Abstract: A method for characterization of metallic powder including presenting a metallic powder sample to a laser and detector system, wherein the metallic powder sample passes through the laser and detector system via a sample introducer; applying a pulsed laser beam to a first location in the metallic powder sample to provide a first micro-plasma at the first location in the metallic powder sample when the pulsed laser beam terminates, the micro-plasma cools to provide spectral emissions at the first location; collecting the spectral emissions at the first location in the metallic powder sample with a detector; analyzing the spectral emissions at the first location to provide a spectral analysis dataset; and identifying inclusions at the first location in the metallic powder sample.

Abstract: An electromagnetic field separation system for separation of metallic powders including a sample introducer, wherein the sample to be introduced comprises particles; a first separator, wherein the first separator is configured to provide a differential charge to the particles of the sample; an electromagnetic separation stage comprising a second separator, wherein the second separator provides an electromagnetic field configured to separate the particles of the sample; and a recovery stage.

Abstract: A method includes identifying at least one region-of-interest (ROI) of an article that is to be additively manufactured by powder bed fusion, determining a thermal profile of the ROI, where the thermal profile includes at least a maximum temperature and a cooling rate, determining a geometry of an insulation layer upon which at least one process-equivalent test specimen (PETS) is to be additively manufactured by powder bed fusion such that a thermal profile of the at least one PETS replicates the thermal profile of the at least one ROI, and fabricating the at least one PETS in accordance with the thermal profile of the PETS by using the determined geometry of the insulation layer such that the at least one PETS and the at least one ROI are metallurgically equivalent.

Abstract: A method for location-specific probabilistic prediction of formation of a defect in powder bed fusion additive manufacturing of an article includes determining first statistical distributions of multiple process parameters selected from laser power, scan speed, laser spot size, and powder layer thickness and density, based on the first statistical distributions, for locations across the article, determining second statistical distributions of a threshold temperature (Tthresh) for formation of the defect at each of the locations, determining a cumulative temperature thermal history (T0) at each of the locations across the article, for each of the locations across the article, determining a probability of formation of the defect based upon a probability of Tthresh versus T0, and from the probability of formation of the defect at each of the locations, generating an article integrity map.

Abstract: A corrosion analysis assembly including a computed tomography scanner positioned relative to a component, the computed tomography scanner configured to non-destructively scan a section of the component to identify corrosion sites and measure spatially resolved characteristic parameters for the corrosion sites to provide a corrosion data set.

Abstract: A method for non-destructive testing and measurement of corrosion attacks includes defining characteristic corrosion attack parameters, exposing a first specimen to corrosive conditions to induce multiple corrosion attack sites, measuring the time of exposure to corrosive conditions, measuring one or more spatially resolved corrosion attack characteristic parameters for the multiple corrosion attack sites to provide a first corrosion data set. The first set of spatially resolved corrosion attack characteristic parameters are measured by a non-destructive technique and the probability of failure for the first specimen from the first corrosion data set is modeled. The composition of the specimen may be changed based on results achieved.

Abstract: The present disclosure provides improved additive manufacturing methods and systems. More particularly, the present disclosure provides advantageous additive manufacturing methods and systems for the production of hierarchical design optimized components (e.g., composite or composite-like materials). The present disclosure provides a methodology to produce hierarchical design optimized additively manufactured parts/materials that include an inhomogeneous structure with variable local mechanical properties across the entire volume. Hierarchical inhomogeneous structure/composite materials can be produced through a laser powder bed fusion (LPBF) process. A novel LPBF method can be used to obtain location-specific properties through in-situ controlling of the local cooling rate during the additive manufacturing process.

Abstract: The present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals. More particularly, the present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals using multiple heating sources. A hybrid modeling-test approach can be used in the design process to improve or optimize the process parameters to achieve location specific and improved/optimal microstructure and residual stress to enhance the part performance. It is also noted that performing the selective heat treatment in a single step can reduce the cycle time significantly. Moreover, large thermal gradients can be avoided in the part as different volumes of the part are heated to their desired temperature simultaneously.

Abstract: The present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals. More particularly, the present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals using multiple induction heating coils. A hybrid modeling-test approach can be used in the design process to improve or optimize the process parameters to achieve location specific and improved/optimal microstructure and residual stress to enhance the part performance. It is also noted that performing the selective heat treatment in a single step can reduce the cycle time significantly. Moreover, large thermal gradients can be avoided in the part as different volumes of the part are heated to their desired temperature simultaneously.

Abstract: The present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals. More particularly, the present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals using a coil-in-furnace configuration. A hybrid modeling-test approach can be used in the design process to improve or optimize the process parameters to achieve location specific and improved/optimal microstructure and residual stress to enhance the part performance. It is also noted that performing the selective heat treatment in a single step can reduce the cycle time significantly. Moreover, large thermal gradients can be avoided in the part as different volumes of the part are heated to their desired temperature simultaneously.

Abstract: Examples described herein provide a method that includes receiving weld data about a weld. The method further includes analyzing, using a physics-based model, the weld data to predict a formation of a defect in the weld. The method further includes providing feedback to enable process optimization during a design stage or active control during welding to control a welding machine to correct for and eliminate the formation of the defect in the weld.

Abstract: Disclosed herein is a suspension plasma spray process that comprises suspending metal oxide particles in a carrier fluid to produce a suspension. The suspension is ejected onto a substrate via a plasma flame. The particles are evaporated in the plasma flame to form a gaseous ceramic during their travel to the substrate. The gaseous ceramic is deposited on the substrate to form columnar grains.

Abstract: The present disclosure provides advantageous probabilistic models and applications for component (e.g., titanium component) design optimization, and related methods of use. More particularly, the present disclosure provides advantageous probabilistic models, systems and applications for component design optimization and related methods of use, and where the probabilistic models, systems and applications can accurately predict the life/failure of components (e.g., titanium components) based on material microstructure statistics and/or product mission specifics and/or variations. Disclosed are probabilistic systems and methods for predicting dwell fatigue behavior of a component (e.g., titanium component). The present disclosure advantageously provides an analytical modeling framework that captures the various physics-based mechanisms for dwell fatigue damage accumulation, crack nucleation, crack propagation and fracture in components or materials (e.g., anisotropic components/materials).

Abstract: Aspects of the disclosure are directed to an analysis of a material of a component. A radiation source is activated to transmit radiation to the component. A beam pattern is obtained based on the component interfering with the radiation. The beam pattern is compared to a reference beam pattern. An anomaly is detected to exist in the material when the comparison indicates a deviation between the beam pattern and the reference beam pattern.

Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.

Abstract: A heat exchanger includes an additively manufactured manifold. The manifold includes an inlet feed manifold and an outlet feed manifold, and a plurality of hypotubes fluidly coupled to the manifold. The hypotubes are round in cross-section, wherein each of the hypotubes has a diameter that has a first value between 0.03 inches and 0.3 inches, and wherein each of the hypotubes has a wall thickness that has a second value between 0.001 inches and 0.0.015 inches.

Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.

Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.

Abstract: Aspects of the disclosure are directed to an analysis of a material of a component. A radiation source is activated to transmit radiation to the component. A beam pattern is obtained based on the component interfering with the radiation. The beam pattern is compared to a reference beam pattern. An anomaly is detected to exist in the material when the comparison indicates a deviation between the beam pattern and the reference beam pattern.

Abstract: An x-ray diffraction system includes an x-ray source having a first interchangeable x-ray generating component, a second interchangeable x-ray generating component, an actuator and a controller operatively connected to the actuator. The first and second interchangeable x-ray generating components are interchangeable with one another. The actuator is operatively connected to the first and second interchangeable x-ray generating components.