Abstract: A method of creating an article of manufacture is provided, which includes directing multiple laser beams to a single galvanometer; and dynamically repositioning the multiple laser beams in counterpart paths using the single galvanometer to shine the multiple laser beams on and melt a first powder material and, upon solidification of the melted first powder material, forming a first series of duplicate three dimensional structures, where each of the multiple laser beams is used to form at least one of the first series of duplicate three dimensional structures.

Abstract: A method for additive manufacturing utilizing a build plate with a release layer is provided. The method includes irradiating a first layer of powder in a powder bed to form a first fused region over a support. The first release layer is provided between the first fused region and the support. The method also includes providing a given layer of powder over the powder bed and irradiating the given layer of powder in the powder bed to form a given fused region. Providing the given layer of powder over the powder bed and irradiating the given layer of powder in the powder bed to form a given fused region are repeated until the object is formed in the powder bed. The object may be formed fusing individual layers with irradiation by laser or ebeam, or by binder jetting. The method further includes separating the object from the support by melting or dissolving the first release layer.

Abstract: A method of making an annular component includes forming sheet feedstock into an annular shape disposed about a central axis; and bonding one portion of the feedstock to another portion of the feedstock using ultrasonic welding, so as to fix the annular shape.

Abstract: The present disclosure generally relates to additive manufacturing systems and methods involving a mechanism for feeding in a desired amount of fresh recoater blade. This can be accomplished by, for example, spooling the fresh blade material from a spool. This helps prevent work stoppage when a portion of a recoater blade becomes damaged. As such, the present disclosure also relates to a system and method for detecting whether a recoater blade is damaged, and if there is damage, then causing a fresh blade portion to be fed in.

Abstract: A method of creating an article of manufacture is provided, which includes directing multiple laser beams to a single galvanometer; and dynamically repositioning the multiple laser beams in counterpart paths using the single galvanometer to shine the multiple laser beams on and melt a first powder material and, upon solidification of the melted first powder material, forming a first series of duplicate three dimensional structures, where each of the multiple laser beams is used to form at least one of the first series of duplicate three dimensional structures.

Abstract: Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Abstract: An additive manufacturing apparatus includes: first and second spaced apart side walls extending along a pre-defined path and defining a build chamber therebetween; one or more build units mounted for movement along the pre-defined path, the one or more build units including at least one of: a powder dispenser positioned above the build chamber; an applicator configured to scrape powder dispensed into the build chamber; and a directed energy source configured to fuse the scraped powder.

Abstract: A method of making a component includes depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.

Abstract: A turbine component includes: a metallic wall having opposed interior and exterior surfaces, the wall configured for directing a combustion gas stream in a gas turbine engine; and a metallic negative CTE structure rigidly attached to one of the surfaces

Abstract: Apparatus and methods for direct writing of single crystal super alloys and metals are provided. In one method, a substrate is heated to a pretermined temperature below its melting point, and a laser is used to form a melt pool on a surface of a substrate. The substrate is positioned on a base plate, and the laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition and the substrate is heated to a temperature below its melting point. A superalloy powder is introduced to the melt pool, and the temperature of the melt pool is controlled to maintain a predetermined thermal gradient on a solid and liquid interface of the melt pool so as to form a single crystal deposit on the substrate.

Abstract: Systems for applying a thermal barrier coating to a superalloy substrate including at least one target for supplying a material for making the thermal barrier coating; at least one laser operably directed toward the target for liberating atomic particles from the target; and a plasma torch for generating a plasma for accelerating and depositing the atomic particles onto the superalloy substrate as the thermal barrier coating where the superalloy substrate is a nickel based superalloy or a cobalt based superalloy.

Abstract: Methods of laser assisted plasma coating at atmospheric pressure including providing a plasma, at least one target, at least one laser, and a superalloy substrate, operably directing the laser toward the target to liberate atomic particles from the target and feed the atomic particles into the plasma, and depositing the atomic particles onto the superalloy substrate using the plasma to produce a thermal barrier coating having a column width of from about 0.5 microns to about 60 microns, and an intra column porosity of from about 0% to about 9%.

Abstract: A method for simultaneously laser shock peening opposite laser shock peening surfaces on opposite sides of an article, such as a gas turbine engine airfoil, with varying thickness using oppositely aimed laser beams and varying surface fluence of the laser beams over the laser shock peening surfaces as a function of the thickness of the article beneath each one of a plurality of laser shock peened spots formed by the beams on the surfaces. The fluence may be equal to the thickness multiplied by a volumetric fluence factor, the volumetric fluence factor being held constant over the laser shock peening surface. The volumetric fluence factor may be in a range of about 1200 J/cm3 to 1800 J/cm3 and more particularly about 1500 J/cm3. Laser beam energy may be varied with a computer program controlling firing of the laser beam.

Abstract: A system and method for monitoring a laser shock peening process includes a sensor connected to a controller. The controller includes an input and a processor. The input is connected to the sensor to receive a signal indicative of a laser shock event at a workpiece. The processor is connected to the input and is configured to determine a time-of-flight of residual energy associated with the laser shock event from the workpiece to the sensor and determine peen quality from the time-of-flight of the residual energy.

Abstract: A manufacturing system and manufacturing method for adjusting the performance of manufacturing operations or steps in manufacturing components having three-dimensional external structural characteristics. An embodiment of the system broadly comprises: (a) a plurality of manufacturing operations for processing a component having three-dimensional external structural characteristics; (b) at least one analytical device for analyzing at least one characteristic of the component after the performance of one or more manufacturing operations to generate a component data set; (c) at least one data storage device for storing the generated component data sets and for providing at least a relevant portion of accumulated component data; and (d) a communication mechanism for transmitting at least a relevant portion of accumulated component data to one or more manufacturing operations so that the performance thereof can be adjusted in response to the transmitted portion of accumulated component data.

Abstract: A method for simultaneously laser shock peening opposite laser shock peening surfaces on opposite sides of an article, such as a gas turbine engine airfoil, with varying thickness using oppositely aimed laser beams and varying surface fluence of the laser beams over the laser shock peening surfaces as a function of the thickness of the article beneath each one of a plurality of laser shock peened spots formed by the beams on the surfaces. The fluence may be equal to the thickness multiplied by a volumetric fluence factor, the volumetric fluence factor being held constant over the laser shock peening surface. The volumetric fluence factor may be in a range of about 1200 J/cm3 to 1800 J/cm3 and more particularly about 1500 J/cm3. Laser beam energy may be varied with a computer program controlling firing of the laser beam.

Abstract: A manufacturing system and manufacturing method for adjusting the performance of manufacturing operations or steps in manufacturing components having three-dimensional external structural characteristics. An embodiment of the system broadly comprises: (a) a plurality of manufacturing operations for processing a component having three-dimensional external structural characteristics; (b) at least one analytical device for analyzing at least one characteristic of the component after the performance of one or more manufacturing operations to generate a component data set; (c) at least one data storage device for storing the generated component data sets and for providing at least a relevant portion of accumulated component data; and (d) a communication mechanism for transmitting at least a relevant portion of accumulated component data to one or more manufacturing operations so that the performance thereof can be adjusted in response to the transmitted portion of accumulated component data.

Abstract: A method for making a turbine airfoil includes providing a mold core and an outer shell which cooperatively define a cavity in the shape of a hollow airfoil having an outer wall, a root, and a tip. A tip portion of the core extends completely through the portion of the cavity defining the tip of the airfoil. The core is restrained to prevent movement between the core and outer shell. Molten metal is introduced into the cavity and solidified to form an airfoil having at least one outer wall which defines an open tip and a hollow interior. A metallic tip cap is formed on the outer wall which substantially closes off the open tip. The tip cap may be formed by packing the airfoil with metallic powder; and laser sintering the exposed powder so as to form a tip cap which is metallurgically bonded to the outer wall.

Abstract: A method for laser shock peening an article, such as a gas turbine engine airfoil, with varying thickness by varying a surface fluence of a laser beam over a laser shock peening surface as a function of the thickness beneath a laser shock peened spot formed by the beam on the surface. The fluence may be equal to the thickness multiplied by a volumetric fluence factor, the volumetric fluence factor being held constant over the laser shock peening surface. The volumetric fluence factor may be in a range of about 1200 J/cm3 to 1800 J/cm3 and more particularly about 1500 J/cm3. The method may include varying energy in the laser beam using a computer program controlling firing of the laser beam. A device such as an optical attenuator external to a laser performing firing may be used to vary the energy.

Abstract: A gas turbine engine airfoil is repaired by machining away airfoil material along at least a portion of at least one of leading and trailing edges and a radially outer tip forming at least one cut-back area and forming a weldment by welding successive beads of welding material into the cut-back area. Desired finished dimensions of the repaired airfoil are obtained by machining away some of the weld bead material in the weldment and then deep compressive residual stresses are imparted in a pre-stressed region extending into and encompassing the weldment and a portion of the airfoil adjacent the weldment. The compressive residual stresses may be are imparted after either rough machining or final finishing thereafter of the weldment. The cut-back area may extend up to about 90% of the airfoil's span and have a maximum cut-back depth up to about 0.22 inches.