Abstract: A flexible, thermal-isolating tube includes a first fluid flow channel portion having a dual-walled configuration, a second fluid flow channel portion having a dual-walled configuration, and a bellows disposed between and coupled to each of the first and second fluid flow channel portions. The flexible, thermal-isolating tube, including each of the first and second fluid flow channel portions, and the bellows, is configured as a unitary structure. The flexible, thermal-isolating tube is manufactured using an additive manufacturing process.

Abstract: A flexible, thermal-isolating tube includes a first fluid flow channel portion having a dual-walled configuration, a second fluid flow channel portion having a dual-walled configuration, and a bellows disposed between and coupled to each of the first and second fluid flow channel portions. The flexible, thermal-isolating tube, including each of the first and second fluid flow channel portions, and the bellows, is configured as a unitary structure. The flexible, thermal-isolating tube is manufactured using an additive manufacturing process. The flexible, thermal-isolating tube is disposed within a gas turbine engine.

Abstract: Devices (herein “powder spreadability inspection tools”) and methods are provided for evaluating the spreadability of powders utilized in additive manufacturing (AM) processes. In embodiments, the powder spreadability inspection tool includes a powder support surface on which a visual inspection area is provided, a spreader system including a spreader implement, and a powder dispenser. The spreader implement is movable relative to the powder support surface along a path, which extends or passes over the visual inspection area. The powder dispenser is operable to dispense a premeasured or metered volume of an AM powder sample onto the powder support surface ahead of the spreader implement. As the spreader implement moves along the path relative to the powder support surface, the spreader implement spreads a layer of the metered powder sample across the visual inspection area to allow a visual evaluation of the spreadability of the AM powder.

Abstract: Devices (herein “powder spreadability inspection tools”) and methods are provided for evaluating the spreadability of powders utilized in additive manufacturing (AM) processes. In embodiments, the powder spreadability inspection tool includes a powder support surface on which a visual inspection area is provided, a spreader system including a spreader implement, and a powder dispenser. The spreader implement is movable relative to the powder support surface along a path, which extends or passes over the visual inspection area. The powder dispenser is operable to dispense a premeasured or metered volume of an AM powder sample onto the powder support surface ahead of the spreader implement. As the spreader implement moves along the path relative to the powder support surface, the spreader implement spreads a layer of the metered powder sample across the visual inspection area to allow a visual evaluation of the spreadability of the AM powder.

Abstract: Methods for manufacturing an article include providing a three-dimensional computer model of the article and providing a metal alloy in powdered form. The metal alloy is a titanium aluminide alloy. The powdered form includes a grain size range of about 5 to about 20 microns and a d50 grain size average of about 10 to about 14 microns. The methods further include, at a binder jet printing apparatus, supplying the metal alloy and loading the three-dimensional model, and, using the binder jet printing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied metal alloy. A liquid binder is applied at each layer, and each layer has a thickness of about 10 to about 150 microns. The methods avoid remelting of the metal alloy and avoid metal alloy cooling rates of greater than about 100 ° F. per minute.

Abstract: Methods for manufacturing an article include providing a three-dimensional computer model of the article and providing a metal alloy in powdered form. The metal alloy is an aluminum-iron-vanadium-silicon alloy. The powdered form includes a grain size range of about 5 to about 22 microns and a d50 grain size average of about 10 to about 13 microns. The methods further include, at a binder jet printing apparatus, supplying the metal alloy and loading the three-dimensional model, and, using the binder jet printing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied metal alloy. A liquid binder is applied at each layer, and each layer has a thickness of about 10 to about 150 microns. The methods avoid remelting of the metal alloy and avoid metal alloy cooling rates of greater than about 100° F. per minute.

Abstract: Methods for manufacturing an article include providing a three-dimensional computer model of the article and providing a metal alloy in powdered form. The metal alloy is a gamma prime precipitation hardened nickel-based superalloy. The powdered form includes a grain size range of about 5 to about 22 microns and a d50 grain size average of about 10 to about 13 microns. The methods further include, at a binder jet printing apparatus, supplying the metal alloy and loading the three-dimensional model, and, using the binder jet printing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied metal alloy. A liquid binder is applied at each layer, and each layer has a thickness of about 10 to about 150 microns. The methods avoid remelting of the metal alloy and avoid metal alloy cooling rates of greater than about 100° F. per minute.

Abstract: Additive Manufacturing Quality Management (AMQM) systems and methods are provided, which enhance quality control across Additive Manufacturing (AM) supply chains from which AM components are obtained. In various embodiments, the AMQM system includes an AM machine utilized to produce AM components in accordance with AM design data. A first sensor is coupled to the AM machine and, during fabrication of AM components by the AM machine, captures sensor readings pertaining to the AM fabrication process. When executed by a processor, computer-executable code causes the AMQM system to: (i) compile part-specific sensor profiles from sensor readings captured by the first sensor during fabrication of the AM components, and (ii) generate user notifications indicating whether remedial action should be performed for any of the AM components based, at least in part, on conformance of the part-specific sensor profiles with a baseline sensor profile corresponding to the AM design data.

Abstract: Methods for manufacturing an article include providing a three-dimensional computer model of the article and providing a metal alloy in powdered form. The metal alloy is a nickel-chromium-tungsten-molybdenum alloy. The powdered form includes a grain size range of about 5 to about 22 microns and a d50 grain size average of about 10 to about 13 microns. The methods further include, at a binder jet printing apparatus, supplying the metal alloy and loading the three-dimensional model, and, using the binder jet printing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied metal alloy. A liquid binder is applied at each layer, and each layer has a thickness of about 10 to about 150 microns. The methods avoid remelting of the metal alloy and avoid metal alloy cooling rates of greater than about 100° F. per minute.

Abstract: A flexible, thermal-isolating tube includes a first fluid flow channel portion having a dual-walled configuration, a second fluid flow channel portion having a dual-walled configuration, and a bellows disposed between and coupled to each of the first and second fluid flow channel portions. The flexible, thermal-isolating tube, including each of the first and second fluid flow channel portions, and the bellows, is configured as a unitary structure. The flexible, thermal-isolating tube is manufactured using an additive manufacturing process.

Abstract: A method for manufacturing a metallic article includes providing or obtaining a metallic material in powder form, using an additive manufacturing process, building the metallic article from the powder-form metallic material, layer-by-layer, in a build direction, wherein as a result of the additive manufacturing process, the metallic article comprises columnar grain structures oriented in the build direction, and conveying the metallic article through a gradient furnace in a direction of conveyance from a first area of the gradient furnace to a second area of the gradient furnace to increase a size of the columnar grain structures in the metallic article. The metallic article is conveyed through the gradient furnace in an orientation such that the columnar structures oriented in the build direction are substantially parallel to the direction of conveyance.

Abstract: Additive Manufacturing Quality Management (AMQM) systems and methods are provided, which enhance quality control across Additive Manufacturing (AM) supply chains from which AM components are obtained. In various embodiments, the AMQM system includes an AM machine utilized to produce AM components in accordance with AM design data. A first sensor is coupled to the AM machine and, during fabrication of AM components by the AM machine, captures sensor readings pertaining to the AM fabrication process. When executed by a processor, computer-executable code causes the AMQM system to: (i) compile part-specific sensor profiles from sensor readings captured by the first sensor during fabrication of the AM components, and (ii) generate user notifications indicating whether remedial action should be performed for any of the AM components based, at least in part, on conformance of the part-specific sensor profiles with a baseline sensor profile corresponding to the AM design data.

Abstract: A nickel-based superalloy component includes a nickel-based superalloy metal. The nickel-based superalloy metal includes, on a weight basis of the overall superalloy metal: about 9.5% to about 10.5% tungsten, about 9.0% to about 11.0% cobalt, about 8.0% to about 8.8% chromium, about 5.3% to about 5.7% aluminum, about 2.8% to about 3.3% tantalum, about 0.3% to about 1.6% hafnium, about 0.5% to about 0.8% molybdenum, about 0.005% to about 0.04% carbon, and a majority of nickel. In some examples, the component includes a gas turbine engine component, such as a turbine blade or a turbine vane, and the metal form of the nickel-based superalloy may be used as a filler metal for welding a casting alloy, a wrought alloy, or a powder metal alloy or other wrought forms.

Abstract: A method of manufacturing a nickel-based superalloy component includes providing or obtaining, in a powdered form, a build material alloy including, on a weight basis of the overall build material alloy: about 9.5% to about 10.5% tungsten, about 9.0% to about 11.0% cobalt, about 8.0% to about 8.8% chromium, about 5.3% to about 5.7% aluminum, about 2.8% to about 3.3% tantalum, about 0.3% to about 1.6% hafnium, about 0.5% to about 0.8% molybdenum, about 0.005% to about 0.04% carbon, and a majority of nickel. The method further includes subjecting the build material alloy to a high energy density beam in an additive manufacturing process to selectively fuse portions of the build material to form a built component and subjecting the built component to a finishing process to precipitate a gamma-prime phase of the nickel-based superalloy.

Abstract: Fire- and electromagnetic interference (EMI)-resistant aircraft components and methods for manufacturing the same are provided. A fire-and EMI-resistant aircraft component includes an article comprised of a polymeric material. A fire-retardant material layer overlies the article. A thermally and electrically conductive coating material layer is disposed intermediate the article and the fire-retardant material layer. Optionally, at least one continuous electrically conductive element is integrated with the polymeric material of the article.

Abstract: Fire- and electromagnetic interference (EMI)-resistant aircraft components and methods for manufacturing the same are provided. A thermally and electrically conductive coating material layer is formed on at least a portion of an intermediate article comprised of a non-metallic material. The thermally and electrically conductive coating material layer is comprised of a metal. A fire-retardant material layer is cold sprayed on the thermally and electrically conductive coating material layer. At least one continuous electrically conductive element may be integrated with the non-metallic material of the intermediate article.

Abstract: A method for manufacturing a metallic article includes providing or obtaining a metallic material in powder form, using an additive manufacturing process, building the metallic article from the powder-form metallic material, layer-by-layer, in a build direction, wherein as a result of the additive manufacturing process, the metallic article comprises columnar grain structures oriented in the build direction, and conveying the metallic article through a gradient furnace in a direction of conveyance from a first area of the gradient furnace to a second area of the gradient furnace to increase a size of the columnar grain structures in the metallic article. The metallic article is conveyed through the gradient furnace in an orientation such that the columnar structures oriented in the build direction are substantially parallel to the direction of conveyance.

Abstract: A coupling apparatus for use in sealingly connecting a first fluid flow path to a second fluid flow path. The coupling apparatus includes a rigid fluid flow channel having a first end and a second end, wherein the fluid flow channel is substantially rigid in an axial direction and a radial direction, a first sealing terminus that is rigidly connected to the first end and that is configured for sealing with the first fluid flow path, and a second sealing terminus that is slidingly disposed about the second end such that the second sealing terminus is configured for relative movement with respect to the second end, and wherein the second sealing terminus is further configured for sealing with the second fluid flow path.

Abstract: A coupling apparatus for use in sealingly connecting a first fluid flow path to a second fluid flow path. The coupling apparatus includes a rigid fluid flow channel having a first end and a second end, wherein the fluid flow channel is substantially rigid in an axial direction and a radial direction, a first sealing terminus that is rigidly connected to the first end and that is configured for sealing with the first fluid flow path, and a second sealing terminus that is slidingly disposed about the second end such that the second sealing terminus is configured for relative movement with respect to the second end, and wherein the second sealing terminus is further configured for sealing with the second fluid flow path.

Abstract: Nickel-based superalloys and additive manufacturing processes using nickel-based superalloys are disclosed herein. For example, a nickel-based superalloy includes, on a weight basis of the overall superalloy: about 9.5% to about 10.5% tungsten, about 9.0% to about 11.0% cobalt, about 8.0% to about 8.8% chromium, about 5.3% to about 5.7% aluminum, about 2.8% to about 3.3% tantalum, about 0.3% to about 1.6% hafnium, about 0.5% to about 0.8% molybdenum, about 0.005% to about 0.04% carbon, and a majority of nickel. Exemplary additive manufacturing processes include subjecting such a nickel-based superalloy in powdered build material form to a high energy density beam in an additive manufacturing process to selectively fuse portions of the build material to form a built component and subjecting the built component to a finishing process to precipitate a gamma-prime phase of the nickel-based superalloy.