Abstract: A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations.

Abstract: Solid-state joining of preformed features, such as bosses, flanges, gaskets, centralizers and other features to substrates or cast parts by a solid-state additive manufacturing process is disclosed. Joining can be between same or different materials using same, similar or dissimilar filler material than the materials of the feature and the part that need to be joined.

Abstract: A technique facilitates construction of a wire-wrapped screen. A wrapping machine is operated with a sensor, e.g. a camera, positioned adjacent the wrapping machine while wire is wrapped to create the wire-wrapped screen. The sensor is used to obtain data on at least one parameter of the wire-wrapped screen during creation of the wire-wrapped screen. Data is provided to a controller in communication with the wrapping machine to improve the quality of the wire-wrapped screen. For example, data from the images obtained via the camera may be provided to the controller which is configured to determine slot width as the wire is wrapped. The controller is then able to provide feedback in real time to the wrapping machine so as to adjust the wrapping machine for maintaining a desired slot width.

Abstract: A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations.

Abstract: A technique facilitates construction of a wire-wrapped screen. A wrapping machine is operated with a sensor, e.g. a camera, positioned adjacent the wrapping machine while wire is wrapped to create the wire-wrapped screen. The sensor is used to obtain data on at least one parameter of the wire-wrapped screen during creation of the wire-wrapped screen. Data is provided to a controller in communication with the wrapping machine to improve the quality of the wire-wrapped screen. For example, data from the images obtained via the camera may be provided to the controller which is configured to determine slot width as the wire is wrapped. The controller is then able to provide feedback in real time to the wrapping machine so as to adjust the wrapping machine for maintaining a desired slot width.

Abstract: An accessory device used in combination with a solid-state additive manufacturing system is described. In some configurations, the accessory device can be used in combination with an additive manufacturing system, such as a solid-state additive manufacturing system, to enable printing of large-scale and complex objects, where the objects are much larger than those printed with existing solid-state manufacturing systems. The disclosed accessory device used in conjunction with the a solid-state additive manufacturing system is capable of manufacturing non-hollow (solid), partially-hollow or completely-hollow objects via different methods.

Abstract: A solid-state additive manufacturing additive manufacturing system applicable to building up 3D structures, coating and functionalizing surfaces, joining structures, adding customized features to objects, compounding proprietary compositions and repairing various structures is disclosed. The solid-state additive manufacturing system enables deposition of different fillers, viz. metals, metal alloys, MMCs, polymers, plastics, composites, hybrids and gradient compositions, as well as controls the resulting deposit structures, e.g. specific nano-/micro-, gradient- and porous-material structures. The system accommodates various feeding-, spindle- and tool-designs for depositing different forms of filler materials, viz. rods, wires, granules, powders, powder-filled-tubes, scrap pieces or their combination, and a working platform with multiple access points.

Abstract: Solid-state additive and subtractive manufacturing processes, completely or partially performed by a solid-state manufacturing system, are disclosed. Solid-state deposition processes of different materials for printing 3D parts, coating, joining or repair are included as examples. Subtractive processing steps, such as machining, drilling, surface grooving, surface activation and others are discussed as well. In addition, other processes performed by other means are mentioned in making the final parts.

Abstract: A technique facilitates joining of components without subsequent heat treatments. The components are joined by using a friction stir process which establishes a desired friction stir region at an appropriate location to securely join the desired components. In well applications, various components of sand screen assemblies may be joined by the friction stir process. For example, metal sand screen components may be securely coupled with a corresponding metal base pipe. The joining technique enables retention of the corrosion resistant properties of the materials without applying post weld heat treatments and/or other subsequent treatments.

Abstract: Solid-state additive manufacturing methods for compounding conductive plastic compositions, fabrication of conductive plastic parts and conductive coatings, and plastic recycling are disclosed. Electrically conductive or thermally conductive plastic compositions are compounded and subsequently printed with the solid-state additive manufacturing system. The solid-state fabricated compositions, parts and coatings can also be manufactured to be both thermally and electrically conductive. Solid-state plastic waste recycling methods are also disclosed where various plastic waste materials and shapes are solid-state processed. The plastic waste can be mixed with virgin plastic material or mixed with other types of materials such as metals, ceramics or their combination. The waste plastic feedstock is reinforced with different types of reinforcing particles or fibers, or various additives are added for improving properties of the final deposits.

Abstract: Solid-state joining of preformed features, such as bosses, flanges, gaskets, centralizers and other features to substrates or cast parts by a solid-state additive manufacturing process is disclosed. Joining can be between same or different materials using same, similar or dissimilar filler material than the materials of the feature and the part that need to be joined.

Abstract: Solid-state additive manufacturing processes for joining dissimilar materials and parts are described. Processes include feeding a first material through a hollow tool of a solid-state additive manufacturing machine to contact a second material, generating deformation of the materials by applying normal, shear and/or frictional forces using a rotating shoulder of the tool such that the materials are in a malleable and/or visco-elastic state in an interface region, and mixing and joining the materials in that region. The joining can include interlocks of various shapes in the interface region. One or multiple taggants can be included in deposited material and/or layers, which taggants respond when triggered by specific external stimulus, such as becoming visible upon subjecting to light of a particular wavelength, heating, electric field, and so on. Some taggants are capable of multiple levels of security effects which can be seen by the naked eye or by using special detectors/readers.

Abstract: A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations.

Abstract: A solid-state additive manufacturing additive manufacturing system applicable to building up 3D structures, coating and functionalizing surfaces, joining structures, adding customized features to objects, compounding proprietary compositions and repairing various structures is disclosed. The solid-state additive manufacturing system enables deposition of different fillers, viz. metals, metal alloys, MMCs, polymers, plastics, composites, hybrids and gradient compositions, as well as controls the resulting deposit structures, e.g. specific nano-/micro-, gradient- and porous-material structures. The system accommodates various feeding-, spindle- and tool-designs for depositing different forms of filler materials, viz. rods, wires, granules, powders, powder-filled-tubes, scrap pieces or their combination, and a working platform with multiple access points.

Abstract: A technique facilitates joining of components without subsequent heat treatments. The components are joined by using a friction stir process which establishes a desired friction stir region at an appropriate location to securely join the desired components. In well applications, various components of sand screen assemblies may be joined by the friction stir process. For example, metal sand screen components may be securely coupled with a corresponding metal base pipe. The joining technique enables retention of the corrosion resistant properties of the materials without applying post weld heat treatments and/or other subsequent treatments.

Abstract: Solid-state joining of preformed features, such as bosses, flanges, gaskets, centralizers and other features to substrates or cast parts by a solid-state MELD additive manufacturing process is disclosed. Joining can be between same or different materials using same, similar or dissimilar filler material than the materials of the feature and the part that need to be joined.