruder of an additive manufacturing system;

depositing a plurality of layers in a build direction; and

friction stir welding the plurality of layers together.

2. The method of claim 1 , further comprising depositing a fiber with the molten metal melt to form a metal matrix composite.

3. The method of claim 2 , wherein the fiber is a metal coated carbon fiber.

4. The method of claim 1 , wherein the temperature is between 1% and 20% above the liquidus temperature of the thixotropic metal alloy, and wherein the thixotropic metal alloy has a melting temperature between 2,000° F. (1093° C.) and 4,000° F. (2,204° C.).

5. The method of claim 1 , wherein a deposition temperature of each layer in the plurality of layers is determined based on a solid to liquid ratio between layers.

6. The method of claim 1 , wherein the gas composition is injected through at least one of the probe and a nozzle of the extruder in the additive manufacturing system.

7. The method of claim 1 , wherein the gas composition further comprises a plurality of interstitial gases, the gas composition configured to strengthen the thixotropic metal alloy.