Abstract: A structure is provided. The structure defines a first direction, a second direction, and a third direction, the three directions orthogonal to each other. The structure includes a first section, a second section, and a third section. The first section includes a plurality of unit cells joined together, wherein the first section has a first average tensile strength and a first average crack growth resistance. The second substantially solid section is within and surrounding each unit cell of the plurality of first section unit cells, wherein the second section has a second average tensile strength and a second average crack growth resistance, the second average tensile strength different from the first average tensile strength and the second average crack growth resistance different from the first average crack growth resistance. The third section surrounds the first section and the second section.

Abstract: Embodiments of the disclosure relate to the aligning of a melting beam source in an additive manufacturing (AM) system. Methods of the disclosure may include forming a first test article and a second test article of different shapes on a build plate. The method further includes measuring a vertical scale, vertical alignment, horizontal scale, and an alignment of the melting beam source using the first and second test articles. The method includes determining whether one of the vertical scale, the vertical alignment, the horizontal scale, or the horizontal alignment of the melting beam source is not within a corresponding tolerance of a target specification. If at least one of the vertical scale, the vertical alignment, the horizontal scale, or the horizontal alignment is within the corresponding tolerance, the method includes adjusting the melting beam source of the AM system to align the melting beam source to yield the target specification.

Abstract: Embodiments of the disclosure provide a test article for additive manufacture and related methods. A test article formed may include a body having a forward face and a rearward face horizontally opposite the forward face. A first surface extending between the forward face and the rearward face of the body may include a plurality of protrusions for removable coupling of the body to a build plate. A second surface on the body may extend between the forward face and the rearward face of the body, and may include a plurality of angled flat surface portions. Each of the plurality of angled flat surface portions may have a distinct angle with respect to a horizontal plane of the body. An angular difference between each adjacent angled flat surface portion in the plurality of angled flat surface portions is substantially uniform.

Abstract: An additive manufacturing (AM) system includes a build chamber, a base adjustably coupled to the build chamber, and a build material applicator for depositing a build material above a build platform for creating the object. The build platform includes a fixed region fixedly and rigidly coupled to the base and a flex region configured to flex relative to the base in response to a force applied to the build platform by an object. The partial flexibility allows deformation caused by thermal distortion of the build platform during use to reduce final object stress. The AM system can produce larger additively manufactured objects out of crack-prone material. In addition, the partial flexibility may prevent damage to the build platform and/or base without an overly complicated arrangement.

Abstract: Embodiments of the disclosure provide a test article for additive manufacture and related methods. A test article formed may include a body having a forward face and a rearward face horizontally opposite the forward face. A first surface extending between the forward face and the rearward face of the body may include a plurality of protrusions for removable coupling of the body to a build plate. A second surface on the body may extend between the forward face and the rearward face of the body, and may include a plurality of angled flat surface portions. Each of the plurality of angled flat surface portions may have a distinct angle with respect to a horizontal plane of the body. An angular difference between each adjacent angled flat surface portion in the plurality of angled flat surface portions is substantially uniform.

Abstract: An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component. The model includes a plurality of elements and at least one region of interest. The control system is also configured to apply a strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile for at least one element of the plurality of elements. The build characteristic contribution profile represents an effect of the strain load applied to the at least one element on a build characteristic of at least one location within the at least one region of interest. The control system is further configured to adjust a build parameter for a location within the component relating to the at least one element of the plurality of elements based on the build characteristic contribution profile.

Abstract: A structure is provided. The structure defines a first direction, a second direction, and a third direction, the three directions orthogonal to each other. The structure includes a first section, a second section, and a third section. The first section includes a plurality of unit cells joined together, wherein the first section has a first average tensile strength and a first average crack growth resistance. The second substantially solid section is within and surrounding each unit cell of the plurality of first section unit cells, wherein the second section has a second average tensile strength and a second average crack growth resistance, the second average tensile strength different from the first average tensile strength and the second average crack growth resistance different from the first average crack growth resistance. The third section surrounds the first section and the second section.

Abstract: A structure is provided. The structure defines a first direction, a second direction, and a third direction, the three directions orthogonal to each other. The structure includes a first section, a second section, and a third section. The first section includes a plurality of unit cells joined together, wherein the first section has a first average tensile strength and a first average crack growth resistance. The second substantially solid section is within and surrounding each unit cell of the plurality of first section unit cells, wherein the second section has a second average tensile strength and a second average crack growth resistance, the second average tensile strength different from the first average tensile strength and the second average crack growth resistance different from the first average crack growth resistance. The third section surrounds the first section and the second section.

Abstract: Turbine shrouds including shot peen screens integrally formed therein. The shroud may include a unitary body having a support portion coupled directly to a turbine casing of the turbine system, an intermediate portion integral with and extending away from the support portion, and a seal portion integral with the intermediate portion, opposite the support portion. The unitary body may also include an inlet opening(s) formed in the support portion, a plenum(s) in fluid communication with the inlet opening(s), and a cooling passage extending through the seal portion and in fluid communication with the plenum(s). Additionally, the unitary body may include a shot peen screen(s) positioned within the plenum(s) and extending within the intermediate portion. The shot peen screen(s) may include a plurality of voids formed therethrough and may prevents shot from passing through the shot peen screen(s) when performing a shot peening process on the unitary body.

Abstract: Turbine shrouds including shot peen screens integrally formed therein. The shroud may include a unitary body having a support portion coupled directly to a turbine casing of the turbine system, an intermediate portion integral with and extending away from the support portion, and a seal portion integral with the intermediate portion, opposite the support portion. The unitary body may also include an inlet opening(s) formed in the support portion, a plenum(s) in fluid communication with the inlet opening(s), and a cooling passage extending through the seal portion and in fluid communication with the plenum(s). Additionally, the unitary body may include a shot peen screen(s) positioned within the plenum(s) and extending within the intermediate portion. The shot peen screen(s) may include a plurality of voids formed therethrough and may prevents shot from passing through the shot peen screen(s) when performing a shot peening process on the unitary body.

Abstract: A structure is provided. The structure defines a first direction, a second direction, and a third direction, the three directions orthogonal to each other. The structure includes a first section, a second section, and a third section. The first section includes a plurality of unit cells joined together, wherein the first section has a first average tensile strength and a first average crack growth resistance. The second substantially solid section is within and surrounding each unit cell of the plurality of first section unit cells, wherein the second section has a second average tensile strength and a second average crack growth resistance, the second average tensile strength different from the first average tensile strength and the second average crack growth resistance different from the first average crack growth resistance. The third section surrounds the first section and the second section.