Abstract: An additive manufacturing system includes a build platform, a plurality of particles positioned on the build platform defining a build layer, a first and second region within the build layer, and at least one consolidation device. The first region and the second region each including a portion of the plurality of particles. The at least one consolidation device is configured to consolidate the plurality of particles within the build layer into a solid, consolidated portion of said build layer. The consolidation device is further configured to consolidate at least one of the plurality of particles within the build layer and the solid, consolidated portion of the build layer into a molten volume of transfer material. The consolidation device is further configured to transfer a portion of the molten volume of transfer material within the first region from the first region to the second region.

Abstract: A manufactured article is comprised of an additively manufactured component having sequentially joined layers of metallic powder. A braze material is disposed on at least a portion of an outer surface of the component. The braze material is located in expected crack locations in the outer surface. At least one crack formed in the outer surface, during a heat treatment, is filled with the braze material. The additively manufactured component comprises a metallic material from a precipitation hardened nickel-based superalloy, which forms a ?? phase.

Abstract: An additive manufacturing system includes a laser device, a build plate, and a scanning device. The laser device is configured to generate a laser beam with a variable intensity. The build plate is configured to support a powdered build material. The scanning device is configured to selectively direct the laser beam across the powdered build material to generate a melt pool on the build plate. The scanning device is configured to oscillate a spatial position of the laser beam while the laser device simultaneously modulates the intensity of the laser beam to facilitate reducing spatter and to facilitate reducing a temperature of the melt pool to reduce overheating of the melt pool.

Abstract: An additive manufacturing system includes a laser device, a build plate, and a scanning device. The laser device is configured to generate a laser beam with a variable intensity. The build plate is configured to support a powdered build material. The scanning device is configured to selectively direct the laser beam across the powdered build material to generate a melt pool on the build plate. The scanning device is configured to oscillate a spatial position of the laser beam while the laser device is configured to simultaneously modulate the intensity of the laser beam to thermally control the melt pool.

Abstract: A method of coating a component using a robotic spray system is provided. The robotic spray system includes a scanning apparatus operable to measure and store surface characteristics before and after coating; a robotic arm operable to move the robotic spray system relative to a surface of a component, the component including one or more reference features which remains uncoated during the coating; a spray nozzle operable to deposit a sprayed coating onto the surface; and a device driver module including circuitry configured to operate the scanning apparatus, the robotic arm, and the spray nozzle.

Abstract: The invention concerns a turbine for a gas turbine comprising a blade, a vane and an abradable lip attached to the blade or to the vane, wherein the blade and the vane are separated by a gap and the abradable lip extends part of the distance across the gap. Embodiments include the addition of an abrasive layer attached on the other side of the gap from the abradable lip. A method of manufacturing is also described.

Abstract: A manufactured article is comprised of an additively manufactured component having sequentially joined layers of metallic powder. A braze material is disposed on at least a portion of an outer surface of the component. The braze material is located in expected crack locations in the outer surface. At least one crack formed in the outer surface, during a heat treatment, is filled with the braze material. The additively manufactured component comprises a metallic material from a precipitation hardened nickel-based superalloy, which forms a ?? phase.

Abstract: A method for manufacturing a mechanical component by additive manufacturing which includes at least one layering sequence of depositing a powder material and locally melting and resolidifying the powder material. In each layering sequence, a solid layer of solidified material is formed, wherein the solid layers jointly form a solid body. An annealing sequence subsequent to at least one layering sequence includes, locally heating at least a region of the solid body in effecting a local heat input to the immediately beforehand manufactured solid layer which was formed by the immediately precedent layering sequence, with temperature being is maintained below a melting temperature of the material.

Abstract: In some cases, an additive manufacturing (AM) system includes: a process chamber for additively manufacturing a component, the process chamber having: a build platform; at least one melting beam scanner configured to emit a melting beam for melting powder on the build platform; an applicator for applying layers of powder to the build platform; and a reservoir for storing powder; and a control system coupled with the set of melting beam scanners, the control system configured to: apply the melting beam to a layer of powder on the build platform along a primary melting path; and apply the melting beam to the layer of powder on the build platform along a re-melting path after applying the melting beam along the primary melting path, the re-melting path overlapping a portion of the primary melting path and applied only in an area proximate a perimeter of the component.

Abstract: Controlling microstructure in an object created by metal powder additive manufacturing is disclosed. During additive manufacturing of one or more objects using an irradiation beam source system, for each respective layer in a selected range of layers including a cross-sectional area of the one or more objects including the selected object, a duration controller controls actuation of each irradiation device to maintain constant a sum of: an irradiation device melting time, an irradiation device idle time, and a recoating time expended applying a new powder material layer, while otherwise maintaining all other operation parameters of each irradiation device constant.

Abstract: An additive manufacturing system includes a build platform, a plurality of particles positioned on the build platform defining a build layer, a first and second region within the build layer, and at least one consolidation device. The first region and the second region each including a portion of the plurality of particles. The at least one consolidation device is configured to consolidate the plurality of particles within the build layer into a solid, consolidated portion of said build layer. The consolidation device is further configured to consolidate at least one of the plurality of particles within the build layer and the solid, consolidated portion of the build layer into a molten volume of transfer material. The consolidation device is further configured to transfer a portion of the molten volume of transfer material within the first region from the first region to the second region.

Abstract: A coupon for replacing a cutout in a hot gas path component of a turbomachine is provided. In one embodiment, the coupon includes a body having an outer surface; and a plurality of grinding depth indicators in the outer surface of the body. In another embodiment, the coupon includes a body having an edge periphery configured to mate with an edge periphery of the cutout, and at least a portion of the edge periphery of the body has a wall thickness greater than a wall thickness of an edge periphery of the cutout. The embodiments may be used together or separately.

Abstract: Controlling microstructure in an object created by metal powder additive manufacturing is disclosed. During additive manufacturing of one or more objects using an irradiation beam source system, for each respective layer in a selected range of layers including a cross-sectional area of the one or more objects including the selected object, a duration controller controls actuation of each irradiation device to maintain constant a sum of: an irradiation device melting time, an irradiation device idle time, and a recoating time expended applying a new powder material layer, while otherwise maintaining all other operation parameters of each irradiation device constant.

Abstract: An additive manufacturing system includes a laser device, a build plate, and a scanning device. The laser device is configured to generate a laser beam with a variable intensity. The build plate is configured to support a powdered build material. The scanning device is configured to selectively direct the laser beam across the powdered build material to generate a melt pool on the build plate. The scanning device is configured to oscillate a spatial position of the laser beam while the laser device is configured to simultaneously modulate the intensity of the laser beam to thermally control the melt pool.

Abstract: An additive manufacturing system includes a laser device, a build plate, and a scanning device. The laser device is configured to generate a laser beam with a variable intensity. The build plate is configured to support a powdered build material. The scanning device is configured to selectively direct the laser beam across the powdered build material to generate a melt pool on the build plate. The scanning device is configured to oscillate a spatial position of the laser beam while the laser device simultaneously modulates the intensity of the laser beam to facilitate reducing spatter and to facilitate reducing a temperature of the melt pool to reduce overheating of the melt pool.

Abstract: The invention refers to a method for selective laser melting additive manufacturing a three-dimensional metallic or ceramic article/component entirely or partly. The method includes successively building up said article/component layer by layer directly from a powder bed of a metallic or ceramic base material by means of remelting the layers with a high energy laser beam, moving repetitively across the areas, which are to be solidified. The movement of the laser beam is made of a superposition of a continuous linear movement and at least one superimposed oscillation with a determined frequency and amplitude. The oscillation is created by a beam deflection device and the same beam deflection device is also used for linear positioning movement.

Abstract: A method of coating a component using a robotic spray system is provided. The robotic spray system includes a scanning apparatus operable to measure and store surface characteristics before and after coating; a robotic arm operable to move the robotic spray system relative to a surface of a component, the component including one or more reference features which remains uncoated during the coating; a spray nozzle operable to deposit a sprayed coating onto the surface; and a device driver module including circuitry configured to operate the scanning apparatus, the robotic arm, and the spray nozzle.

Abstract: A coated substrate is described including a substrate material, which is coated at least in part with an oxidation-resistant coating, wherein the coating consists of a wear-resistant abrasive coating layer, which contains or consists of coated abrasive particles embedded in an oxidation-resistant matrix material, wherein at least some of the abrasive particles consist of ?-Al2O3 and the abrasive particles are coated with a first particle coating layer disposed on the abrasive particles and an optional second particle coating layer disposed on the first particle coating layer, wherein the matrix material contains or consists of the compound MCrAlY, wherein M is at least one element selected from the group consisting of Ni, Co and Fe. A method for manufacturing such a coated substrate is also disclosed.

Abstract: In some cases, an additive manufacturing (AM) system includes: a process chamber for additively manufacturing a component, the process chamber having: a build platform; at least one melting beam scanner configured to emit a melting beam for melting powder on the build platform; an applicator for applying layers of powder to the build platform; and a reservoir for storing powder; and a control system coupled with the set of melting beam scanners, the control system configured to: apply the melting beam to a layer of powder on the build platform along a primary melting path; and apply the melting beam to the layer of powder on the build platform along a re-melting path after applying the melting beam along the primary melting path, the re-melting path overlapping a portion of the primary melting path and applied only in an area proximate a perimeter of the component.

Abstract: A method for manufacturing a mechanical component by additive manufacturing which includes at least one layering sequence of depositing a powder material and locally melting and resolidifying the powder material. In each layering sequence, a solid layer of solidified material is formed, wherein the solid layers jointly form a solid body. An annealing sequence subsequent to at least one layering sequence includes, locally heating at least a region of the solid body in effecting a local heat input to the immediately beforehand manufactured solid layer which was formed by the immediately precedent layering sequence, with temperature being is maintained below a melting temperature of the material.