Abstract: A method of additive manufacturing an article from a feed material in a chamber includes evacuating at least some of a first gas from the chamber, thereby reducing a pressure therein from a first pressure to a second pressure and reducing the first gas from a first concentration to a second concentration. At least some of the first gas is then gettered from the chamber using a getter, thereby lowering the first gas concentration to a third concentration. The article is then additive manufactured from the feed material in the chamber using the getter as a substrate. The gettering comprises heating the getter at least in part using a fusion source, and the additive manufacturing comprises heating the feed material at least in part using the fusion source.

Abstract: A method of fabricating, at least in part, an article from a precursor thereof, the method comprising: providing the precursor, wherein the precursor comprises a metal having a closed pore therein; and hot isostatic pressing, HIPing, the precursor at an Nth temperature of a set of temperatures, at an Nth pressure of a set of pressures and for an Nth duration of a set of durations, thereby fabricating, at least in part, the article; wherein HIPing the precursor comprises regulating the set of temperatures, the set of pressures and/or the set of durations to control, at least in part, a morphology of the closed pore.

Abstract: A method of forming a metal component from metal powder which includes exposing the metal powder to an inert gas; consolidating the metal powder into a solid metal; followed by exposing the solid metal to a hot isostatic pressing process to form a metal component, wherein the hot isostatic pressing process has one initial compression cycle followed by at least one decompression and recompression cycle.

Abstract: A method of friction-stir welding, FSW, a joint J, for example a T joint J, between a first workpiece W1 and a second workpiece W2 is described.

Abstract: A method of manufacturing a part, the method involving providing an apparatus, the apparatus having a metal skin component; a metal HIP can and a hollow space between a portion of the HIP can and a portion of the skin component, the method further involving filling the HIP can with a metal powder; evacuating the HIP can; sealing the evacuated HIP can; and applying a HIP process to the apparatus in a HIP chamber so as to form the part.

Abstract: There is disclosed a heat exchanger comprising at least one set of channels having a proximal end and a distal end, the set of channels comprising: a first channel defined by a first skin and a wall; and a second channel defined by a second skin and the wall, wherein the wall located between the first channel and the second channel comprises a first at least one aperture to allow fluid to pass through the wall from the first channel to the second channel.

Abstract: There is disclosed a heat exchanger comprising at least one set of channels having a proximal end and a distal end, the set of channels comprising: a first channel defined by a first skin and a wall; and a second channel defined by a second skin and the wall, wherein the wall located between the first channel and the second channel comprises a first at least one aperture to allow fluid to pass through the wall from the first channel to the second channel.

Abstract: A method of forming a metal component from metal powder which includes exposing the metal powder to an inert gas; consolidating the metal powder into a solid metal; followed by exposing the solid metal to a hot isostatic pressing process to form a metal component, wherein the hot isostatic pressing process has one initial compression cycle followed by at least one decompression and recompression cycle.

Abstract: A process and apparatus for forming a structure comprising: a) forming a pack from a skin sheet and a core sheet, wherein venting grooves are formed in a surface of a sheet that is adjacent to the other sheet; b) placing the pack in a mould and heating the pack; c) injecting a first gas between the core and skin sheets to urge the skin sheet against the mould; d) injecting a second gas on the side of the core sheet remote from the skin sheet to urge the core sheet against the skin sheet; e) maintaining gas pressure of the second gas thereby diffusion bonding the sheets; and f) withdrawing some or all of the first gas from the cavity.

Abstract: A process and apparatus for forming a structure comprising: a) forming a pack from a skin sheet and a core sheet, wherein venting grooves are formed in a surface of a sheet that is adjacent to the other sheet; b) placing the pack in a mould and heating the pack; c) injecting a first gas between the core and skin sheets to urge the skin sheet against the mould; d) injecting a second gas on the side of the core sheet remote from the skin sheet to urge the core sheet against the skin sheet; e) maintaining gas pressure of the second gas thereby diffusion bonding the sheets; and f) withdrawing some or all of the first gas from the cavity.

Abstract: A method of manufacturing a part, the method involving providing an apparatus, the apparatus having a metal skin component; a metal HIP can and a hollow space between a portion of the HIP can and a portion of the skin component, the method further involving filling the HIP can with a metal powder; evacuating the HIP can; sealing the evacuated HIP can; and applying a HIP process to the apparatus in a HIP chamber so as to form the part.

Abstract: An airframe (10) for an air vehicle comprising an outer skin layer (12) and a support layer (13) defining a fuselage of said air vehicle, wherein said outer skin layer (12) is magnetically coupled to said support layer (13).

Abstract: Additive manufacturing apparatus for fabricating a three-dimensional object, the apparatus comprising: means for directing energy onto a growth surface of a workpiece to form thereon a liquid melt-pool; means for feeding additional material into the melt-pool so as to cause the additional material to become incorporated into the liquid of the melt-pool; and means for cryogenically cooling the liquid melt-pool, thereby to achieve a cooling rate of the liquid melt pool of at least 100° C. per second and to cause the liquid melt-pool to solidify.

Abstract: An airframe (10) for an air vehicle comprising an outer skin layer (12) and a support layer (13) defining a fuselage of said air vehicle, wherein said outer skin layer (12) is magnetically coupled to said support layer (13).

Abstract: A process of forming a structure by diffusion bonding and superplastic forming includes forming a pack from at least one skin sheet and at least one core sheet, placing the pack in a mould and heating it. A gas is injected between the skin sheet and the core sheet to urge the skin sheet against an internal face of the mould, thereby forming a cavity. Gas is also injected on the other side of the core sheet to urge it against the skin sheet, and gas pressure is maintained on said side of the core sheet thereby forming a diffusion bond between the skin sheet and the core sheet. Helium gas is used to maintain a regulated pressure of helium in the cavity between the skin sheet and the core sheet, which allows such gas trapped between the skin sheet and the core sheet to diffuse through the core sheet.