Abstract: An additively manufactured alloy component has a first portion formed of the alloy and having a first grain size, and a second portion formed of the alloy and having a second grain size smaller than the first grain size. In an embodiment, the alloy component is an alloy turbine disk, the first portion is a rim region of the alloy turbine disk, and the second portion is a hub region of the alloy turbine disk. The first and second grain sizes may be achieved by controllably varying the laser power and/or scan speed during additive manufacturing.

Abstract: A process of forming a MAXMET composite coating or component on an article, that in the case of components can be removed, comprising providing an article having a substrate. The process includes providing at least one powder containing the MAXMET composite, wherein the MAXMET composite comprises a mixture of MAX phase particles and metal. Cold spraying the at least one powder on the substrate at a critical velocity. Forming a layer of the MAXMET composite on the substrate.

Abstract: A method of making an article using an additive manufacturing technique includes depositing a powder. The powder includes particles formed from an article material and having particle surfaces. A coating formed from a sacrificial coating is deposited over the particle surface. The sacrificial material has a composition that is different from the composition of the article material and is separated from the article material during fusing of the article material into a layer of an additively manufactured article.

Abstract: A structure includes a first substrate and a variable grain layer disposed on or formed into the first substrate. The variable grain layer includes a first grain portion having a first grain size and second grain portion having a second grain size. The first grain size is smaller than the second grain size.

Abstract: A method for processing a powder material includes feeding a powder material through an additive processing machine to deposit multiple layers of the powder material onto one another and using an energy beam to thermally fuse selected portions of the layers to one another with reference to data relating to a particular cross-section of an article being formed. The powder material has spherical metal particles and a spaced-apart distribution of ceramic nanoparticles attached to the surfaces of the particles. The ceramic nanoparticles form a dispersion of reinforcement through the formed article.

Abstract: A process comprising providing a metallic first powder having a plurality of first particles. The process includes adding a second material to the first powder, the second material having a plurality of second particles. The process includes combining the first powder with the second material to form a modified powder including modified powder particles having an interior portion containing an interior composition, and an outer surface portion with an outer composition different from the interior composition.

Abstract: A structural panel includes a first skin, a second skin and a core. The core is connected to the first skin and the second skin. The core includes a corrugated sheet of wire mesh that includes a plurality of corrugations. Each of the corrugations extends vertically between and engages the first skin and the second skin.

Abstract: A pressure vessel assembly includes a plurality of lobes, each lobe having at least one vertically arranged interior wall, the lobes positioned in a side by side arrangement such that a first interior wall of a first lobe is positioned adjacent a second interior wall of a second lobe, the first interior wall having a first wall top and bottom side, the second interior wall having a second wall top and bottom side, the first wall top side joined to the second wall top side and the first wall bottom side joined to the second wall bottom side. Also included are first and second end wall surfaces of each of the plurality of lobes. Further included is a plurality of end caps, each of the end caps joined to the end wall surfaces of the lobes, each of the end caps joined to at least one adjacent end cap.

Abstract: A method for heat treating metal alloy powder includes (a) introducing metal alloy powder to a chamber having a floor and a sidewall; (b) flowing a fluidizing gas through the floor and into the chamber to fluidize the metal alloy powder in the chamber; (c) flowing an additional gas through the sidewall into the chamber; and (d) heating the chamber to heat treat the metal alloy powder in the chamber. A system for heat treating metal alloy powder includes an inner chamber having a porous floor and a porous sidewall; an outer chamber, the inner chamber being inside of the outer chamber and defining an annular space between the outer chamber and the inner chamber, wherein the outer chamber and the inner chamber are inside a furnace; a source of fluidizing gas connected to the porous floor through the annular space; and a source of additional gas communicated with the porous sidewall through the annular space.

Abstract: A system for treatment of atomized powder including a fluidized bed operable to treat feedstock alloy powders. A method of treating atomized powder including communicating an inert gas into a fluidized bed; communicating an atomized powder into the fluidized bed; and heating the atomized powder in the fluidized bed, eject the treated powders out of the fluidized bed to quench the powders.

Abstract: A method for processing a powder material includes cleaning surfaces of a powder material that has spherical metal particles, coating the cleaned surfaces with an organic bonding agent, mixing the coated particles with a dispersion that contains ceramic nanoparticles, drying the mixture to remove a carrier of the dispersion and deposit the ceramic nanoparticles with a spaced-apart distribution onto the organic bonding agent on the surfaces of the particles, and thermally removing the organic bonding agent to attach the ceramic nanoparticles to the surface of the particles.

Abstract: An electrical device includes an electromagnetic component configured to generate a magnetic flux. The electromagnetic component includes a soft magnetically-conductive material configured to pass magnetic flux therethrough along a flux path. The soft magnetically-conductive material includes at least one grain oriented portion having metal grains that are oriented parallel with respect to the magnetic flux.

Abstract: A particulate for an additive manufacturing technique includes a particulate body formed from a particulate material and a coating disposed over particulate body. The coating includes a carbonaceous material that has a reflectivity that is lower than a reflectivity of the particulate material to reduce an energy input requirement of the particulate such that less energy is necessary to fuse the particulate into a layer of an article fabricated using the additive manufacturing technique. A method of making particulate is also disclosed.

Abstract: A method for processing a powder material includes cleaning surfaces of a powder material that has spherical metal particles, coating the cleaned surfaces with an organic bonding agent, mixing the coated particles with a dispersion that contains ceramic nanoparticles, drying the mixture to remove a carrier of the dispersion and deposit the ceramic nanoparticles with a spaced-apart distribution onto the organic bonding agent on the surfaces of the particles, and thermally removing the organic bonding agent to attach the ceramic nanoparticles to the surface of the particles.

Abstract: A process of forming a MAXMET composite coating or component on an article, that in the case of components can be removed, comprising providing an article having a substrate. The process includes providing at least one powder containing the MAXMET composite, wherein the MAXMET composite comprises a mixture of MAX phase particles and metal. Cold spraying the at least one powder on the substrate at a critical velocity. Forming a layer of the MAXMET composite on the substrate.