Abstract: In general, techniques are described for fused filament fabrication of abradable coatings. An additive manufacturing system comprising a substrate defining a major surface, a filament delivery device, and a computing device may be configured to perform various aspects of the techniques. The computing device may be configured to control the filament delivery device to deposit a filament on the substrate, the filament including a powder and a binder, wherein the binder is configured to be substantially removed from the filament and the powder includes a metal or alloy configured to be sintered to form an abradable layer.

Abstract: An additive manufacturing technique includes depositing, via a filament delivery device, a filament onto a surface of a substrate. The filament includes a binder and a high entropy alloy powder. The technique also includes sacrificing the binder to form a preform and sintering the preform to form a component.

Abstract: A material deposition head includes a body portion and at least one nozzle. The body portion includes a first end, a second end, and a first exterior surface extending from the first end to the second end. The at least one nozzle is coupled to the body portion at or near the second end. The nozzle defines a second exterior surface and a material delivery channel that is fluidically coupled to a fluidized powder source configured to provide a plurality of particles of a material. At least one of the first exterior surface or the second exterior surface includes a microtextured surface configured to reduce a wettability of molten particles of the plurality of particles thereon.

Abstract: An additively manufactured component that includes a tool with a region having a plurality of overlying metal layers each derived from a metal powder filament. The region has a predetermined yield point selected based on an operation to be performed with the tool.

Abstract: In some examples, an additive manufacturing technique including forming an as-deposited coating on a substrate by depositing a filament via a filament delivery device, wherein the filament includes a sacrificial binder and a powder; removing substantially all the binder from the as-deposited coating; and sintering the as-deposited coating to form a thermal coating; wherein the thermal coating is configured to ablate in response to absorption of energy from an external environment, and wherein the ablation of the thermal coating reduces the energy transferred to the substrate.

Abstract: In some examples, an additive manufacturing technique for forming a vacuum insulator. For example, a method including forming an article including a first layer, a second layer, and at least one support member extending between the first and second layer by depositing a filament via a filament delivery device, wherein the filament includes a sacrificial binder and a powder, and wherein the first layer, second layer, and at least one support member define an open cavity within the article; removing the binder; and sintering the article to form the vacuum insulator, wherein the vacuum insulator defines a vacuum environment in the cavity.

Abstract: A system may include a stationary component including: a substrate and an abradable layer on the substrate. The system also may include a rotating component including a tip and an abrasive coating system on the tip. The abrasive coating system may include a barrier layer and an abrasive material. The barrier layer may include at least one of hafnon, hafnium oxide, a blend of hafnium oxide and silicon or silicon oxide, a rare earth silicate, BSAS, stabilized zirconia, or stabilized hafnia. The blade track or blade shroud and the gas turbine blade are configured so the abrasive coating system contacts a portion of the abradable layer during rotation of the rotating component. The abradable layer is configured to be abraded by the contact by the abrasive coating system.

Abstract: In some examples, a method for additively manufacturing a heat pipe, the method including depositing, via a filament delivery device, a filament to form a heat pipe preform, wherein the filament includes a binder and a metal or alloy powder; and sintering the heat pipe preform to form the heat pipe, the heat pipe including an outer shell, a wicking region, and a vapor transport region defined by the metal or alloy.

Abstract: An additive manufacturing system may include an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component; a powder delivery device configured to direct a powder stream toward the melt pool; a plurality of mass sensors, each mass sensor associated with a portion of the additive manufacturing system; a plurality of heat sensors; and one or more computing devices. The computing device(s) are configured to receive data from the plurality of mass sensors; determine an overall mass flux based on the data from the mass sensors; control the powder delivery device based on the overall mass flux; receive data from the plurality of heat sensors; determine an overall heat flux based on the data from the heat sensors; and control the energy delivery device based on the overall heat flux.

Abstract: A method may include fused filament fabricating a fused filament fabricated component by delivering a softened filament to selected locations at or adjacent to a build surface. The softened filament may include a sacrificial binder and a powder including a shape memory alloy (SMA). The method also may include removing substantially all the sacrificial binder from the fused filament fabricated component to leave an unsintered component; and sintering the unsintered component to join particles of the SMA and form an SMA component.

Abstract: In some examples, an additive manufacturing technique including forming an as-deposited coating on a substrate by depositing a filament via a filament delivery device, wherein the filament includes a sacrificial binder and a powder; removing substantially all the binder from the as-deposited coating; and sintering the as-deposited coating to form a thermal coating; wherein the thermal coating is configured to ablate in response to absorption of energy from an external environment, and wherein the ablation of the thermal coating reduces the energy transferred to the substrate.

Abstract: In some examples, a method for forming a ballistic armor article, the method including forming a preform article by depositing a filament via a filament delivery device, wherein the filament includes a sacrificial binder and a powder; removing the binder from the preform article; and sintering the preform article to form the ballistic armor article, wherein the ballistic armor article is configured to absorb energy from an external projectile that impacts the ballistic armor article, and wherein the ballistic armor article is configured to prevent the projectile from penetrating through the ballistic armor article.

Abstract: A system may include a stationary component including: a substrate and an abradable layer on the substrate. The system also may include a rotating component including a tip and an abrasive coating system on the tip. The abrasive coating system may include a barrier layer and an abrasive material. The barrier layer may include at least one of hafnon, hafnium oxide, a blend of hafnium oxide and silicon or silicon oxide, a rare earth silicate, BSAS, stabilized zirconia, or stabilized hafnia. The blade track or blade shroud and the gas turbine blade are configured so the abrasive coating system contacts a portion of the abradable layer during rotation of the rotating component. The abradable layer is configured to be abraded by the contact by the abrasive coating system.

Abstract: A material deposition head includes a body portion and at least one nozzle. The body portion includes a first end, a second end, and a first exterior surface extending from the first end to the second end. The at least one nozzle is coupled to the body portion at or near the second end. The nozzle defines a second exterior surface and a material delivery channel that is fluidically coupled to a fluidized powder source configured to provide a plurality of particles of a material. At least one of the first exterior surface or the second exterior surface includes a microtextured surface configured to reduce a wettability of molten particles of the plurality of particles thereon.

Abstract: In some examples, an additive manufacturing technique for forming a vacuum insulator. For example, a method including forming an article including a first layer, a second layer, and at least one support member extending between the first and second layer by depositing a filament via a filament delivery device, wherein the filament includes a sacrificial binder and a powder, and wherein the first layer, second layer, and at least one support member define an open cavity within the article; removing the binder; and sintering the article to form the vacuum insulator, wherein the vacuum insulator defines a vacuum environment in the cavity.

Abstract: A method may include cold isostatic pressing a fused filament fabricated component comprising a plurality of roads and channels between at least some roads of the plurality of roads. The plurality of roads may include a sacrificial binder and a powder including a metal or alloy. The cold isostatic pressing reduces a presence of the channels between the at least some roads to form a compacted fused filament fabricated component. The method also may include removing substantially all the sacrificial binder from the compacted fused filament fabricated component and leave a powder component; and sintering the powder component to form a sintered component.

Abstract: In general, techniques are described for fused filament fabrication of abradable coatings. An additive manufacturing system comprising a substrate defining a major surface, a filament delivery device, and a computing device may be configured to perform various aspects of the techniques. The computing device may be configured to control the filament delivery device to deposit a filament on the substrate, the filament including a powder and a binder, wherein the binder is configured to be substantially removed from the filament and the powder includes a metal or alloy configured to be sintered to form an abradable layer.

Abstract: In some examples, a method for additively manufacturing a heat pipe, the method including depositing, via a filament delivery device, a filament to form a heat pipe preform, wherein the filament includes a binder and a metal or alloy powder; and sintering the heat pipe preform to form the heat pipe, the heat pipe including an outer shell, a wicking region, and a vapor transport region defined by the metal or alloy.

Abstract: An additive manufacturing technique may include depositing, via a filament delivery device, a filament onto a surface of a substrate. The filament includes a binder and a powder including at least one metal or alloy and at least one braze alloy. The technique also includes sacrificing the binder to form a preform. The technique also includes sintering the preform to form a component including the at least one metal or alloy and the at least one braze alloy.

Abstract: An additively manufactured component that includes a tool with a region having a plurality of overlying metal layers each derived from a metal powder filament. The region has a predetermined yield point selected based on an operation to be performed with the tool.