Abstract: A system includes a powder reuse system (PRS) executable via a processor and configured to receive one or more inputs for a build of a first machine component in a sintering system. The PRS is further configured to retrieve a model configured to model a reuse of a sintering powder, and to derive a time during which a surplus unsintered powder left after printing the machine component via the sintering system using the sintering powder may be reused to build a second machine component by applying the one or more inputs to the model.

Abstract: A method includes applying a material coating on a surface of a machine component using a thermal spray, wherein the material coating is formed from a combination of a hardfacing material and aluminum-containing particles. The method also includes thermally treating the material coating to generate an oxide layer comprising aluminum from the aluminum-containing particles, wherein the oxide layer is configured to reduce oxidation of the hardfacing material.

Abstract: A method includes applying a material coating on a surface of a machine component using a thermal spray, wherein the material coating is formed from a combination of a hardfacing material and aluminum-containing particles. The method also includes thermally treating the material coating to generate an oxide layer comprising aluminum from the aluminum-containing particles, wherein the oxide layer is configured to reduce oxidation of the hardfacing material.

Abstract: A method includes applying a material coating on a surface of a machine component using a thermal spray, wherein the material coating is formed from a combination of a hardfacing material and aluminum-containing particles. The method also includes thermally treating the material coating to generate an oxide layer comprising aluminum from the aluminum-containing particles, wherein the oxide layer is configured to reduce oxidation of the hardfacing material.

Abstract: A method includes applying a material coating on a surface of a machine component using a thermal spray, wherein the material coating is formed from a combination of a hardfacing material and aluminum-containing particles. The method also includes thermally treating the material coating to generate an oxide layer comprising aluminum from the aluminum-containing particles, wherein the oxide layer is configured to reduce oxidation of the hardfacing material.

Abstract: A method of making a component with an integral strain indicator includes forming the component from a first material, where the component has an outer surface and an internal volume; and directly depositing a plurality of fiducial markers on a portion of the outer surface. The fiducial markers are formed from a second material that is compatible with the first material, and the portion of the outer surface defines an analysis region on the outer surface of the component. The analysis region defines a gage length, and each fiducial marker of the plurality of fiducial markers has a maximum diameter of between one-tenth and one-twentieth of the gage length. Periodic measurement of the fiducial marker positions is performed to monitor component strain.

Abstract: A method of controlling an extent of a thermal barrier coating (TBC) sheet spall and a hot gas path (HGP) component are disclosed. The method provides an HGP component having a body with an exterior surface. Controlling the extent of the TBC sheet spall includes forming a TBC over a selected portion of the exterior surface of the body. The TBC includes a plurality of segments in a cellular pattern. Each segment is defined by one or more slots in the TBC, and each segment has a predefined area such that the extent of the TBC sheet spall is limited by the predefined area of each of the plurality of segments that constitute the TBC sheet spall.

Abstract: A method for protecting a coating on a surface of a component is provided. The method includes a coating step for coating at least a portion of the component with a ceramic slurry. A projecting step is used for projecting a pattern of light onto the component with a lithographic process to expose and solidify a ceramic layer. A removing step is used for removing unexposed portions of the ceramic slurry from the component. A heating step heats the component to sinter the ceramic layer. The ceramic layer is formed with multiple fracture planes.

Abstract: A method for protecting a coating on a surface of a component is provided. The method includes a coating step that coats at least a portion of the component with a ceramic slurry. A projecting step projects a pattern of light onto the component with a lithographic process to expose and solidify a ceramic layer. A removing step removes unexposed portions of the ceramic slurry from the component. The ceramic layer comprises multiple stress raising elements or multiple anchoring elements.

Abstract: A method for protecting a coating on a surface of a component is provided. The method includes a coating step for coating at least a portion of the component with a ceramic slurry. A projecting step is used for projecting a pattern of light onto the component with a lithographic process to expose and solidify a ceramic layer. A removing step is used for removing unexposed portions of the ceramic slurry from the component. A heating step heats the component to sinter the ceramic layer. The ceramic layer comprises multiple ridges with each of the ridges having a curvilinear pattern.

Abstract: A method for protecting a coating on a surface of a component is provided. The method includes a coating step that coats at least a portion of the component with a ceramic slurry. A projecting step projects a pattern of light onto the component with a lithographic process to expose and solidify a ceramic layer. A removing step removes unexposed portions of the ceramic slurry from the component. The ceramic layer comprises multiple stress raising elements or multiple anchoring elements.

Abstract: A method for protecting a coating on a surface of a component is provided. The method includes a coating step for coating at least a portion of the component with a ceramic slurry. A projecting step is used for projecting a pattern of light onto the component with a lithographic process to expose and solidify a ceramic layer. A removing step is used for removing unexposed portions of the ceramic slurry from the component. A heating step heats the component to sinter the ceramic layer. The ceramic layer is formed with multiple fracture planes.

Abstract: A method of controlling an extent of a thermal barrier coating (TBC) sheet spall and a hot gas path (HGP) component are disclosed. The method provides an HGP component having a body with an exterior surface. Controlling the extent of the TBC sheet spall includes forming a TBC over a selected portion of the exterior surface of the body. The TBC includes a plurality of segments in a cellular pattern. Each segment is defined by one or more slots in the TBC, and each segment has a predefined area such that the extent of the TBC sheet spall is limited by the predefined area of each of the plurality of segments that constitute the TBC sheet spall.

Abstract: Methods for monitoring component strain, and methods for making a component with an integral strain indicator. A method of making a component with an integral strain indicator includes forming the component with an internal volume formed from a first material and an outer surface and directly depositing a plurality of fiducial markers on a portion of the outer surface. The fiducial markers are formed from a second material that is compatible with the first material and the portion of the outer surface defines an analysis region on the outer surface of the component. The analysis region defines a gage length, and each fiducial marker of the plurality of fiducial markers has a maximum diameter of between one-tenth and one-twentieth of the gage length.