Abstract: Embodiments of the disclosure provide a test article for additive manufacture and related methods. A test article formed may include a body having a forward face and a rearward face horizontally opposite the forward face. A first surface extending between the forward face and the rearward face of the body may include a plurality of protrusions for removable coupling of the body to a build plate. A second surface on the body may extend between the forward face and the rearward face of the body, and may include a plurality of angled flat surface portions. Each of the plurality of angled flat surface portions may have a distinct angle with respect to a horizontal plane of the body. An angular difference between each adjacent angled flat surface portion in the plurality of angled flat surface portions is substantially uniform.

Abstract: Embodiments of the disclosure provide a test article for additive manufacture and related methods. A test article formed may include a body having a forward face and a rearward face horizontally opposite the forward face. A first surface extending between the forward face and the rearward face of the body may include a plurality of protrusions for removable coupling of the body to a build plate. A second surface on the body may extend between the forward face and the rearward face of the body, and may include a plurality of angled flat surface portions. Each of the plurality of angled flat surface portions may have a distinct angle with respect to a horizontal plane of the body. An angular difference between each adjacent angled flat surface portion in the plurality of angled flat surface portions is substantially uniform.

Abstract: A test feature is disclosed that is formed during metal powder additive manufacturing of a production part. The test feature may include a metal powder sample capsule including a chamber for capturing unfused powder from the metal powder additive manufacturing, and a removable cap closing an end of the chamber. Alternatively, a test feature may include a quality control (QC) part, and at least one additional test element including a metal powder sample capsule integrally coupled to the QC part and including a chamber for capturing unfused powder from the metal powder additive manufacturing. The QC part is identical to the production part excepting the at least one test element. The QC part and the at least one test element are formed during the same metal powder additive manufacturing as the production part.

Abstract: Manufactured articles, and methods of manufacturing enhanced surface smoothed components and articles. More particularly, surface smoothed components and articles, such as combustor components of turbine engines, having surface treatment conferring reduced roughness for enhanced performance and reduced wear related reduction in part life.

Abstract: A test feature is disclosed that is formed during metal powder additive manufacturing of a production part. The test feature may include a metal powder sample capsule including a chamber for capturing unfused powder from the metal powder additive manufacturing, and a removable cap closing an end of the chamber. Alternatively, a test feature may include a quality control (QC) part, and at least one additional test element including a metal powder sample capsule integrally coupled to the QC part and including a chamber for capturing unfused powder from the metal powder additive manufacturing. The QC part is identical to the production part excepting the at least one test element. The QC part and the at least one test element are formed during the same metal powder additive manufacturing as the production part.

Abstract: Manufactured articles, and methods of manufacturing enhanced surface smoothed components and articles. More particularly, surface smoothed components and articles, such as combustor components of turbine engines, having surface treatment conferring reduced roughness for enhanced performance and reduced wear related reduction in part life.

Abstract: A method for inspection and assessment of 3D manufactured parts and operational performance of a 3D manufacturing apparatus is provided. The method includes the step of obtaining, in real-time during a 3D printing build process in which at least one structure or part is built by the 3D manufacturing apparatus, an electro-magnetic scan of an area of a build platform on which the at least one structure is built. An evaluating step evaluates, by a processor, the electro-magnetic scan. A determining step determines, based on the evaluating step, whether an operational flaw with the 3D manufacturing apparatus has occurred.

Abstract: A component, a method of making a component and a method of monitoring strain. The component has an array of internal nodes with a radiopacity distinct from the predominant radiopacity of the component. Displacement of the nodes can be measured and used to calculate strain on the component.

Abstract: Methods of reducing an initial cross-sectional area of a hole in a component to a predetermined cross-sectional area including preparing a composition comprising at least an aluminum alloy with a melting temperature higher than aluminum, applying the composition to an interior surface of the hole, and then heating the component to cause a metal within the component to diffuse from the component into the composition and react with the aluminum alloy in the composition to form a coating on the interior surface of the hole. The heating step is performed to selectively modify the initial cross-sectional area of the hole and thereby directly attain the predetermined cross-sectional area thereof.

Abstract: A turbine component and a process of fabricating a component are disclosed. The process includes excavating a base metal of the component to form a fill region and filling the fill region with a filler metal. The filler metal has a filler metal elongation that is at least 25% greater than a base metal elongation of the base metal. The filler includes, by weight, between about 4% and about 7% iron, between about 14% and about 17% chromium, between about 15% and about 17% molybdenum, between about 3% and about 5% tungsten, up to about 0.02% carbon, up to about 1% manganese, up to about 2.5% cobalt, and a balance of nickel and/or the filler metal elongation is greater than about 35% in/in per two inches.

Abstract: Methods of reducing an initial cross-sectional area of a hole in a component to a predetermined cross-sectional area including preparing a composition comprising at least an aluminum alloy with a melting temperature higher than aluminum, applying the composition to an interior surface of the hole, and then heating the component to cause a metal within the component to diffuse from the component into the composition and react with the aluminum alloy in the composition to form a coating on the interior surface of the hole. The heating step is performed to selectively modify the initial cross-sectional area of the hole and thereby directly attain the predetermined cross-sectional area thereof.

Abstract: A turbine component and a process of fabricating a component are disclosed. The process includes excavating a base metal of the component to form a fill region and filling the fill region with a filler metal. The filler metal has a filler metal elongation that is at least 25% greater than a base metal elongation of the base metal. The filler includes, by weight, between about 4% and about 7% iron, between about 14% and about 17% chromium, between about 15% and about 17% molybdenum, between about 3% and about 5% tungsten, up to about 0.02% carbon, up to about 1% manganese, up to about 2.5% cobalt, and a balance of nickel and/or the filler metal elongation is greater than about 35% in/in per two inches.