Abstract: The disclosure relates to an apparatus for manufacturing a metallic component, and corresponding methods. The apparatus may include a build plate with a build surface and an aperture. The apparatus may also include an actuator operable to translate a metallic component such that an end portion of the metallic component is positioned within the aperture of the build plate and below the build surface. The apparatus may further include a seal coupled within the aperture of the build plate and configured to engage the end portion of the metallic component. The aperture of the build plate, the seal, and the end portion of the metallic component may cooperate to form a powder bed to hold metallic powder therein. The apparatus may also include an external heat control mechanism operable to form a predetermined temperature profile of the end portion of the component to prevent cracking of the component.

Abstract: A method of processing a powdered feedstock to form a fabricated component is provided. The fabricated component includes a plurality of grains having a nominal grain size. The method includes providing the powdered feedstock material having a population of phase particulates with a first nominal size distribution disposed within a host matrix material. The method includes building a consolidated component from the powdered feedstock material in an additive manufacturing process, and fabricating the fabricated component from the consolidated component. The first nominal size distribution of the population of phase particulates is sized such that at least a portion of the population of phase particulates persists throughout the additive manufacturing process and is present as a processed population of phase particulates in the consolidated component.

Abstract: The disclosure relates to an apparatus for manufacturing a metallic component, and corresponding methods. The apparatus may include a build plate with a build surface and an aperture. The apparatus may also include an actuator operable to translate a metallic component such that an end portion of the metallic component is positioned within the aperture of the build plate and below the build surface. The apparatus may further include a seal coupled within the aperture of the build plate and configured to engage the end portion of the metallic component. The aperture of the build plate, the seal, and the end portion of the metallic component may cooperate to form a powder bed to hold metallic powder therein. The apparatus may also include an external heat control mechanism operable to form a predetermined temperature profile of the end portion of the component to prevent cracking of the component.

Abstract: A method that includes additively manufacturing with an additive manufacturing (AM) system a sub-component that has a locator element. Using a control system of the AM system for positioning a first location of the locator element. Selectively placing a portion of another sub-component adjacent to the locator element, based on the positioning. Then attaching the second sub-component to the first sub-component in a region, wherein the region is based on the positioning knowledge from the control system so as to make a component. A component that comprises a first sub-component that has an AM locator element; and a second sub-component attached to the first sub-component, wherein the locator element is attached to the second sub-component within the same additive manufacturing build chamber as the first sub-component.

Abstract: An apparatus and method for rapid screening of material properties in a plurality of additively manufactured test specimens. The apparatus includes a build plate having the plurality of additively manufactured test specimens disposed on a first substantially planar surface. The plurality of additively manufactured test specimens are coupled to at least one actuator to one of individually or simultaneously translationally displace each of the test specimens along an axis “z”, and perpendicular to the build plane of the build plate to test material properties of each of the plurality of additively manufactured test specimens. A sensor is coupled to each of the plurality of additively manufactured test specimens. Load vs. displacement data may be used to monitor the progression of monotonic and/or cyclic tests of the plurality of additively manufactured test specimens.

Abstract: A pressurized consolidation assembly for an additive manufacturing system is provided. The pressurized consolidation assembly defines a first direction, a second direction, and a third direction, the three directions orthogonal to each other. The pressurized consolidation assembly includes a build platform configured to hold a plurality of particles and a pressure chamber surrounding the build platform. The pressure chamber is configured to retain a first volume of a gas having a first pressure. The pressure chamber includes an energy beam window. The energy beam window extends through a first section of the pressure chamber and is configured to enable an energy beam to pass through the energy beam window to be incident on the plurality of particles on the build platform.

Abstract: The disclosure relates to an apparatus for manufacturing a metallic component, and corresponding methods. The apparatus may include a build plate with a build surface and an aperture. The apparatus may also include an actuator operable to translate a metallic component such that an end portion of the metallic component is positioned within the aperture of the build plate and below the build surface. The apparatus may further include a seal coupled within the aperture of the build plate and configured to engage the end portion of the metallic component. The aperture of the build plate, the seal, and the end portion of the metallic component may cooperate to form a powder bed to hold metallic powder therein. The apparatus may also include an external heat control mechanism operable to form a predetermined temperature profile of the end portion of the component to prevent cracking of the component.

Abstract: A method that includes additively manufacturing with an additive manufacturing (AM) system a sub-component that has a locator element. Using a control system of the AM system for positioning a first location of the locator element. Selectively placing a portion of another sub-component adjacent to the locator element, based on the positioning. Then attaching the second sub-component to the first sub-component in a region, wherein the region is based on the positioning knowledge from the control system so as to make a component. A component that comprises a first sub-component that has an AM locator element; and a second sub-component attached to the first sub-component, wherein the locator element is attached to the second sub-component within the same additive manufacturing build chamber as the first sub-component.

Abstract: A method of processing a powdered feedstock to form a fabricated component is provided. The fabricated component includes a plurality of grains having a nominal grain size. The method includes providing the powdered feedstock material having a population of phase particulates with a first nominal size distribution disposed within a host matrix material. The method includes building a consolidated component from the powdered feedstock material in an additive manufacturing process, and fabricating the fabricated component from the consolidated component. The first nominal size distribution of the population of phase particulates is sized such that at least a portion of the population of phase particulates persists throughout the additive manufacturing process and is present as a processed population of phase particulates in the consolidated component.

Abstract: A method that includes additively manufacturing with an additive manufacturing (AM) system a sub-component that has a locator element. Using a control system of the AM system for positioning a first location of the locator element. Selectively placing a portion of another sub-component adjacent to the locator element, based on the positioning. Then attaching the second sub-component to the first sub-component in a region, wherein the region is based on the positioning knowledge from the control system so as to make a component. A component that comprises a first sub-component that has an AM locator element; and a second sub-component attached to the first sub-component, wherein the locator element is attached to the second sub-component within the same additive manufacturing build chamber as the first sub-component.

Abstract: An apparatus and method for rapid screening of material properties in a plurality of additively manufactured test specimens. The apparatus includes a build plate having the plurality of additively manufactured test specimens disposed on a first substantially planar surface. The plurality of additively manufactured test specimens are coupled to at least one actuator to one of individually or simultaneously translationally displace each of the test specimens along an axis “z”, and perpendicular to the build plane of the build plate to test material properties of each of the plurality of additively manufactured test specimens. A sensor is coupled to each of the plurality of additively manufactured test specimens. Load vs. displacement data may be used to monitor the progression of monotonic and/or cyclic tests of the plurality of additively manufactured test specimens.

Abstract: A method for reducing surface roughness of an article includes contacting a surface of an article with a molten metal agent, the surface having an initial roughness; altering at least a portion of the surface in the molten metal agent; and removing the surface from contact with the agent; wherein, after the removing step, the surface has a processed roughness that is less than the initial roughness.

Abstract: The disclosure relates to an apparatus for manufacturing a metallic component, and corresponding methods. The apparatus may include a build plate with a build surface and an aperture. The apparatus may also include an actuator operable to translate a metallic component such that an end portion of the metallic component is positioned within the aperture of the build plate and below the build surface. The apparatus may further include a seal coupled within the aperture of the build plate and configured to engage the end portion of the metallic component. The aperture of the build plate, the seal, and the end portion of the metallic component may cooperate to form a powder bed to hold metallic powder therein. The apparatus may also include an external heat control mechanism operable to form a predetermined temperature profile of the end portion of the component to prevent cracking of the component.

Abstract: A method that includes additively manufacturing with an additive manufacturing (AM) system a sub-component that has a locator element. Using a control system of the AM system for positioning a first location of the locator element. Selectively placing a portion of another sub-component adjacent to the locator element, based on the positioning. Then attaching the second sub-component to the first sub-component in a region, wherein the region is based on the positioning knowledge from the control system so as to make a component. A component that comprises a first sub-component that has an AM locator element; and a second sub-component attached to the first sub-component, wherein the locator element is attached to the second sub-component within the same additive manufacturing build chamber as the first sub-component.

Abstract: A method for reducing surface roughness of an article includes contacting a surface of an article with a molten metal agent, the surface having an initial roughness; altering at least a portion of the surface in the molten metal agent; and removing the surface from contact with the agent; wherein, after the removing step, the surface has a processed roughness that is less than the initial roughness.

Abstract: A steel composition resistant to sulfidic corrosion has been discovered. The newly discovered steel composition comprises the elements Fe, C, Si, Cu, and Mn wherein the composition comprises from about 96.80 to about 99.00 percent by weight iron, from about 0.10 to about 0.30 percent by weight carbon, from about 0.20 to about 1.40 percent by weight silicon, from about 0.50 to about 1.50 percent by weight copper, and from about 0.20 to about 1.00 percent by weight manganese, wherein the composition is substantially free of chromium, and wherein the composition contains less than 0.1 percent by weight nickel, molybdenum, or tungsten.

Abstract: An emitter is disclosed. The emitter includes a base layer comprising an array of nanocavities on an emission surface of the base layer, wherein facets of the nanocavities are substantially along equivalent crystallographic planes of one or more families of planes having substantially equal surface energies, wherein the equivalent crystallographic planes have surface energies equal to or lower than a surface energy of the crystallographic plane of the emission surface. Methods of making such emitters and radiation sources including such emitters are also disclosed.

Abstract: An article made of an alloy, and a method for making the article, are presented. The alloy is substantially free of martensite, and comprises the following composition: at least about 75 weight percent titanium; up to about 10 weight percent of a beta stabilizing component; from about 3 weight percent to about 15 weight percent of an alpha stabilizing component; and from about 0.05 weight percent to about 5 weight percent germanium. Another embodiment is a method for fabricating an article. The method comprises providing a billet made of an alloy as described above, and stabilizing the billet microstructure to form a stabilized billet; the method may further comprise superplastically processing the stabilized billet to form a processed item.

Abstract: An emitter is disclosed. The emitter includes a a base layer comprising an array of nanocavities on an emission surface of the base layer, wherein facets of the nanocavities are substantially along equivalent crystallographic planes of one or more families of planes having substantially equal surface energies, wherein the equivalent crystallographic planes have surface energies equal to or lower than a surface energy of the crystallographic plane of the emission surface. Methods of making such emitters and radiation sources including such emitters are also disclosed.