Abstract: A method of powder bed fusion additive manufacture includes forming a component in a powder bed in a layer-by-layer process. The method may include sintering, without melting, selected regions of powder with an energy beam to form at least one support adjacent to the component; and melting further selected regions of the powder bed with an energy beam to form a component by layer-by-layer melting of material. The method may include directing an energy beam at selected regions of powder to form a friable support, the friable support including bonded powder which act as a solid and provide compressive support; and melting further regions of the powder bed with an energy beam to form a component by layer-by-layer melting of material.

Abstract: Apparatus and a method for forming a metallic component by additive layer manufacturing are provided. The method includes the steps of using a heat source such as a laser to melt the surface of a work piece and form a weld pool; adding wire or powdered metallic material to the weld pool and moving the heat source relative to the work piece so as to progressively form a new layer of metallic material on the work piece; applying forced cooling to the formed layer; stress relieving the cooled layer by applying a peening step, for example with a pulsed laser, and repeating the above steps as required to form the component layer by layer.

Abstract: A method for forming a joint between a fiber reinforced composite component and a metallic component and a joint are provided. The metallic component and the composite component each define a joint surface for mating with the joint surface of the other to join the two components together and the composite component defines a free surface opposed to the joint surface thereof. The joint surface of the metallic component defines an array of pins extending therefrom with each pin defining a pin head at an end distal from the joint surface. The method includes the steps of pressing together the joint surfaces of the two components whereby to cause the array of pins to penetrate through the fiber reinforcing material, and modifying the effective cross sectional shape of the pin heads whereby to increase the constraint applied to the composite component against peeling of the composite component from the joint surface of the metallic component.

Abstract: Modular armour is provided. The armour comprises a series of regularly-shaped armour elements and corresponding anchor elements releasably to anchor the armour elements to a platform. Each anchor element comprises an armour engaging section extending between first and second ends thereof, the first end being engageable with an armour mount on the platform and the second end including means releasably to secure the armour element, while engaged with the anchor element, to the platform. The platform may be fixed or mobile and includes land, water-born and air vehicles.

Abstract: A method and apparatus for forming an object by additive layer manufacturing. The method comprises: a) applying, by a heat source (4), heat to a portion of a surface of a workpiece (1) sufficient to melt said portion; b) adding material to the melted portion and moving the heat source (4) relative to the workpiece (1) whereby progressively to form a layer of material (10) on the workpiece (1); c) cooling the formed layer (10) to bring at least part of the layer (10) to a state of crystallisation, there producing a modified workpiece; d) peening, using a plurality of independently controllable impact treatment devices (7), the modified work-piece so as to plastically deform the cooled at least part of the layer (10); and repeating steps a) to d) as required whereby to form the object.

Abstract: Apparatus and a method of forming a composite component (8) by additive layer manufacturing are provided. The method includes the steps of providing an elongate tape (2) of carbon nanotubes (CNTs), applying stretching force to the tape (2) whereby to align the carbon nanotubes to the tape and form an aligned tape (27), impregnating the tape (27) with matrix material (40, 48, 50), forming the aligned tape (27) into portions (43) of required size and transferring the portions as required to a component build location whereby to form the component (8), layer by layer.

Abstract: Apparatus and a method for forming a metallic component by additive layer manufacturing are provided.

Abstract: A selective layer melting or other additive layer fabrication method in which powdered material is fused by heating it with a pulsed laser, the pulses being modulated while the laser is traversing the substrate so as to control the thickness and/or width of the layer being formed. Initial layers of the fabrication structure may be formed more thickly than subsequent layers, e.g. by means of a CW laser, to reduce distortion. This aspect of the invention may be employed independently of the use of a pulsed laser to form the subsequent layers.

Abstract: Apparatus and a method for forming a metallic component by additive layer manufacturing are provided.

Abstract: The invention relates to the manufacture of hybrid joints more particularly to the manufacture of joints between parts made of differing materials and most particularly to the manufacture of a metallic component comprising a plurality of preformed projections which penetrate composite fabric within a composite part. Particularly there is a method of forming an array of projections on a surface of a metallic component, the method including the steps of bringing at least one preformed projection into at least close proximity to the surface of the component and causing a portion of the projection and a portion of the component in the region of an intersection thereof to at least partially melt, and causing them to be joined together.

Abstract: A method for forming a joint between a fibre reinforced composite component and a metallic component and a joint are provided. The metallic component and the composite component each define a joint surface for mating with the joint surface of the other to join the two components together and the composite component defines a free surface opposed to the joint surface thereof. The joint surface of the metallic component defines an array of pins extending therefrom with each pin defining a pin head at an end distal from the joint surface. The method includes the steps of pressing together the joint surfaces of the two components whereby to cause the array of pins to penetrate through the fibre reinforcing material, and modifying the effective cross sectional shape of the pin heads whereby to increase the constraint applied to the composite component against peeling of the composite component from the joint surface of the metallic component.

Abstract: Apparatus and a method for forming a metallic component by additive layer manufacturing are provided. The method includes the steps of using a heat source such as a laser to melt the surface of a work piece and form a weld pool; adding wire or powdered metallic material to the weld pool and moving the heat source relative to the work piece so as to progressively form a new layer of metallic material on the work piece; applying forced cooling to the formed layer; stress relieving the cooled layer by applying a peening step, for example with a pulsed laser, and repeating the above steps as required to form the component layer by layer.

Abstract: Apparatus and a method of forming a structure (304) are disclosed. The method includes applying a heat treatment to a first area (206) on a first surface (201A) of a work piece (200), wherein at least one dimension of the first area corresponds to a maximum design dimension of a structure (304) to be formed. The structure is then formed on a second area (303) on an opposite surface (201B) of the work piece, the second area having a location corresponding to the first area.

Abstract: A method and apparatus for forming a layered structure. At least one raised area (202) is formed on a work piece (200), and a structure (302) is formed on the raised area using an Additive Layer Manufacturing (ALM) process.

Abstract: An additive layer manufacturing system and method are provided. The system includes a powder delivery system providing at least one powder feed from a powder stock to a powder exit adjacent a deposition point. The powder delivery system further comprises at least one valve system proximal to the powder exit for controlling the flow of the at least one powder feed at the deposition point.

Abstract: A selective layer melting or other additive layer fabrication method in which powdered material is fused by heating it with a pulsed laser, the pulses being modulated whilst the laser is traversing the substrate so as to control the thickness and/or width of the layer being formed. Initial layers of the fabrication structure may be formed more thickly than subsequent layers, e.g. by means of a CW laser, to reduce distortion. This aspect of the invention may be employed independently of the use of a pulsed laser to form the subsequent layers.

Abstract: A selective layer melting or other additive layer fabrication method in which powdered material is fused by heating it with a pulsed laser, the pulses being modulated whilst the laser is traversing the substrate so as to control the thickness and/or width of the layer being formed. Initial layers of the fabrication structure may be formed more thickly than subsequent layers, e.g. by means of a CW laser, to reduce distortion. This aspect of the invention may be employed independently of the use of a pulsed laser to form the subsequent layers.

Abstract: A method of fabricating an object is disclosed. A first layer of powder is deposited onto a substrate in a configuration defining a first cross-section of the object, and is consolidated by laser irradiation. To fabricate the object, further layers of powder are deposited onto the sintered first layer of powder to define further cross-sections of the object. The further layers are consolidated. A heat source is applied to the substrate to mitigate distortion of the substrate during fabrication of the object.

Abstract: A coolant delivery device (100) comprises a coolant outlet (124) and an exhaust (140, 160). The coolant outlet (124) is contained within a housing (150) that has an opening provided with sealing means (180), to which opening the coolant outlet (124) is arranged to direct a coolant. In use of the device, coolant is delivered to a surface to be cooled, and the coolant vaporises at the surface so as to produce coolant gas. Since the sealing means (180), in use of the device, form a seal between the housing (150) and the surface, the coolant gas is constrained to escape the device through the exhaust (140, 160), and does not disturb or disrupt the ambient environment. The device is particularly useful for applying thermal tensioning to welds through the delivery of a cryogenic spray to a weld line.