Abstract: One embodiment includes a method for enhancing bond strength between a powder deposit and a substrate. Powder is deposited on the substrate. Powder is shot peened with peening media that is harder than both the powder and the substrate to produce bond strength between the powder and the substrate that is at least twice bond strength between the powder and the substrate without shot peening.

Abstract: A method of making an integrally bladed rotor with hollow blades. A plurality of segmented layers are sequentially placed to form each one of a plurality of blades on a radially outward surface of a hub. This is done using an additive manufacturing process. The placement of the segmented layers also comprises omitting portions of one or more of the plurality of segmented layers to form one or more cavities and intermittently removing a quantity of particles from the one or more cavities using an evacuation tool.

Abstract: The invention provides a self-peening feedstock material for cold spray deposition comprising a higher ductility matrix material and a hardened particle.

Abstract: A powder classification apparatus (10; 110; 210) includes a first chamber (12; 112; 212) that includes a fluidized bed and has an inlet (16; 116; 216A) and an outlet (18; 118; 218), the inlet (16; 116; 216A) configured to receive a gas (G) and distribute the gas (G) in a uniform flow through the first chamber (12; 112; 212), the first chamber (12; 112; 212) configured to receive a powder (P) and the gas (G) and create a fluidization zone, the outlet (18; 118; 218) configured to allow at least a portion of the powder (P) to exit the first chamber (12; 112; 212); and a second chamber (14; 114; 214) having a powder inlet (24; 124; 224) configured to accept at least a portion of the powder (P) from the outlet (18; 118; 218) in the first chamber (12; 112; 212) caused by at least a portion of the powder (P) being ejected from the first chamber (12; 112; 212) by the gas (G).

Abstract: A method of applying a metal comprising titanium to a substrate is disclosed. The method comprises nitriding the surface of metal powder particles comprising titanium by contacting the particles with a first gas comprising nitrogen in a fluidized bed reactor, and depositing the metal powder particles onto the substrate with cold spray deposition using a second gas.

Abstract: A powder feeder for a cold spray system includes a rotatable drum body, a housing surrounding the drum body, and a support structure. The support structure couples to the housing and supports the housing such that the drum body rotates about a rotation axis to provide in-situ blending of powder disposed within an interior of the drum body.

Abstract: A vibration damper for an additively manufactured structure includes a structure at least partially formed with an additive manufacturing technique. Also included is a damping element embedded within the structure at an internal location of the structure. A method of damping vibration of an additively manufactured component is provided. The method includes additively manufacturing a structure. The method also includes embedding at least one damping element within the structure at an internal location of the structure.

Abstract: A method of repairing or, in certain cases, strengthening a metallic substrate at a damage site is provided and includes removing material from the substrate around the damage site to form a recess, and cold spraying particulate material into the recess to form a bead of deposited material.

Abstract: An embedded magnetic identification assembly includes a base component formed of a material. Also included is a plurality of elements formed in an array at a surface of the base component, wherein the plurality of elements is formed of a magnetic material.

Abstract: A component may be self-monitoring having a sensor assembly located on a surface of a substrate and covered by an encapsulating layer additively manufactured over the sensor assembly and thereby bonded to the substrate. The sensor may be wireless, self-powered, and embedded into the substrate such that it is unobtrusive and may not limit the performance or function of the Ccomponent.

Abstract: A powder feeder for a cold spray system includes a rotatable drum body, a housing surrounding the drum body, and a support structure. The support structure couples to the housing and supports the housing such that the drum body rotates about a rotation axis to provide in-situ blending of powder disposed within an interior of the drum body.

Abstract: An embedded sensor apparatus for enabling wireless signal transmission while protecting an embedded sensor is disclosed. In various embodiments, an embedded sensor apparatus may comprise a substrate with a cavity, a wireless sensor embedded in the cavity of the substrate, a protective cover coupled to the wireless sensor, and a ferrite layer covering the protective cover. Further, the embedded sensor apparatus may comprise an electromagnetic reflector coupled between the wireless sensor and the substrate. In addition, the ferrite layer may be a ferrite plug, a deposited ferrite layer, or a combination thereof. Furthermore, in various embodiments, covering the protective cover with the ferrite layer may comprise depositing the ferrite layer on the protective cover using a cold spray process. In another embodiment, covering the protective cover with the ferrite layer may comprise depositing the ferrite layer on the protective cover using a thermal spray process.

Abstract: A particulate for an additive manufacturing technique includes metallic particulate bodies with exterior surfaces bearing a polymeric coating. The polymeric coating is conformally disposed over the exterior surface that prevents the underlying metallic body from oxidation upon exposure to the ambient environment by isolating the metallic particulate bodies from the ambient environment. Feedstock materials for additive manufacturing techniques, and methods of making such feedstock, are also disclosed.

Abstract: Material is provided for forming a part using a manufacturing system. The material includes a plurality of discrete particles. Each of the particles includes a metal powder core encapsulated by a non-metal coating. At least the cores of the particles are adapted to be solidified together by the manufacturing system to form the part.

Abstract: A system for quality monitoring of additive manufacturing includes an acoustic emission (AE) sensor configured to be attached to an additive manufacturing substrate and to output a sensor signal indicative of acoustic vibrations received at the AE sensor and an AE module. The AE module is configured to receive the sensor signal from the AE sensor and process the sensor signal to determine at least one characteristic of an additive manufacturing process and/or an additively manufactured article.

Abstract: A system comprises a furnace, a fluidized bed assembly and a powder bed. The fluidized bed assembly is positioned in the furnace and comprises an outer chamber having an outer chamber inlet for receiving gas, an inner chamber positioned inside of the outer chamber. The inner chamber comprises an inner chamber inlet in fluid communication with the outer chamber, and an outlet through which the gas may exit the inner chamber and the outer chamber. The powder bed is disposed in the inner chamber.

Abstract: A sensing system may comprise a reader device including a primary magnetic coil, and a sensing device including a secondary magnetic coil and a sensing platform configured to acquire sensing data. The sensing system may further include a first part having the sensing device embedded therein. The reader device and the sensing device may be configured to communicate over a non-contact wireless interface using low frequency wireless power transfer.

Abstract: A sensor system includes a load-carrying element, an encoder structure, and a magnetic flux transducer. The load-carrying element is formed of substantially non-magnetic material, while the encoder structure is formed of magnetic material deposited via cold spray additive manufacturing within the load-carrying element. The magnetic flux transducer is disposed adjacent the load-carrying element to sense changes in magnetic flux caused by relative motion of the encoder structure.

Abstract: A powder classification apparatus (10; 110; 210) includes a first chamber (12; 112; 212) that includes a fluidized bed and has an inlet (16; 116; 216A) and an outlet (18; 118; 218), the inlet (16; 116; 216A) configured to receive a gas (G) and distribute the gas 30 (G) in a uniform flow through the first chamber (12; 112; 212), the first chamber (12; 112; 212) configured to receive a powder (P) and the gas (G) and create a fluidization zone, the outlet (18; 118; 218) configured to allow at least a portion of the powder (P) to exit the first chamber (12; 112; 212); and a second chamber (14; 114; 214) having a powder inlet (24; 124; 224) configured to accept at least a portion of the powder (P) from the outlet (18; 118; 218) in the first chamber (12; 112; 212) caused by at least a portion of the powder (P) being ejected from the first chamber (12; 112; 212) by the gas (G).

Abstract: The invention provides a self-peening feedstock material for cold spray deposition comprising a higher ductility matrix material and a hardened particle.