System and Method for Forming Nano-Particles in Additively-Manufactured Metal Alloys

In some embodiments, a method of producing a metallic article includes providing a metallic powder, selecting a predetermined concentration for a reactive component, providing a controlled atmosphere including the reactive component at the predetermined concentration, and additively manufacturing the metallic article from the metallic powder under the controlled atmosphere. The metallic powder includes a metallic element or metallic alloy. The reactive component reacts with the metallic powder in a weld pool formed during the additive manufacturing to form a dispersion of nano-particles in the weld pool. The nano-particles are dispersed throughout the metallic article in a substantially uniform manner. In some embodiments, the metallic powder includes the reactive component. Metallic articles formed by the disclosed methods are also disclosed.