Abstract: A powder spray applicator system may include an applicator device configured to eject particles of powder in a stream of a heated gas. The applicator device defining a particle path along which particles of the powder stream move upon introduction into a flow chamber and a gas path along which a primary gas stream moves upon introduction into the flow chamber. The applicator device may include a body assembly defining an outer annular gap forming a first section of the gas path and an inner annular gap forming a second section of the gas path, and a spray nozzle defining a flow passage extending between an entry opening of the spray nozzle and an exit opening of the spray nozzle. The flow passage may have an initial section with a converging shape and a final section with a straight shape.

Abstract: An example method of modifying a powder according to the present disclosure includes contacting a powder comprising particles with a nitrogen-containing gas and improved flowability of the powder. A method of providing a powder and a reactor are also disclosed.

Abstract: A feedstock for an additive manufacturing process includes a pre-ceramic polymer intermixed with a base material. A method of additive manufacturing includes melting and pyrolizing a feedstock containing metal and a pre-ceramic polymer. An article of manufacture includes an additive manufacturing component including a pyrolized feedstock.

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 system for treatment of atomized powder including a fluidized bed operable to treat feedstock alloy powders. A method of treating atomized powder including communicating an inert gas into a fluidized bed; communicating an atomized powder into the fluidized bed; and heating the atomized powder in the fluidized bed, eject the treated powders out of the fluidized bed to quench the powders.

Abstract: A heat exchanger is disclosed. The heat exchanger includes a hollow tube including a first aluminum alloy extending along an axis from a tube inlet to tube outlet. A first plurality of fins including a second aluminum alloy extends outwardly from an outer surface of the tube. A second plurality of fins including a third aluminum alloy extends outwardly from the outer surface of the tube, interspersed along the axis with the fins including the second aluminum alloy. The third aluminum alloy is less noble than each of the first aluminum alloy and the second aluminum alloy, and includes an alloying element selected from tin, indium, gallium, or combinations thereof. A first fluid flow path is disposed through hollow tube from the tube inlet to the tube outlet. A second fluid flow path is disposed across an outer surface of the hollow tube through spaces between adjacent fins.

Abstract: A system for treatment of atomized powder including a fluidized bed operable to treat feedstock alloy powders. A method of treating atomized powder including communicating an inert gas into a fluidized bed; communicating an atomized powder into the fluidized bed; and heating the atomized powder in the fluidized bed, eject the treated powders out of the fluidized bed to quench the powders.

Abstract: A method of determining a tool path for an additive deposition on a surface, the method including receiving primary edges data of the surface of a three-dimensional (3D) object; calculating a number of raster lines for applying an additive deposition on the surface; mapping a raster pattern to the surface of the 3D object; calculating surface normal and rotational angles along the raster lines; calculating a nozzle velocity of an additive application used for producing the additive deposition on the surface; identifying curvature effects of the 3D object; and establishing an order of performing passes of the additive deposition on the surface based on a selected direction for performing the additive deposition and a consideration of a residual stress profile of a resulting deposit.

Abstract: A system and method for controlling cold spray deposit adhesion for induced release of a deposit from a substrate includes tuning a material surface condition of a substrate used to support a build of a cold spray material to a level proportionate with deposition conditions of the cold spray material for adhesion to the substrate; selecting an impact velocity for deposition of the cold spray material to be substantially equal to or greater than a critical velocity for adhesion of the cold spray material to the substrate; depositing the cold spray material on the substrate to form a deposit; and releasing the deposit from the substrate without permanently damaging the substrate to allow for reuse of the substrate for a subsequent cold spray deposition process.

Abstract: A heat exchanger is disclosed. The heat exchanger includes a hollow tube extending from a tube inlet to a tube outlet. The hollow tube includes a wall that includes a core of a first aluminum alloy, and a cladding over the core of a second aluminum alloy. The second aluminum alloy is less noble than the first aluminum alloy and includes an alloying element selected from tin, indium, or gallium, or combinations thereof. A first fluid flow path is disposed along an inner surface of the wall from the tube inlet to the tube outlet, and a second fluid flow path is disposed across an outer surface of the wall.

Abstract: A heat exchanger is disclosed. The heat exchanger includes a hollow tube extending from a tube inlet to a tube outlet. The hollow tube includes a wall inner surface comprising a copper alloy or a first aluminum alloy. A first fluid flow path is disposed along the wall inner surface from the tube inlet to the tube outlet. A turbulator is disposed within the hollow tube along the first fluid flow path, and the turbulator comprises a second aluminum alloy that is less noble than the copper or first aluminum alloy. A second fluid flow path is disposed across an outer surface of the wall.

Abstract: A compressor is disclosed, including an outer casing and a fluid guide around a cavity within the casing. An inlet is in operative fluid communication with the cavity, and an outlet is also in operative fluid communication with the cavity. A prime mover includes an actuator disposed in the cavity. The actuator includes a surface arranged to receive fluid in the cavity from the inlet, impart compression to received fluid in the cavity, and discharge compressed fluid to the outlet. A surface of the compressor includes a cladding of a second aluminum alloy over a core of a first aluminum alloy, wherein the second aluminum alloy is less noble than the first aluminum alloy and includes an alloying element selected from tin, indium, gallium, or combinations thereof.

Abstract: A marked article includes a substrate including a first surface and a surface material, a raised pad on the first surface, the raised pad including a second surface, and a design on the raised pad. The raised pad is formed on the first surface using a material addition process to prevent mechanical stress from being propagated from the raised pad to the substrate in response to the design being formed on the raised pad.

Abstract: A fluidized powder heat treatment classification assembly includes a gas source. A fluidized bed is connected to the gas source via a metered connection. The fluidized bed includes a first output connected to a powder classifier via at least a first valve. The powder classifier includes a catch container operable to decelerate a gas flow from the output and operable to catch particles entrained in the gas flow.

Abstract: Material is provided for forming a part using a manufacturing system. The material includes a plurality of discrete particles. Each of the particles includes a metal powder core encapsulated by a non-metal coating. At least the cores of the particles are adapted to be solidified together by the manufacturing system to form the part.

Abstract: A method for marking an article may comprise forming a raised pad on a substrate of the existing article by applying a material to a surface of the substrate using a material addition process, and forming a design on a surface of the raised pad. The raised pad may be formed on the surface of the substrate to prevent mechanical stress from being propagated from the raised pad to the substrate in response to the design being formed on the raised pad.

Abstract: A manufacturing process is provided in which material is supported within a chamber. This material includes a plurality of discrete metal particles and ceramic disposed between at least some of the metal particles. At least a portion of the material is solidified together using an additive manufacturing system to form an object.

Abstract: An adapter for connecting a cold-spray nozzle to a cold-spray machine includes a receiver having a first end and a second end and defining an internal space for receiving the cold-spray nozzle; an end cap engageable with the first end of the receiver for securing the cold-spray nozzle in the receiver and having an opening aligned with an outlet of the cold-spray nozzle; and a threaded connection at the second end of the receiver, the threaded connection being configured for connection to the cold-spray machine.

Abstract: A feedstock for a cold spray process includes a plurality of globule bodies. The globule bodies include a plurality of discrete particles bonded to one another to define porous globule bodies. The bonds between the particles are of sufficient strength such that the globule bodies can retain both the body integrity as well as the body shape when the body experiences acceleration from a conveying gas in a cold spray technique. Methods of making the feedstock and globule bodies are also described.

Abstract: A gas turbine engine includes an airfoil having a core that has a first hardness and a surface on the core. The surface includes a plurality of geometric features that have a second, greater hardness. The geometric features define a surface porosity by area percent and a corresponding surface solidity by area percent. The surface includes a ratio of the surface solidity divided by the surface porosity that is 1.8 or greater. The geometric features and the ratio establish the surface to be hydrophobic, and the second, greater hardness and the ratio establish an erosion rate of the surface that is equal to or less than an erosion rate of the core under identical erosion conditions.