Laser powder bed fusion (L-PBF) additive manufacturing technology can print multi-material parts with multiple functions/properties, and has great potential for working in harsh application environments. However, the metal blank formed by sintering metal powder material with binder added through L-PBF has an obvious porous structure and insufficient mechanical properties, and few studies have been conducted studying this. In this paper, epoxy resin was used to impregnate the blank of porous metal parts formed by L-PBF with iron-based powder material at a certain temperature, and a cross-linked curing reaction was carried out with three kinds of phenolic resin in different proportions under the action of a curing agent, so as to fill the pores and achieve the desired mechanical properties. The characteristic peaks of each group of epoxy resin were characterized using Fourier transform infrared spectroscopy (FT-IR) and H-nuclear magnetic resonance (¹H-NMR) spectrums. The microstructure, decomposition temperature, and residue of four epoxy resin dispersion systems were analyzed with a scanning electron microscope (SEM), a thermal gravimetric analyzer (TGA), and derivative thermogravimetry (DTG). The results show that the density of the porous metal parts was obviously improved, the heat resistance temperature of the parts could reach 350 °C, and the tensile strength of the sample after EP2-1 impregnation was increased by 4–6 times after curing at 160 °C for 6 h. Therefore, the use of an epoxy resin dispersion system can increase the porosity of L-PBF porous metal parts, but can also significantly improve their mechanical properties, which can help them to meet the requirements of applications as model materials, biological materials, and functional materials to provide a feasible solution.

Epoxy resin, known for its excellent corrosion resistance, water resistance, and high-temperature resistance, is extensively utilized in construction and water-related projects. Within water conservancy projects, natural factors such as water impact and weathering often result in cracks within rock formations. Consequently, the application of epoxy resin materials for repair and reinforcement has emerged as a common solution. This research investigates the impact of five epoxy grouting materials, YDS (100:6.4), RH-1 (6.1:1), PSI (9:1), TK (100:8), and HK-G (5:1), on the repair and reinforcement of faulted rock at the Yebatan Hydropower Station. Penetration experiments were conducted on rock samples, and the strength of the epoxy grout samples was tested under ambient conditions of 20 °C, 15 °C, and 0 °C. The experimental results indicate that all five epoxy grout materials successfully penetrated the faulted rock samples. Among them, the PSI (9:1) epoxy grouting material exhibited the most exceptional reinforcing effect across different temperatures, with grouting samples demonstrating strengths in the range of 20 to 25 MPa. This paper confirms that epoxy resin effectively repairs and reinforces rock structures, thereby enhancing the safety and durability of water conservancy projects.