Abstract: A method of manufacturing an (AM) component includes generating a computer-aided design (CAD) model of target AM component having a target physical profile, and predicting deformation of a target area that is expected to realize deformation. The method further includes determining a pre-deformed profile of witness lines that are to be formed in the target area based on the predicted deformation of the target area and that are expected to deform into a target profile indicating the target physical profile is met. The method further includes performing an AM component build to build the AM component and form pre-deformed witness lines having the pre-deformed profile in the target area.

Abstract: A method of additively manufacturing a component is provided and includes generating a three-dimensional (3D) model of the component, generating a heat map of the 3D model which is illustrative of thermal effects the component is expected to experience, updating the 3D model to include 3D heat exchange fin models for reducing the thermal effects and updating the 3D model with the 3D heat exchange fin models to include 3D weight reduction cavity models for weight-neutralizing the 3D heat exchange fin models.

Abstract: A method of manufacturing an (AM) component includes generating a computer-aided design (CAD) model of target AM component, and determining a target machining area on the target AM component. The target machining area is designated to receive a machining process. The method further comprises determining a witness line region corresponding to the target machining area of the component, and performing an AM component build to build the AM component and form a plurality of textured witness lines in the witness line region.

Abstract: A method of additively manufacturing a component is provided. The method includes generating a three-dimensional (3D) model of the component, generating a first heat map of the 3D model which is illustrative of first thermal effects the component is expected to experience during additive manufacturing, generating a second heat map of the 3D model which is illustrative of second thermal effects the component is expected to experience during operational use, updating the 3D model to include 3D heat exchange fin models for reducing each of the first and second thermal effects and updating the 3D model with the 3D heat exchange fin models to include 3D weight reduction cavity models for weight-neutralizing the 3D heat exchange fin models.

Abstract: A method of additive manufacturing of a component is provided. The method includes building up the component to have a first uppermost layer and a foundation to have a second uppermost layer below the first uppermost layer, evacuating powder from around the component and the foundation to expose the second uppermost layer, disposing, on the second uppermost layer, a forged flange having an upper surface coplanar with the first uppermost layer, backfilling powder about the component and the forged flange, applying a thin additive manufacturing layer to the upper surface and completing a building up of the component by building up on the thin additive manufacturing layer.

Abstract: A method of additive manufacturing of a component is provided and includes building up the component to have a first uppermost layer and a foundation to have a second uppermost layer below the first uppermost layer, evacuating powder from around the component and the foundation to expose the second uppermost layer, disposing, on the second uppermost layer, a forged flange having an upper surface coplanar with the first uppermost layer, backfilling powder about the component and the forged flange and completing a building up of the component by building up on the forged flange.

Abstract: The present disclosure is directed towards different embodiments of additively manufacturing and smoothing an AM preform to configure an AM preform for downstream processing (working, forging, and the like).

Abstract: In some embodiments, an exemplary method directed toward non-destructive methods of inspecting additively manufactured parts includes: additively manufacturing a metal part, the metal part configured with an additive manufacturing grain structure indicative of the type of additive process utilized to construct the metal part, wherein the grain structure is configured with a first ultrasonic signal attenuation level when assessed via ultrasonic inspection; imparting an amount of strain on the metal part to transform the additive manufacturing grain structure having a first ultrasonic signal attenuation level to a grain structure having second ultrasonic signal attenuation level, wherein the second ultrasonic signal attenuation level is lower than the first ultrasonic signal attenuation level; and inspecting the metal part via a non-destructive testing evaluation method to confirm whether the metal part passes a part build specification.

Abstract: The present disclosure relates to new metal powders for use in additive manufacturing, and aluminum alloy products made from such metal powders via additive manufacturing. The composition(s) and/or physical properties of the metal powders may be tailored. In turn, additive manufacturing may be used to produce a tailored aluminum alloy product.

Abstract: The present disclosure relates to new metal powders, wires and other physical forms for use in additive manufacturing, welding and cladding, and multi-component alloy products made from such metal powders, wires and forms via additive manufacturing, welding and cladding. The composition(s) and/or physical properties of the metal powders, wires or forms may be tailored. In turn, additive manufacturing, welding and cladding may be used to produce a tailored multi-component alloy product.

Abstract: Wires for use in electron beam or plasma arc additive manufacturing of titanium alloys are disclosed. The wires have a first portion comprising a first material, and a second portion comprising a second material. The combination of the first and second materials results in a titanium alloy product of the appropriate composition.

Abstract: The present disclosure is directed towards different embodiments of additively manufacturing and smoothing an AM preform to configure an AM preform for downstream processing (working, forging, and the like).

Abstract: Generally, the present disclosure is directed various embodiments to additively manufacture AM preforms to reduce, prevent, and/or eliminate defects that occur in post processing operations (e.g. forging, shot peening, machining, or other post processing operations).

Abstract: A method, article of manufacture, and system for joining different materials is described. In a principal embodiment, two articles, for example different metals, are placed in proximity to one another with an interfacial area. One article is heated using a laser that is scanned across from a point remote from the interface to a point at or just short of the interface. In embodiments, the interfacial bond region is characterized by a homogenous mixed phase region with very low to substantially no brittle intermetallics.

Abstract: The present disclosure relates to aluminum-based products having 1-30 vol. % of a ceramic phase. The aluminum alloy products may be produced via additive manufacturing techniques to facilitate production of the aluminum-based products having the 1-30 vol. % of the ceramic phase.

Abstract: The present disclosure relates to new metal powders for use in additive manufacturing, and aluminum alloy products made from such metal powders via additive manufacturing. The composition(s) and/or physical properties of the metal powders may be tailored. In turn, additive manufacturing may be used to produce a tailored aluminum alloy product.

Abstract: A method, article of manufacture, and system for joining different materials is described. In a principal embodiment, two articles, for example different metals, are placed in proximity to one another with an interfacial area. One article is heated using a laser that is scanned across from a point remote from the interface to a point at or just short of the interface. In embodiments, the interfacial bond region is characterized by a homogenous mixed phase region with very low to substantially no brittle intermetallics.