Abstract: An AM apparatus for an AM process is provided. The AM apparatus includes a build chamber with a build plate to support one or more parts built with a powder, during a build operation. The AM apparatus further includes a laser assembly operable to deliver a melting laser beam, to melt and fuse the powder used to build the one or more parts. The AM apparatus further includes a part detachment assembly, separate from the laser assembly and operable for a cutting operation. The part detachment assembly includes one or more laser beam delivery apparatuses, each operable to deliver a cutting laser beam, and a part holder apparatus. During the cutting operation, the part holder apparatus holds the one or more parts, and each of the laser beam delivery apparatus(es) delivers the cutting laser beam, to detach the one or more parts from the build plate within the AM apparatus.

Abstract: A steel alloy including, by weight percent: Ni: 18 to 19%; Co: 11.5 to 12.5%; Mo: 4.6 to 5.2%; Ti: 1.3 to 1.6%; Al: 0.05 to 0.15%; Nb: 0.15 to 0.30%; B: 0.003 to 0.020%; Cr: max 0.25%; Mn: max 0.1%; Si: max 0.1%; C: max 0.03%; P: max 0.005%; and S: max 0.002%, the balance being iron plus incidental impurities.

Abstract: There is provided an AM apparatus for an AM process. The AM apparatus has an AM assembly with a build chamber to support part(s) built with a powder, in a build operation. Unused powder accumulates in the build chamber during the build operation. The AM apparatus has a vacuum assembly with duct line(s) in flow communication with the build chamber, and a powder receptacle in flow communication with the duct line(s). The powder receptacle has coupling member(s) allowing the powder receptacle to be reversibly attached to the duct line(s). The vacuum assembly includes a vacuum apparatus coupled to, and in flow communication with, the powder receptacle, via vacuum duct line(s). The vacuum assembly pulls the unused powder from the build chamber to the powder receptacle, and provides an automated removal of the unused powder from the build chamber into the powder receptacle, to avoid manual removal of the unused powder.

Abstract: A laser deposition apparatus includes a sealed enclosure configured to hold a substrate, a powder source configured to hold a powder material, a peen source configured to hold a shot peen media, and a deposition system fluidly connected to the powder source and the peen source. The deposition system includes a laser configured to generate a laser beam. The deposition system is configured to deposit at least one layer on the substrate by injecting a stream of the powder material into the laser beam. The deposition system is configured to shot peen the at least one layer by propelling the shot peen media onto an exterior surface of the at least one layer.

Abstract: A steel alloy includes about 1.65 to about 2 percent by weight nickel (Ni), about 0.7 to about 0.9 percent by weight chromium (Cr), about 0.6 to about 0.9 percent by weight manganese (Mn), about 0.58 to about 0.63 percent by weight carbon (C), about 0.25 to about 0.35 percent by weight niobium (Nb), about 0.15 to about 0.35 percent by weight silicon (Si), about 0.2 to about 0.3 percent by weight molybdenum (Mo), about 0.005 to about 0.01 percent by weight boron (B), and iron (Fe).

Abstract: There is provided an AM apparatus for an AM process. The AM apparatus has an AM assembly with a build chamber to support part(s) built with a powder, in a build operation. Unused powder accumulates in the build chamber during the build operation. The AM apparatus has a vacuum assembly with duct line(s) in flow communication with the build chamber, and a powder receptacle in flow communication with the duct line(s). The powder receptacle has coupling member(s) allowing the powder receptacle to be reversibly attached to the duct line(s). The vacuum assembly includes a vacuum apparatus coupled to, and in flow communication with, the powder receptacle, via vacuum duct line(s). The vacuum assembly pulls the unused powder from the build chamber to the powder receptacle, and provides an automated removal of the unused powder from the build chamber into the powder receptacle, to avoid manual removal of the unused powder.

Abstract: An AM apparatus for an AM process is provided. The AM apparatus includes a build chamber with a build plate to support one or more parts built with a powder, during a build operation. The AM apparatus further includes a laser assembly operable to deliver a melting laser beam, to melt and fuse the powder used to build the one or more parts. The AM apparatus further includes a part detachment assembly, separate from the laser assembly and operable for a cutting operation. The part detachment assembly includes one or more laser beam delivery apparatuses, each operable to deliver a cutting laser beam, and a part holder apparatus. During the cutting operation, the part holder apparatus holds the one or more parts, and each of the laser beam delivery apparatus(es) delivers the cutting laser beam, to detach the one or more parts from the build plate within the AM apparatus.

Abstract: A laser deposition apparatus includes a sealed enclosure configured to hold a substrate, a powder source configured to hold a powder material, a peen source configured to hold a shot peen media, and a deposition system fluidly connected to the powder source and the peen source. The deposition system includes a laser configured to generate a laser beam. The deposition system is configured to deposit at least one layer on the substrate by injecting a stream of the powder material into the laser beam. The deposition system is configured to shot peen the at least one layer by propelling the shot peen media onto an exterior surface of the at least one layer.

Abstract: A steel alloy including, by weight percent: Ni: 18 to 19%; Co: 11.5 to 12.5%; Mo: 4.6 to 5.2%; Ti: 1.3 to 1.6%; Al: 0.05 to 0.15%; Nb: 0.15 to 0.30%; B: 0.003 to 0.020%; Cr: max 0.25%; Mn: max 0.1%; Si: max 0.1%; C: max 0.03%; P: max 0.005%; and S: max 0.002%, the balance being iron plus incidental impurities.

Abstract: Disclosed are methods and systems to nondestructively detect cracks at or near a countersink of a fastener, such as a rivet, in a thin walled structure using Lamb waves. Generation and detection of Lamb waves at symmetric locations relative to the fastener provides signals used to calculate a symmetry parameter. The symmetry parameter represents a comparison of the relative amplitudes of the detected Lamb wave signals and provides a simple indication of whether a crack exists.

Abstract: Disclosed are methods and systems to nondestructively detect cracks at or near a countersink of a fastener, such as a rivet, in a thin walled structure using Lamb waves. Generation and detection of Lamb waves at symmetric locations relative to the fastener provides signals used to calculate a symmetry parameter. The symmetry parameter represents a comparison of the relative amplitudes of the detected Lamb wave signals and provides a simple indication of whether a crack exists.

Abstract: A ceramic die for a hot press is provided, along with a method of constructing a ceramic die. The ceramic die includes a ceramic die body defining a mold surface configured to shape a part during a superplastic forming process. The mold surface defines at least one curved surface and at least one non-curved surface, spaced apart from the at least one curved surface. The ceramic die also includes a plurality of fibers disposed within the ceramic die body. The plurality of fibers may be preferentially located proximate the at least one curved surface such that a first portion of the ceramic die body proximate the at least one curved surface has a greater percentage of fibers than a second portion of the ceramic die body proximate the at least one non-curved surface.