Abstract: A method of manufacturing soft magnetic thin laminates includes producing a bulk component comprising a soft magnetic material, wherein the bulk component extends in an axial direction, and slicing the bulk component in a radial direction, perpendicular to the axial direction, to produce a plurality of soft magnetic thin laminates.

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a parameter development module comprising a processor, a defined geometry for one or more parts, wherein the parts are manufactured with an additive manufacturing machine, and wherein a stack is formed from one or more parts; fabricating the one or more parts with the additive manufacturing machine based on a first parameter set; collecting in-situ monitoring data from one or more in-situ monitoring systems of the additive manufacturing machine for one or more parts; determining whether each stack should receive an additional part based on an analysis of the collected in-situ monitoring data; and fabricating each additional part based on the determination the stack should receive the additional part. Numerous other aspects are provided.

Abstract: A method for fabricating a component of with an additive manufacturing system include entraining a first portion of first material particles in an airflow generated by a vacuum source and engaging the first portion of the first material particles against an air permeable screen. The first portion of the first material particles is deposited onto a build platform. The method also includes entraining a second portion of second material particles in the airflow and engaging the second portion of the second material particles against the air permeable screen. The second portion of the second material particles is deposited onto the build platform. An energy source transfers heat to at least a portion of at least one of the first portion of the first material particles or the second portion of the second material particles to facilitate consolidating material particles to fabricate the component.

Abstract: A thermal structure for management of thermal energy, the thermal structure including: a first wall structure defining a first cavity; a second wall structure defining a second cavity, the second cavity in fluid communication with the first cavity; and a barrier cavity defined at least in-part by the first wall structure and the second wall structure, wherein the barrier cavity is disposed between the first cavity and the second cavity and includes a pressurized barrier fluid therein or is configured to receive the pressurized barrier fluid during operation of the thermal structure.

Abstract: A titanium-based component having a high heat capacity surface. The high heat capacity surface prevents or inhibits titanium fires. The component is titanium-based, forming the substrate, and includes a high heat capacity surface overlying the titanium substrate. A diffusion barrier is intermediate the titanium-based substrate and the high heat capacity surface. The diffusion barrier is non-reactive with both the titanium-based substrate and the high heat capacity surface. The system eliminates the formation of detrimental phases due to diffusion between the applied high heat capacity surface and the titanium substrate. The high heat capacity material has a coefficient of thermal expansion compatible with the coefficient of thermal expansion of the titanium-based substrate.

Abstract: Dual-phase magnetic components include an intermixed first region and second region formed from a single material, wherein the first region includes a magnetic ferrous composition, and wherein the second region includes a non-magnetic austenite composition and a dispersion of nitride precipitates.

Abstract: A thermal structure for management of thermal energy, the thermal structure including: a first wall structure defining a first cavity; a second wall structure defining a second cavity, the second cavity in fluid communication with the first cavity; and a barrier cavity defined at least in-part by the first wall structure and the second wall structure, wherein the barrier cavity is disposed between the first cavity and the second cavity and includes a pressurized barrier fluid therein or is configured to receive the pressurized barrier fluid during operation of the thermal structure.

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a parameter development module comprising a processor, a defined geometry for one or more parts, wherein the parts are manufactured with an additive manufacturing machine, and wherein a stack is formed from one or more parts; fabricating the one or more parts with the additive manufacturing machine based on a first parameter set; collecting in-situ monitoring data from one or more in-situ monitoring systems of the additive manufacturing machine for one or more parts; determining whether each stack should receive an additional part based on an analysis of the collected in-situ monitoring data; and fabricating each additional part based on the determination the stack should receive the additional part. Numerous other aspects are provided.

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a parameter development module comprising a processor, a defined geometry for one or more parts, wherein the parts are manufactured with an additive manufacturing machine, and wherein a stack is formed from one or more parts; fabricating the one or more parts with the additive manufacturing machine based on a first parameter set; collecting in-situ monitoring data from one or more in-situ monitoring systems of the additive manufacturing machine for one or more parts; determining whether each stack should receive an additional part based on an analysis of the collected in-situ monitoring data; and fabricating each additional part based on the determination the stack should receive the additional part. Numerous other aspects are provided.

Abstract: A method for fabricating a component of with an additive manufacturing system include entraining a first portion of first material particles in an airflow generated by a vacuum source and engaging the first portion of the first material particles against an air permeable screen. The first portion of the first material particles is deposited onto a build platform. The method also includes entraining a second portion of second material particles in the airflow and engaging the second portion of the second material particles against the air permeable screen. The second portion of the second material particles is deposited onto the build platform. An energy source transfers heat to at least a portion of at least one of the first portion of the first material particles or the second portion of the second material particles to facilitate consolidating material particles to fabricate the component.

Abstract: A method for fabricating a component of with an additive manufacturing system include entraining a first portion of first material particles in an airflow generated by a vacuum source and engaging the first portion of the first material particles against an air permeable screen. The first portion of the first material particles is deposited onto a build platform. The method also includes entraining a second portion of second material particles in the airflow and engaging the second portion of the second material particles against the air permeable screen. The second portion of the second material particles is deposited onto the build platform. An energy source transfers heat to at least a portion of at least one of the first portion of the first material particles or the second portion of the second material particles to facilitate consolidating material particles to fabricate the component.

Abstract: A surface of an article is modified by aluminizing an initial surface at a first temperature to form a first aluminized layer and a sublayer, removing at least a portion of the first aluminized layer, aluminizing the sublayer at a second temperature to form a second aluminized layer, and finally removing at least a portion of the second aluminized layer to form a processed surface. The second temperature is less than the first temperature and a roughness of the processed surface is less than the roughness of the initial surface.

Abstract: Methods of forming an intermediate alloy and a Ni-base super alloy are disclosed along with the intermediate alloy and the Ni-base super alloy formed by the method. The method includes at least partially melting and solidifying a powder including about 5 to 15 wt. % of Co, 10 to 20 wt. % of Cr, 3 to 6 wt. % of Mo, 3 to 6 wt. % of W, 2 to 4 wt. % of Al, 4.2 to 4.7 wt. % of Ti, 0.01 to 0.05 wt. % of Zr, 0.015 to 0.060 wt. % of C, 0.001 to 0.030 wt. % of B and balance substantially Ni to form an intermediate alloy including a dendrite structure that includes columnar regions and intercolumnar regions and a primary dendrite arm spacing less than about 3 micrometers. The intermediate alloy is heat-treated to form the texture-free Ni-base super alloy.

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a parameter development module comprising a processor, a defined geometry for one or more parts, wherein the parts are manufactured with an additive manufacturing machine, and wherein a stack is formed from one or more parts; fabricating the one or more parts with the additive manufacturing machine based on a first parameter set; collecting in-situ monitoring data from one or more in-situ monitoring systems of the additive manufacturing machine for one or more parts; determining whether each stack should receive an additional part based on an analysis of the collected in-situ monitoring data; and fabricating each additional part based on the determination the stack should receive the additional part. Numerous other aspects are provided.

Abstract: A method of processing a powdered feedstock to form a fabricated component is provided. The fabricated component includes a plurality of grains having a nominal grain size. The method includes providing the powdered feedstock material having a population of phase particulates with a first nominal size distribution disposed within a host matrix material. The method includes building a consolidated component from the powdered feedstock material in an additive manufacturing process, and fabricating the fabricated component from the consolidated component. The first nominal size distribution of the population of phase particulates is sized such that at least a portion of the population of phase particulates persists throughout the additive manufacturing process and is present as a processed population of phase particulates in the consolidated component.

Abstract: An additive manufactured product, along with methods of its formation, is provided. The additive manufactured product may include a fused multilayer component comprising a nickel superalloy having a composition comprising, by weight: 7% to 11% of cobalt; 9% to 14% of chromium; 1.5% to 8% of molybdenum; up to 8% of tungsten; 4% to 6% of aluminum; 1% to 4% of titanium; up to 4.6% tantalum; up to 2% hafnium; up to 0.04% zirconium; up to 0.05% carbon; up to 0.04% boron; up to 1% niobium; and the balance nickel along with unavoidable residual elements in trace amounts. This composition may have a sum of the weight percentages of zirconium and boron that is up to 0.06%.

Abstract: Methods of forming an intermediate alloy and a Ni-base super alloy are disclosed along with the intermediate alloy and the Ni-base super alloy formed by the method. The method includes at least partially melting and solidifying a powder including about 5 to 15 wt. % of Co, 10 to 20 wt. % of Cr, 3 to 6 wt. % of Mo, 3 to 6 wt. % of W, 2 to 4 wt. % of Al, 4.2 to 4.7 wt. % of Ti, 0.01 to 0.05 wt. % of Zr, 0.015 to 0.060 wt. % of C, 0.001 to 0.030 wt. % of B and balance substantially Ni to form an intermediate alloy including a dendrite structure that includes columnar regions and intercolumnar regions and a primary dendrite arm spacing less than about 3 micrometers. The intermediate alloy is heat-treated to form the texture-free Ni-base super alloy.

Abstract: A control system for use in an additive manufacturing system. A recoating device is configured to distribute powder for forming a component and a recoating motor is configured to move at least one of the powder bed and the recoating device relative to each other. The control system includes at least one vibration sensor configured to collect vibration data, a torque sensor coupled to the recoating motor and configured to collect the torque output data, and an optical sensor configured to collect reflected light data. The control system includes a controller configured to receive the vibration data, receive the torque output data, and receive the reflected light data, the controller further configured to determine at least one powder bed characteristic based on at least one of the data, and control at least one recoating parameter of the recoating device based on the at least one determined powder bed characteristic.

Abstract: Methods of forming an intermediate alloy and a Ni-base super alloy are disclosed along with the intermediate alloy and the Ni-base super alloy formed by the method. The method includes at least partially melting and solidifying a powder including about 5 to 15 wt. % of Co, 10 to 20 wt. % of Cr, 3 to 6 wt. % of Mo, 3 to 6 wt. % of W, 2 to 4 wt. % of Al, 4.2 to 4.7 wt. % of Ti, 0.01 to 0.05 wt. % of Zr, 0.015 to 0.060 wt. % of C, 0.001 to 0.030 wt. % of B and balance substantially Ni to form an intermediate alloy including a dendrite structure that includes columnar regions and intercolumnar regions and a primary dendrite arm spacing less than about 3 micrometers. The intermediate alloy is heat-treated to form the texture-free Ni-base super alloy.

Abstract: An apparatus and method for rapid screening of material properties in a plurality of additively manufactured test specimens. The apparatus includes a build plate having the plurality of additively manufactured test specimens disposed on a first substantially planar surface. The plurality of additively manufactured test specimens are coupled to at least one actuator to one of individually or simultaneously translationally displace each of the test specimens along an axis “z”, and perpendicular to the build plane of the build plate to test material properties of each of the plurality of additively manufactured test specimens. A sensor is coupled to each of the plurality of additively manufactured test specimens. Load vs. displacement data may be used to monitor the progression of monotonic and/or cyclic tests of the plurality of additively manufactured test specimens.