Abstract: Systems and methods for rotational additive manufacturing are disclosed. An apparatus in accordance with an aspect of the present disclosure comprises a build floor, a depositor system configured to deposit a layer of powder onto the build floor, a motor system causing a rotational motion between the depositor system and the build floor, wherein the depositor system deposits the layer of powder during the rotational motion, a receptacle wall configured to contain the powder on the build floor, an energy beam source configured to apply an energy beam in an active area of the layer of powder to selectively fuse a portion of the powder in the active area to form a portion of a build piece and a gas flow system configured to provide a gas flow across the active area while the energy beam selectively fuses the portion of the layer of powder in the active area.

Abstract: A buffer block apparatus for securing a node may be described. The buffer block apparatus may include a first surface having disposed thereon at least one first zero-point feature configured for a first zero-point interface with a robotic assembly apparatus; and a second surface, different from the first surface, configured to connect with a first surface of a node and form a first rigid connection between the buffer block apparatus and the node, wherein the buffer block apparatus provides at least one reference coordinate system with respect to the node.

Abstract: Aspects are provided for additively manufacturing a component with reduced surface roughness based on direct energy deposition (DED). A DED apparatus for additively manufacturing a component includes a material supply, one or more deposition heads coupled to the material supply to deposit feedstock from the material supply, and an energy source configured to heat the feedstock as the feedstock is being deposited by the one or more deposition heads. The energy source is configured to reheat one or more portions of a surface of the component to reduce surface roughness as the component is being additively manufactured. The one or more deposition heads may also comprise a plurality of deposition heads which are sized to deposit the feedstock from the material supply at different resolutions to form a surface of the component with reduced surface roughness as the component is being additively manufactured. Thus, structural integrity may be improved.

Abstract: Aspects are provided for additively manufacturing a component based on direct energy deposition (DED). An apparatus may include a DED system configured to additively manufacture a part. The apparatus may further include a forging tool configured to forge a region of the part during the additive manufacturing. In various embodiments, a solid body is used opposite to the forging tool during the forgery. For example, the solid body may include a mandrel against which the region of the part is forged.

Abstract: Techniques for rapid powder removal in a 3-D printer are disclosed. In various embodiments, the 3-D printer has a build plate for supporting a build piece. The build plate includes first structures for supporting unfused powder on a top of the build plate when the first structures are in a closed configuration. The first structures can transition to an open configuration to expose paths for allowing the unfused powder to pass through the build plate, and a second structure for preventing the build piece from passing through the build plate when the first structures are in the open configuration. In various embodiments, the unfused powder can thereafter be replaced with cool powder to assist in forming a predictable microstructure that makes up the build piece.

Abstract: Alloyed metals, and techniques for creating parts from alloyed metals, are disclosed. An apparatus in accordance with an aspect of the present disclosure comprises an alloy. Such an alloy comprises magnesium (Mg), zirconium (Zr), manganese (Mn), and aluminum (Al), wherein inclusion of the Mg, the Zr, and the Mn produce a structure of the alloy, the structure having a yield strength of at least 80 Megapascals (MPa) and having an elongation of at least 10 percent (%).

Abstract: Ultrasonic additive manufacturing (UAM) of surface members for a box-like part such as a crash structure or load-bearing structure in a vehicle is disclosed. In one aspect of the disclosure, a method for building a box-like part includes 3-D printing separately, using UAM, the one or more flat surface members in a horizontal plane relative to a print substrate. The method further includes assembling together the surface members at or proximate respective edges thereof to form the box-like part. In some embodiments, protrusions and other features are added to the surface members. In embodiments involving crash structures, trenches are machined into the inner surfaces to enable tailored deformation of the crash structure during an impact event.

Abstract: A resin composition can includes a first isocyanurate component and a first bonding component bonded to the first isocyanurate component. The first bonding component can be configured to bond to a second bonding component that is bonded to a second isocyanurate component. The first bonding component can be configured to bond to the second bonding component based upon an application of an initiator to the resin composition. In this way, the first isocyanurate component can be coupled to the second isocyanurate component. The resin composition can be either in a pre-cured state in which the first isocyanurate component is not coupled to the second isocyanurate component or in a post-cured state in which at least a portion of the first isocyanurate component is coupled to at least a portion of the second isocyanurate component.

Abstract: Methods and apparatuses for producing spherical metallic powders through continuous ball milling are described. The apparatus comprises a comminution component including an inlet to receive a metallic material at a first region within the comminution component and an outlet to dispense the metallic powder from a second region within the comminution component. The apparatus further comprises a plurality of grinding components to grind the metallic material, the plurality of grinding components being arranged within the comminution component. The apparatus comprises a drive component, connected with the comminution component, to induce movement of the metallic material and the plurality of grinding components within the comminution component such that the metallic material is fragmented through contact with the plurality of grinding components at the first region and an external surface of the fragmented metallic material is altered at the second region to produce the metallic powder.

Abstract: Adaptable manufacturing systems, methods, and apparatuses are disclosed. An apparatus for manufacturing a product in accordance with the present disclosure may include a design apparatus, an assembly apparatus, and a control apparatus, coupled to the design apparatus and the assembly apparatus. The control apparatus receives input information from the design apparatus and the assembly apparatus. The control apparatus provides output information for altering at least one parameter used by at least one of the design apparatus and the assembly apparatus in the manufacture of the product.

Abstract: A fan casing assembly, connection assembly and method for moving a fan casing cooler. The fan casing assembly for the turbine engine can include an annular fan casing with a peripheral wall having a flow path defined through the casing. A fan casing cooler can mount along the peripheral wall in order to confront a cooling fluid flow within the flow path in order to cool a fluid through the fan casing cooler.

Abstract: A heat exchanger can include a cooling air conduit having at least one baffle, as well as a hot air conduit having at least two passes through the cooling air conduit. The heat exchanger can further include at least one perforation extending into the least one baffle. The perforation can have a passage connecting an inlet to an outlet.

Abstract: A duct assembly may include a first duct, a second duct, and a flexible joint assembly coupling the first duct to the second duct. The flexible joint assembly may include a bellows having a first end and a second end and a plurality of convolutions located therebetween, and a gimbaled joint assembly. The gimbaled joint assembly may include a first support surrounding the first end of the bellows and a first portion of the plurality of convolutions, a second support surrounding the second end of the bellows and a second portion of the plurality of convolutions, and a gimbal ring assembly operably coupled to the first support and the second support. The gimbal ring assembly may include a ring body and a plurality of flexure hinges interconnected with the ring body.

Abstract: A method for fabricating aircraft engine external target parts including complex geometries utilizes reusable reconfigurable shape memory polymer and conformable woven braided carbon fiber sleeves. The method includes providing a tubular three-dimensional reusable shape memory polymer mandrel assembly designed for a target part, and heating the shape memory polymer mandrel.

Abstract: Techniques for dehumidifying powder used as print material in a powder bed fusion (PBF) three-dimensional (3-D) system are disclosed. A hopper includes one or more ultrasonic transducers (UTs) positioned at strategic locations. When activated, the UTs use sound pressure at ultrasonic frequencies to agitate the powder particles held in the hopper. The movement of the particles drives moisture trapped between the particles into one or more desiccants. In various embodiments, the desiccants may be supported by desiccators suspended in the powder, such as via the casing of the hopper. In other embodiments, the desiccants may be desiccant bags provided in a desiccant insert. The moisture accumulates in the desiccants. Among other advantages, no separate thermal source is needed to dry the powder, which can be provided directly to the PBF 3-D system via the re-coater for depositing layers to form a build piece.

Abstract: A manufacturing process for making aircraft engine parts utilizes reusable reconfigurable smart memory polymer mandrel tooling, low temperature metal deposition, and composite part lay-up with resin coated conformable braided carbon fiber sleeves, to fabricate both metal internal engine parts and non-metal external parts for turbine engines.

Abstract: A flexible joint assembly for a joint between a first duct and a second duct for providing a flow of fluid, such as bleed air in an aviation implementation. The flexible joint includes a bellows supported by a mounting assembly having a first support and a second support, each surrounding a portion of the bellows. A set of flexures provided on a joint ring of the joint assemblies can operably couple the first support and the second support.

Abstract: Techniques for pre-heating the powders of layer deposited on the powder bed during a 3-D print process conducted by a 3-D printer are disclosed. A re-coater includes a heat source that pre-heats the deposited layer as a leveling member of the re-coater smooths the layer onto the powder bed. In some embodiments, the re-coater reheats the powder bed following the selective fusing of a layer by an energy beam source. The consistent pre-heating and re-heating of the powder directly on the surface of the powder bed maximally reduces damage, cracks, dimensional flaws, and other artifacts created by excessive thermal gradients in the case where heat is not used.

Abstract: An apparatus and method for cooling a fluid within a turbine engine. A fan casing assembly for the turbine engine can include an annular fan casing with a peripheral wall having a flow path defined through the casing. A fan casing cooler includes a body to confront the peripheral wall with at least one conduit configured to carry a flow of heated fluid to convectively cool the heated fluid with a flow of air through the flow path.

Abstract: A duct for a turbine engine, such as a gas turbine engine, can be utilized to carry a fluid from one portion of the engine to another. The duct can include a metallic tubular element having one of a varying wall thickness, a varying cross section, or a tight bend. Such a duct can be formed utilizing additive manufacturing or metal deposition on an additively manufactured mandrel.