Abstract: An article includes a completed fabric structure that has multiple plies of fiber reinforced fabric. A first portion of the fabric structure has a three-directional fiber reinforced configuration and, exclusive of the first portion, a second portion of the fabric structure having a two-directional fiber reinforced configuration. In the three-directional fiber reinforced configuration there are multiple plies that are bound together via a matrix and a plurality of fibers normal through the multiple plies. In the two-directional fiber reinforced configuration the multiple plies are bound to one another via the matrix and not fibers normal through the multiple plies.

Abstract: A Selective Laser Melting (SLM) system includes an annular powder bed.

Abstract: An exhaust includes a wall that has a first composite material having a first coefficient of thermal expansion and a second composite material having a second coefficient of the thermal expansion that is less than the first coefficient of thermal expansion.

Abstract: An additive manufacturing assembly includes a work space including a plurality of separate regions and an energy transmitting device for focusing an energy beam to a specific location within one of the plurality of regions within the work space. The energy transmitting device includes features for expanding the workspace for fabricating parts of increased size and volume.

Abstract: An additive manufacturing machine includes a base plate for supporting fabrication of a desired part geometry. The base plate includes a support portion defined based on the desired part geometry and an open region that includes a plurality of openings surrounding the support portion. A material applicator deposits material onto the base plate and an energy directing device directs energy to form the deposited material into a desired part geometry. The additive manufacturing machine manages large amounts of material required for fabricating the part by defining a boundary surrounding a periphery of a desired part geometry and forming a retaining wall along the defined boundary and the desired part geometry to retain excess material between the formed wall and the part. Excess material outside of the retaining wall falls through the open area below the base plate and is reclaimed for reuse.

Abstract: An additive manufacturing process includes the steps of measuring a parameter of a part supported within a workspace after a heat treat or other stress relieving process. The measured parameter being a part characteristic that is desired to be within a desired range prior to proceeding with an additional fabrication process. The process further includes the step of applying at least one additional layer on the part based on the measured parameter to adjust the measured parameter to within the desired range.

Abstract: An additive manufacturing process performed by an additive manufacturing machine includes strain gauges that detect stress within a part during fabrication within a defined workspace. When the detected stress is exceeds a desired level the fabrication steps are paused and a stress relieving process is performed within the chamber without moving the part. The additive manufacturing machine includes heaters and coolers for changing the temperature within the chamber to perform the desired stress relieving process in the same space as fabrication is performed. Once it is confirmed that stresses within the part are within acceptable limits the part fabrication process is resumed.

Abstract: A method and system for depositing multiple materials onto a substrate is described. The method broadly comprises the steps of providing a source of a first powder material to be deposited, providing a source of a second powder material to be deposited, and sequentially depositing the first powder material and the second powder material onto the substrate at a velocity sufficient to deposit the materials by plastically deforming the materials without metallurgically transforming the particles of powder forming the materials.

Abstract: An exhaust includes a wall that has a first composite material having a first coefficient of thermal expansion and a second composite material having a second coefficient of the thermal expansion that is less than the first coefficient of thermal expansion.

Abstract: Methods are described for applying abradable material onto a seal backing material to form an abradable seal between rotating and stationary components of turbines using cold spray deposition technology to control the density, porosity and thickness of the sealing layer.

Abstract: A method of fabricating a combustion system includes cold depositing a starting material onto a substrate as a solid metal fuel to produce a combustion structure.

Abstract: A method of manufacturing homogenous metal matrix composite (MMC) powders and using the powders as the feedstock with cold spray deposition is described to produce composite coatings and freestanding bulk forms. Measured quantities of metal and ceramic powders having predetermined particle sizes are blended to produce homogeneous MMC powders. Spray parameters and procedures are controlled to produce dense, strong and well-bonded MMC coatings on any substrate.

Abstract: A process for forming an article, such as a combustion chamber liner, comprises the steps of providing a mandrel formed from a material, such as an aluminum containing material, having a net shape of the article to be made, depositing a powdered metal material onto the mandrel without melting the powdered metal material, and removing the material forming the mandrel to leave a free standing monolithic article. In a preferred embodiment of the present invention, the powdered metal material comprises powdered GRCop-84. Alternatively, the powdered metal material may be GRCop-42.

Abstract: A process for forming an article, such as a combustion chamber liner, comprises the steps of providing a mandrel formed from a material, such as an aluminum containing material, having a net shape of the article to be made, depositing a powdered metal material onto the mandrel without melting the powdered metal material, and removing the material forming the mandrel to leave a free standing monolithic article. In a preferred embodiment of the present invention, the powdered metal material comprises powdered GRCop-84. Alternatively, the powdered metal material may be GRCop-42.

Abstract: A nozzle for use in a cold spray technique is described. The nozzle has a passageway for spraying a powder material, the passageway having a converging section and a diverging section, and at least the diverging section being formed from polybenzimidazole. In one embodiment of the nozzle, the converging section is also formed from polybenzimidazole.

Abstract: A method of manufacturing homogenous metal matrix composite (MMC) powders and using the powders as the feedstock with cold spray deposition is described to produce composite coatings and freestanding bulk forms. Measure quantities of metal and ceramic powders having predetermined particle sizes are blended to produce homogeneous MMC powders. Spray parameters and procedures are controlled to produce dense, strong and well-bonded MMC coatings on any substrate.

Abstract: Methods are described for applying braze filler material onto a component part interface having a uniform thickness regardless of the interface contour using cold spray deposition technology.

Abstract: Methods are described for applying abradable material onto a seal backing material to form an abradable seal between rotating and stationary components of turbines using cold spray deposition technology to control the density, porosity and thickness of the sealing layer.

Abstract: A nozzle for use in a cold spray technique is described. The nozzle has a passageway for spraying a powder material, the passageway having a converging section and a diverging section, and at least the diverging section being formed from polybenzimidazole. In one embodiment of the nozzle, the converging section is also formed from polybenzimidazole.