Abstract: Disclosed herein is a method for making a metal article including repetitively depositing a layer of metal and cold working each metal layer to form the metal article. The method can be used to make a new article or repair an existing article. The metal article includes a customized local grain structure orientation which can vary by region based on design requirements.

Abstract: A method of providing a protective titanium layer to an outer surface of an aluminum component includes providing an aluminum component and forming a first layer of titanium-based bulk metallic glass on the component, wherein formation of the bulk metallic glass layer comprises depositing a titanium alloy powder using pulsed directed energy deposition.

Abstract: A method of forming an aircraft component includes providing an aluminum alloy. The method further includes mixing a shape memory alloy (SMA) with the aluminum alloy to form a combination of the SMA and the aluminum alloy. The method further includes forming the aircraft component with the combination of the SMA and the aluminum alloy.

Abstract: A metal lattice for a carbon dioxide scrubber includes a metal lattice body defining a plurality of intersecting ligaments, wherein nodes are formed at intersections of the plurality of intersecting ligaments, wherein a node density of the metal lattice body varies.

Abstract: Methods, systems, and apparatuses for component manufacturing are provided. A component may be manufactured via an extrusion of loose substrate material into a unitary tubing. Features may be added to the tubing via friction stir additive manufacturing to manufacture a component. In this manner, a component may be manufactured from titanium alloys while processing challenges such as iron segregation or material loss through machining are ameliorated. Such a component may replace steel or other high strength components and further exhibits corrosion resistance.

Abstract: A method for deep roll peening a workpiece includes deep roll peening a workpiece by moving the workpiece along a feed path through multiple groups of opposed rollers that are arranged in series. Each group of opposed rollers includes a rim that defines a workpiece engagement surface that exerts a deep roll peening force on the workpiece. A deep roll peening system includes multiple groups of opposed rollers. Each of the opposed rollers is rotatably mounted and has a rim that defines a workpiece engagement surface. The workpiece engagement surfaces are spaced apart from each other by a gap. The groups are arranged in series such that the gaps define a feed path for receiving a workpiece into serial contact with the workpiece engagement surfaces.

Abstract: A manufacturing process may comprise: stacking a plurality of friction discs together, each friction disc comprising a lug defining a surface; and depositing a composition to bond to the surface of a first friction disc in the plurality of friction discs to form a wear pad defining a wear surface.

Abstract: A method of evaluating an additive manufacturing process includes receiving a set of additive manufacturing parameters and an additive manufacturing part design at an analysis module, receiving a set of random values at the analysis module, determining a probability distribution of stochastic flaws within a resultant additively manufactured article using at least one multidimensional space physics model, and categorizing the additive manufacturing part design as defect free when the probability distribution is below a predefined threshold. Each value in the set of random values corresponds to a distinct variable in a set of variables. Each variable in the set of variables at least partially defines at least one of an uncontrolled additive manufacturing parameter and an uncontrollable additive manufacturing parameter.

Abstract: An electrical device includes an electromagnetic component configured to generate a magnetic flux. The electromagnetic component includes a soft magnetically-conductive material configured to pass magnetic flux therethrough along a flux path. The soft magnetically-conductive material includes at least one grain oriented portion having metal grains that are oriented parallel with respect to the magnetic flux.

Abstract: A novel manufacturing method for functionally graded component includes a cold sprayed additive manufactured core material and a cold sprayed additive manufactured set of teeth around said core made from another material.

Abstract: A method of forming an aircraft component includes providing an aluminum alloy. The method further includes mixing a shape memory alloy (SMA) with the aluminum alloy to form a combination of the SMA and the aluminum alloy. The method further includes forming the aircraft component with the combination of the SMA and the aluminum alloy.

Abstract: A system is provided for additively manufacturing a part. This additive manufacturing system includes a base, a solidification device and a detection device. The base is adapted to support material; e.g., powder material. The solidification device is adapted to solidify at least a portion of the supported material to form at least a portion of the part. The detection device is adapted to detect emissions produced by the solidification of at least a portion of the material.

Abstract: A metal lattice for a carbon dioxide scrubber includes a metal lattice body defining a plurality of intersecting ligaments, wherein nodes are formed at intersections of the plurality of intersecting ligaments, wherein a node density of the metal lattice body varies.

Abstract: A method of providing a protective titanium layer to an outer surface of an aluminum component includes providing an aluminum component and forming a first layer of titanium-based bulk metallic glass on the component, wherein formation of the bulk metallic glass layer comprises depositing a titanium alloy powder using pulsed directed energy deposition.

Abstract: A method of evaluating an additive manufacturing process includes receiving a set of additive manufacturing parameters and an additive manufacturing part design at an analysis module, receiving a set of random values at the analysis module, determining a probability distribution of stochastic flaws within a resultant additively manufactured article using at least one multidimensional space physics model, and categorizing the additive manufacturing part design as defect free when the probability distribution is below a predefined threshold. Each value in the set of random values corresponds to a distinct variable in a set of variables. Each variable in the set of variables at least partially defines at least one of an uncontrolled additive manufacturing parameter and an uncontrollable additive manufacturing parameter.

Abstract: An additive manufacturing (AM) system includes a process distortion compensation computing system and an AM peripheral device. The process distortion compensation computing system determines a digital nominal model that represents a physical target object excluding a distortion, and a digital distortion model that represents the physical target object including at least one distortion. The AM peripheral device forms a three-dimensional (3D) physical object based on a digital compensation model. The process distortion compensation computing system also determines a digital skeletal model indicating a predicted change in at least one of the shape and volume of the nominal model, and generates the digital compensation model based on the skeletal model that compensates for the at least one distortion.

Abstract: An adjacent safety configuration for an elevator includes a second pair of safeties displaced from a first pair of safeties by at least 0.1 seconds of travel time at a rated speed of the elevator. An adjacent safety configuration for an elevator including a second pair of safeties displaced from the first pair of safeties to provide a predetermined time period before the second pair of safeties pass over a point on a guide rail previously passed over by the first pair of safeties to permit the guide rail surface to decrease by a predetermined temperature. A method of spacing an adjacent safety configuration for an elevator system including de-rating a pair of trailing safeties with respect to a pair of leading safeties as a function of a rated speed of the elevator and a spacing between the pair of trailing safeties and the pair of leading safeties.

Abstract: A metal lattice for a carbon dioxide scrubber may comprise a metal lattice body defining a plurality of intersecting ligaments, wherein nodes are formed at said intersections. In various embodiments, the metal lattice may be manufactured using an additive manufacturing process. A node density of the metal lattice may vary. A ligament thickness of the metal lattice may vary. The metal lattice may comprise liner defining a channel extending through the metal lattice.

Abstract: An additive manufacturing system includes an additive manufacturing (AM) device, a first sensor device, and a compute device. The AM device is configured to form a bulk component in a layer-by-layer manner, by at least iteratively depositing a first layer of raw material onto a working surface in a deposition chamber, consolidating the initial layer into an initial additive portion of the bulk component, then forming subsequent additive portions of the bulk component by depositing and consolidating a subsequent plurality of layers of the raw material onto the first additive portion. The first sensor device is configured to measure an actual composition of at least one first byproduct portion formed upon consolidation of one of the first or subsequent layers of raw material in the deposition chamber. The compute device includes a processor and a memory, and is communicatively coupled to the additive manufacturing device and first sensor device.

Abstract: A method of providing a protective titanium layer to an outer surface of an aluminum component includes providing an aluminum component and forming a first layer of titanium-based bulk metallic glass on the component, wherein formation of the bulk metallic glass layer comprises depositing a titanium alloy powder using pulsed directed energy deposition.