Abstract: This disclosure relates to a component formed using an additive manufacturing process. Further disclosed is a method for providing a component for use with a combustion device. In the method, a component formed using an additive manufacturing process is provided. The component is left with a plurality of powder particles only partially fused to an internal passage thereof as a result of the additive manufacturing process. The method further includes removing the partially fused powder particles from the internal passage with a thermal energy process.

Abstract: A method of forming a nanocomposite thermoelectric material having microstructural stability at temperatures greater than 1,000° C. The method includes creating nanocrystalline powder by cryomilling. The method is particularly useful in forming SiGe alloy powder.

Abstract: Disclosed is a method of manufacturing an airfoil. The method includes establishing an Argon (Ar)-free environment, providing a bed within the Argon free environment, providing a set of data instructions for manufacturing the airfoil, and providing a powdered Nickel (Ni)-based alloy on the bed. In one example, the powdered Nickel (Ni)-based alloy consists essentially of about 4.8 wt. % Iron (Fe), about 21 wt. % Chromium (Cr), about 8.6 wt. % Molybdenum (Mo), about 0.07 wt. % Titanium (Ti), about 0.40% Aluminum (Al), about 5.01 wt. % Niobium (Nb), about 0.03 wt. % Carbon (C), about 0.14 wt. % Silicon (Si), and a balance Nickel (Ni). The method further includes fusing the powdered Nickel (Ni)-based alloy with an electron beam with reference to the data instructions to form the airfoil.

Abstract: An additive manufacturing assembly includes a work space including a plurality of separate regions and an energy transmitting device for focusing an energy beam to a specific location within one of the plurality of regions within the work space. The energy transmitting device includes features for expanding the workspace for fabricating parts of increased size and volume.

Abstract: An additive manufacturing process includes the steps of measuring a parameter of a part supported within a workspace after a heat treat or other stress relieving process. The measured parameter being a part characteristic that is desired to be within a desired range prior to proceeding with an additional fabrication process. The process further includes the step of applying at least one additional layer on the part based on the measured parameter to adjust the measured parameter to within the desired range.

Abstract: An additive manufacturing process performed by an additive manufacturing machine includes strain gauges that detect stress within a part during fabrication within a defined workspace. When the detected stress is exceeds a desired level the fabrication steps are paused and a stress relieving process is performed within the chamber without moving the part. The additive manufacturing machine includes heaters and coolers for changing the temperature within the chamber to perform the desired stress relieving process in the same space as fabrication is performed. Once it is confirmed that stresses within the part are within acceptable limits the part fabrication process is resumed.

Abstract: An additive manufacturing machine includes a base plate for supporting fabrication of a desired part geometry. The base plate includes a support portion defined based on the desired part geometry and an open region that includes a plurality of openings surrounding the support portion. A material applicator deposits material onto the base plate and an energy directing device directs energy to form the deposited material into a desired part geometry. The additive manufacturing machine manages large amounts of material required for fabricating the part by defining a boundary surrounding a periphery of a desired part geometry and forming a retaining wall along the defined boundary and the desired part geometry to retain excess material between the formed wall and the part. Excess material outside of the retaining wall falls through the open area below the base plate and is reclaimed for reuse.

Abstract: A thermal expansion compensator is provided and includes a first electrode structure having a first surface, a second electrode structure having a second surface facing the first surface and an elastic element bonded to the first and second surfaces and including a conductive element by which the first and second electrode structures electrically and/or thermally communicate, the conductive element having a length that is not substantially longer than a distance between the first and second surfaces.

Abstract: A method of forming a nanocomposite thermoelectric material having microstructural stability at temperatures greater than 1,000° C. The method includes creating nanocrystalline powder by cryomilling. The method is particularly useful in forming SiGe alloy powder.

Abstract: An electrode including a first portion to be electrically coupled to a first thermoelectric leg and mechanically coupled to a first heat collector part, a second portion to be electrically coupled to a second thermoelectric leg and mechanically coupled to a second heat collector part and a flexible portion connected between the first and second portions whereby current is transmittable between the first and second thermoelectric legs.

Abstract: A thermal expansion compensator is provided and includes a first electrode structure having a first surface, a second electrode structure having a second surface facing the first surface and an elastic element bonded to the first and second surfaces and including a conductive element by which the first and second electrode structures electrically and/or thermally communicate, the conductive element having a length that is not substantially longer than a distance between the first and second surfaces.

Abstract: A thermal expansion compensator is provided and includes a first electrode structure having a first surface, a second electrode structure having a second surface facing the first surface and an elastic element bonded to the first and second surfaces and including a conductive element by which the first and second electrode structures electrically and/or thermally communicate, the conductive element having a length that is not substantially longer than a distance between the first and second surfaces.

Abstract: A thermal expansion compensator is provided and includes a first electrode structure having a first surface, a second electrode structure having a second surface facing the first surface and an elastic element bonded to the first and second surfaces and including a conductive element by which the first and second electrode structures electrically and/or thermally communicate, the conductive element having a length that is not substantially longer than a distance between the first and second surfaces.