Abstract: An embodiment of an apparatus includes a raw material deposition head in communication with a working surface, an energy beam generator, a wire feed, and an ultrasonic head. The energy beam generator is directed toward the working surface for consolidating raw material disposed on the working surface by the raw material deposition head. The wire feed dispenses pre-formed wire to the raw material consolidated on the working surface by an energy beam from the energy beam generator. The ultrasonic head is directed to embed the dispensed pre-formed wire into the consolidated raw material.

Abstract: A particulate for an additive manufacturing technique includes metallic particulate bodies with exterior surfaces bearing a polymeric coating. The polymeric coating is conformally disposed over the exterior surface that prevents the underlying metallic body from oxidation upon exposure to the ambient environment by isolating the metallic particulate bodies from the ambient environment. Feedstock materials for additive manufacturing techniques, and methods of making such feedstock, are also disclosed.

Abstract: A micro cold spray printer system having: a printer housing having a longitudinal axis; a transfer tube defining an optical chamber oriented parallel and coaxial to a the longitudinal axis of the housing the optical chamber having an exit; a particle supply inlet fluidly connected to the optical chamber, the particle supply inlet in operation supplying particles to flow through the optical chamber along the longitudinal axis and out the exit; and a laser that in operation emits a laser beam into the optical chamber to heat the particles to a selected temperature. The laser beam is directed at an angle that is not parallel to the longitudinal axis.

Abstract: A multilayer structure for deicing an aircraft airfoil component includes an electrically and thermally insulating bottom layer formed in a defined pattern directly on the aircraft airfoil component, an electrothermal middle layer of electrically resistant heater element arrays formed in the defined pattern on the electrically and thermally insulating bottom layer, and a thermally conductive and electrically insulating top layer encapsulating the electrically and thermally insulating bottom layer and the electrothermal middle layer of electrically resistant heater element arrays. The multilayer structure may be directly applied to the airfoil component by direct writing/additive manufacturing, and may be done with the assistance of a multi-axis robot.

Abstract: A panel includes a substrate and an electro-thermal layer disposed on the substrate. A thermally conductive and electrically insulating top layer is disposed on the electro-thermal layer. The top layer, electro-thermal layer, and substrate can all be printed layers. The electro-thermal layer can be a first electro-thermal layer and the top layer can be a first top layer, wherein at least one additional electro-thermal layer and at least one additional top layer are disposed on the first top layer, wherein the additional electro-thermal and top layers are disposed in an alternating order.

Abstract: A wear monitoring system for measuring incursion depth into an abradable coating includes a layer of abradable coating including a depth. At least one measurement circuit includes a plurality of conductive leads disposed within the abradable coating. The conductive leads are spaced radially apart within a common radial plane corresponding to the depth of the abradable coating. A plurality of resistor elements corresponds with the plurality of conductive leads. Each of the plurality of resistor elements are in electrical communication with one of the plurality of conductive leads disposed within the common radial plane of the corresponding one of the plurality of conductive leads. An electrical characteristic of the circuit varies responsive to cutting of one or more of the plurality of conductive leads by a passing airfoil. A gas turbine engine and method are also disclosed.

Abstract: A micro cold spray printer system having: a printer housing having a longitudinal axis; a transfer tube defining an optical chamber oriented parallel and coaxial to a the longitudinal axis of the housing the optical chamber having an exit; a particle supply inlet fluidly connected to the optical chamber, the particle supply inlet in operation supplying particles to flow through the optical chamber along the longitudinal axis and out the exit; and a laser that in operation emits a laser beam into the optical chamber to heat the particles to a selected temperature. The laser beam is directed at an angle that is not parallel to the longitudinal axis.

Abstract: A method of tailoring an amount of graphene in an electrically conductive structure, includes arranging a substrate material in a plurality of strands and arranging at least one graphene layer coated circumferentially on one or more of the strands of the plurality of strands, the graphene layer being a single atom-thick layer of carbon atoms arranged in a hexagonal pattern, the substrate material and the at least one graphene layer having an axial direction. A first cross-section taken along the axial direction of the substrate and the at least one graphene layer includes a plurality of layers of the substrate material and at least one internal layer of the graphene alternatively disposed between the plurality of layers of the substrate material.

Abstract: A method for fabricating printed electronics includes printing a trace of an electrical component on a first substrate to form a first layer. The method further includes printing a trace of an electrical component on at least one additional substrate to form at least one additional layer. The first layer is stacked with the at least one additional layer to create an assembled electrical device. At least one of the layers is modified after printing.

Abstract: A method of producing electrical coils includes preparing a plurality of coil layers. Each coil layer is prepared by printing an electrically conductive coil pattern on a layer substrate. Each coil pattern includes an inner end at a first via through the substrate at a point radially inside the coil pattern, and an outer end at a second via through the substrate at a point radially outside the coil pattern. The method also includes joining the coil layers into a stack and electrically connecting successive coil patterns of the plurality of coil layers to one another through the vias to form a conductive coil extending through the stack.

Abstract: A method for fabricating printed electronics includes printing a trace of an electrical component on a first substrate to form a first layer. The method further includes printing a trace of an electrical component on at least one additional substrate to form at least one additional layer. The first layer is stacked with the at least one additional layer to create an assembled electrical device. At least one of the layers is modified after printing.

Abstract: A method for forming a trivalent chromium coating on an aluminum alloy substrate includes adding a chromium-containing solution to a vessel, immersing the aluminum alloy substrate in the chromium-containing solution, immersing a counter electrode in the chromium-containing solution, and applying an electrical potential bias to the aluminum alloy substrate with respect to its equilibrium potential to form a trivalent chromium coating on an outer surface of the aluminum alloy substrate. A method for forming a trivalent chromium coating on a metal substrate includes adding a chromium-containing solution to a vessel, immersing the metal substrate in the chromium-containing solution, immersing a counter electrode in the chromium-containing solution, and modulating an electrical potential difference between the metal substrate and the counter electrode to form a trivalent chromium coating on an outer surface of the metal substrate.

Abstract: A sensor assembly for detecting open or closed state in windows and doors includes a passive infrared sensor configured to produce a change in an electrical signal based on a change in infrared radiation incident on the passive infrared sensor. A lens is operatively connected to the passive infrared sensor. At least a portion of the lens is configured to be mounted in an interface between a frame and a door or window mounted to open and close within the frame. The lens is configured to guide ambient infrared radiation to the passive infrared sensor at a first level when the door or window is closed and at a second level when the door or window is open or ajar.

Abstract: A particulate for an additive manufacturing technique includes metallic particulate bodies with exterior surfaces bearing a polymeric coating. The polymeric coating is conformally disposed over the exterior surface that prevents the underlying metallic body from oxidation upon exposure to the ambient environment by isolating the metallic particulate bodies from the ambient environment. Feedstock materials for additive manufacturing techniques, and methods of making such feedstock, are also disclosed.

Abstract: In accordance with at least one aspect of this disclosure, an ultraviolet radiation (UV) sensor includes a UV sensitive material and a first electrode and a second electrode connected in series through the UV sensitive material such that UV radiation can reach the UV sensitive material. The UV sensitive material can include at least one of zinc tin oxide, magnesium oxide, magnesium zinc oxide, or zinc oxide. The electrodes can be interdigitated comb electrodes.

Abstract: A method of making a composite material includes disposing a carbon-based particulate material, such as graphene or carbon nanotubes, in an activation solution and activating surfaces of the carbon-based particulate material using the activation solution. Once the surfaces of the carbon-based particulate material have been activated a metallic coating is applied to the activated surfaces to form a composite material. The composite material is then recovered as a particulate material formed having carbon-based particulate material with a metallic coating that is suitable for fusing together for forming electrical conductors, such as with an additive manufacturing technique.

Abstract: A method of making a component comprises producing a layer of sheet material including an aperture over a movable support. An insulating material is deposited in a first portion of the aperture to form an insulating coating with one or more pockets. A conductive material is deposited in the one or more pockets. Heat and pressure are applied to the layer and the movable support is lowered by a thickness of the layer. The steps are repeated to form a laminated stack defining the component. In some embodiments, the laminated stack of sheet materials forms an induction machine.

Abstract: A method of tailoring an amount of graphene in an electrically conductive structure, includes arranging a substrate material in a plurality of strands and arranging at least one graphene layer coated circumferentially on one or more of the strands of the plurality of strands, the graphene layer being a single atom-thick layer of carbon atoms arranged in a hexagonal pattern, the substrate material and the at least one graphene layer having an axial direction. A first cross-section taken along the axial direction of the substrate and the at least one graphene layer includes a plurality of layers of the substrate material and at least one internal layer of the graphene alternatively disposed between the plurality of layers of the substrate material.

Abstract: An instrumented article includes a ceramic-based substrate and at least one conformal electronic device deposited on a surface of the ceramic-based substrate. A compliant layer is located between the ceramic-based substrate and the one or more conformal electronic devices. The compliant layer has a thermal expansion that is intermediate of the thermal expansions of, respectively, the ceramic-based substrate and the one or more conformal electronic devices.

Abstract: An exemplary detector includes a source of radiation. A detection chamber is configured to at least temporarily contain a fluid. At least some of the radiation ionizes at least some of the fluid. At least some of the radiation produces light in the detection chamber. An ionization sensor provides an output corresponding to an amount of fluid ionization in the detection chamber. A light sensor provides an output corresponding to an amount of the light detected by the light sensor.