Abstract: A process for providing a manufacturing modality for a hybrid article includes defining a model for a build surface on a part in a three dimensional space, and defining a model for an additive structure, the model including an interface surface of the additive structure that corresponds with the build surface in the three dimensional space. The process further includes orienting the x, y and z coordinates of each of the build surface of the part and the interface surface of the model in relation to a three dimensional work space, aligning contours of each of the build surface and the interface surface relative to the work space, and directing a cladding system to define toolpaths for two or more cladding layers that are defined by vertical planar segments or slices of the additive structure model.

Abstract: A process for providing a manufacturing modality for a hybrid article includes defining a model for a build surface on a part in a three dimensional space, and defining a model for an additive structure, the model including an interface surface of the additive structure that corresponds with the build surface in the three dimensional space. The process further includes orienting the x, y and z coordinates of each of the build surface of the part and the interface surface of the model in relation to a three dimensional work space, aligning contours of each of the build surface and the interface surface relative to the work space, and directing a cladding system to define toolpaths for two or more cladding layers that are defined by vertical planar segments or slices of the additive structure model.

Abstract: A method for manufacturing a rotary article comprises: providing a cold metal transfer welding apparatus comprising a welding torch; providing a rotary substrate; providing a digital representation of the rotary article having at least one internal flo passage; defining a welding path on the rotary substrate based on the digital representation; rotating the rotary substrate while depositing a filler metal layer by layer on the welding path of the rotary substrate to form the rotary article; and separating the rotary substrate from the rotary article.

Abstract: A method for manufacturing a rotary article comprises: providing a cold metal transfer welding apparatus comprising a welding torch; providing a rotary substrate; providing a digital representation of the rotary article having at least one internal flow passage; defining a welding path on the rotary substrate based on the digital representation; rotating the rotary substrate while depositing a filler metal layer by layer on the welding path of the rotary substrate to form the rotary article; and separating the rotary substrate from the rotary article.

Abstract: A powder micro-spark deposition system is provided. The deposition system includes an electrode and a powder feed channel configured within or at least partially surrounding the electrode for guiding powder comprising electrically conductive material into a gap between the electrode and the substrate. A powder micro-spark deposition method is also provided.

Abstract: An apparatus for controlling a machining system is provided. The apparatus include an optical unit configured to capture an image of an object based upon radiation generated from the object and an image processing unit configured to process the image and to obtain real-time estimation of parameters associated with manufacture or repair of the object. The apparatus also includes a process model configured to establish target values for the parameters associated with the manufacture or repair of the object based upon process parameters for the machining system and a controller configured to control the process parameters for the machining system based upon the estimated and target values of the parameters associated with the manufacture or repair of the object.