Abstract: A power distribution system element formed via an additive manufacturing technique, such as applying a conductive material to a memory metal substrate, are discussed herein. In operation (e.g. in response to delivering current through the distribution system), the memory metal contracts while the conductive material expands. The result is distribution system element having reduced thermal expansion, which can be net zero coefficient of thermal expansion.

Abstract: A method includes placing an additively manufactured article having one or more internal channels in a non-reactive liquid to remove remainder powder from within the one or more internal channels, wherein the non-reactive liquid is a gas at room temperature and/or pressure. Placing the additively manufactured article in the non-reactive liquid includes can include placing the additively manufactured article in liquid nitrogen.

Abstract: A method includes issuing a state change fluid into an internal passage of an additively manufactured article and causing the state change fluid to change from a first state having a first viscosity to a second state that is either solid or has a second viscosity that is higher than the first viscosity within the internal passage. The method can also include causing the state change fluid to change back from the second state to the first state and flushing the state change fluid from the internal passage to remove residual powder from the additively manufactured article.

Abstract: Embodiments are directed to obtaining a specification of at least one operational requirement for at least one capacitor, generating a design of the at least one capacitor to satisfy the at least one operational requirement, the design of the at least one capacitor comprising a plurality of layers and a first integrated busbar coupled to at least a portion of the layers, and based on the design, manufacturing the at least one capacitor by utilizing an additive manufacturing technique.

Abstract: A method for forming a part includes: forming a first portion of the part at a first level; forming a second portion of the part at a second level; wherein forming the first and second portions includes exposing the first and second levels to a sintering process and portions of the first and second levels to an electron beam; causing a magnetorheological (MR) fluid to move into a passage inside the first and second portions; exposing the first and second portions to a magnetic field causing motion of particles in the MR fluid to move and break up sintered material in the passage; and removing some or all of the sintered material in the passage.

Abstract: A Litz wire terminal assembly includes a wire bundle having a plurality of electrically conductive strands extending between a first end and a second end to define a length. Each strand includes an insulative cover having a proximate cover end at the first end and a distal cover end at the second end. The distal cover end is flush with the second end. The Litz wire terminal assembly further includes a ferrule on the wire bundle. The ferrule has a distal ferrule end at the second end of the conductive strands.

Abstract: Housing for electrical components includes a housing body, an insulating body and a bus bar. The insulating body is disposed within the housing body and is integral with the housing body. The bus bar is disposed within the within the housing body and embedded in the insulating body. The insulating body and housing body are integral with one another for fixing the bus bar within the housing body.

Abstract: Embodiments are directed to obtaining a specification of at least one operational requirement for at least one capacitor, generating a design of the at least one capacitor to satisfy the at least one operational requirement, the design of the at least one capacitor comprising a plurality of layers and a first integrated busbar coupled to at least a portion of the layers, and based on the design, manufacturing the at least one capacitor by utilizing an additive manufacturing technique.

Abstract: A part identification system includes a part made of at least a first material having a first density, and an identifier made of a second material embedded in the first material and having a second density greater than the first density, and wherein the identifier is visually invisible. A security reader of the system is constructed and arranged to read the identifier and may be a radiographic reader. A method of manufacturing the part may include additive manufacturing.

Abstract: A method for making an article is disclosed. The method involves first generating a digital model of the article. The digital model is inputted into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder includes an aluminum alloy having 78.80-92.00 wt. % aluminum, 5.00-6.00 wt. % copper, 2.50-3.50 wt. % magnesium, 0.50-1.25 wt. % manganese, 0-5.00 wt. % titanium, 0-3.00 wt. % boron, 0-0.15 wt. % vanadium, 0-0.15 wt. % zirconium, and 0-0.25 wt. % silicon, 0-0.25 wt. % iron, 0-0.50 wt. % chromium, 0-1.0 wt. % nickel, and 0-0.15 wt. % other alloying elements, based on the total weight of the aluminum alloy.

Abstract: A method for making an article is disclosed. The method involves first generating a digital model of the article. The digital model is inputted into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder includes an aluminum alloy having 83.35-93.00 wt. % aluminum, 6.00-8.00 wt. % silicon, 1.00-3.00 wt. % magnesium, 0-0.50 wt. % iron, 0-0.50 wt. % manganese, 0-2.00 wt. % titanium, 0-0.50 wt. % boron, 0-1.50 wt. % nickel, 0-0.25 wt. % vanadium, 0-0.25 wt. % zirconium, and 0-0.15 wt. % other alloying elements, based on the total weight of the aluminum alloy.

Abstract: A method for making an article is disclosed. The method involves first generating a digital model of the article. The digital model is inputted into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder includes an aluminum alloy having 90.15-95.80 wt. % aluminum, 3.00-4.50 wt. % silicon, 0.70-1.50 wt. % magnesium, 0.50-1.00 wt. % manganese, 0-0.50 wt. % iron, 0-0.10 wt. % copper, 0-0.50 wt. % titanium, 0-0.20 wt. % boron, 0-1.50 wt. % nickel, and 0-0.05 wt. % other alloying elements, based on the total weight of the aluminum alloy.

Abstract: A method for making an article is disclosed. The method involves first generating a digital model of the article. The digital model is inputted into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder includes an aluminum alloy having 85.20-96.40 wt. % aluminum, 2.50-4.00 wt. % magnesium, 0.10-0.50 wt. % copper, 0.50-1.00 wt. % nickel, 0.50-5.50 wt. % zinc, 0-0.15 wt. % chromium, 0-3.00 wt. % titanium, 0-0.50 wt. % boron, and 0-0.15 wt. % other alloying elements, based on the total weight of the aluminum alloy.

Abstract: A cold plate assembly is provided having a base defining a cooling channel and a heat exchanger friction-stir welded to the base, wherein the heat exchanger is located within a portion of the cooling channel, and the friction-stir welding between the heat exchanger and the base forms a fluid seal.

Abstract: A particulate feedstock for an additive manufacturing process includes particles formed from an aluminum base alloy. The alloy includes both aluminum and copper, and the amount of aluminum in the alloy is greater than the amount of copper in the alloy as a percentage of total weight. The alloy also includes at least one other material including at least one of magnesium manganese, titanium, nickel, and boron. The amount of copper in the alloy is greater than the amounts of each of the magnesium, manganese, titanium, nickel, and/or boron included in the alloy to render the particulate amenable to high energy density joining techniques.

Abstract: A method of forming an air data probe comprises the steps of utilizing an additive manufacturing technique to lay down a portion of a wall of an air data probe, and also utilizing an additive manufacturing technique to lay down a conductive portion of a heater element within the wall. An air data probe is also disclosed.

Abstract: An inspection method include introducing a mixture of expanding foam and a particulate material into a region of interest of an object, fixing the powder within the region of the interest relative to the object, and acquiring image data of the object and particulate mixture using an x-ray source and an x-ray detector. The particulate has a density that is greater than the density of a material forming the object to provide contrast between the region of interest and the object in an image generated using the image data.

Abstract: A method for forming a part. The method includes: forming a first portion of the part at a first level; forming a second portion of the part at a second level; wherein forming the first and second portions includes exposing the first and second levels to a sintering process and portions of the first and second levels to an electron beam; forming a wire in the passage formed inside the first and second portions by exposing a portion of the passage to the electron beam; applying a signal to the wire to break up sintered material in the passage; and removing the wire.

Abstract: An integrated circuit assembly element formed via an additive manufacturing technique, such as mixing a conductive material with a memory metal to form a portion of a substrate in desired locations, such as along the footprint of die, are discussed herein. In operation (e.g. in response to thermal cycling of the assembly) the memory metal contracts while the conductive material expands. The result is an element having reduced thermal expansion, which can be net zero coefficient of thermal expansion and/or be catered to the coefficient of thermal expansion of a desired material, such as the silicon die.

Abstract: A magnetic device includes an electrically insulating body and a conductor coil. The insulating body defines an internal cavity for a magnetic device core and a coolant channel routed about the internal cavity. The conductor coil extends through the insulating body and winds about the internal cavity. The electrically insulating body electrically insulates the internal cavity and coolant channel from the conductor coil.