Abstract: Example systems may include an energy source, a material delivery device, and a computing device. The computing device, based on a target height of a layer deposited on a component by directed energy deposition, may control an energy source directed at a component and may control a material delivery device. Controlling the energy source may include advancing an energy beam along a first path to form an advancing molten pool on the component. Controlling the material delivery device may include delivering a material to the advancing molten pool. The material may combine with the advancing molten pool to form a first raised track having an actual height. The layer may include the first raised track. A deposited region of the component may include the layer. The actual height may affect a resultant microstructure within the deposited region.

Abstract: An example spray nozzle distribution pattern testing system may include coaxial collection tubes extending substantially parallel to a major axis, where each coaxial collection tube includes a first end defining an orifice, where the first end is disposed at a first position on a plane substantially orthogonal to the major axis, a second end coupled to an end of a respective outlet tube, and a collection tube wall extending from the first end to the second end, where the collection tube wall at the first end includes a first diameter, where the collection tube wall at a second position between the first end and the second end includes a second diameter greater than the first diameter, where the collection tube wall extending from the second position to the first position tapers toward the major axis at a first angle.

Abstract: A material deposition head may include a body that defines first and second ends, an exterior surface, an interior surface, and one or more material delivery channels, where the exterior surface includes fluting. In some examples, a system may include a fluted material deposition head, a fluidized powder source, and an energy source.

Abstract: An example spray nozzle distribution pattern testing system may include coaxial collection tubes extending substantially parallel to a major axis, where each coaxial collection tube includes a first end defining an orifice, where the first end is disposed at a first position on a plane substantially orthogonal to the major axis, a second end coupled to an end of a respective outlet tube o, and a collection tube wall extending from the first end to the second end, where the collection tube wall at the first end includes a first diameter, where the collection tube wall at a second position between the first end and the second end includes a second diameter greater than the first diameter, where the collection tube wall extending from the second position to the first position tapers toward the major axis at a first angle.

Abstract: Example systems may include an energy source, a material delivery device, and a computing device. The computing device, based on a target height of a layer deposited on a component by directed energy deposition, may control an energy source directed at a component and may control a material delivery device. Controlling the energy source may include advancing an energy beam along a first path to form an advancing molten pool on the component. Controlling the material delivery device may include delivering a material to the advancing molten pool. The material may combine with the advancing molten pool to form a first raised track having an actual height. The layer may include the first raised track. A deposited region of the component may include the layer. The actual height may affect a resultant microstructure within the deposited region.

Abstract: A method for repairing a blade for use in a gas turbine engine, the method comprising removing a distal tip of an airfoil included in the blade to remove damaged portions of the airfoil and to expose previously internal cooling passages. The method further comprising positioning a tip cap in the place of the removed distal tip to cover the internal cooling passages, and welding the tip cap to the airfoil by applying a directed energy beam onto the tip cap and the airfoil at a joint between the tip cap and the airfoil.

Abstract: A material deposition head may include a body that defines first and second ends, an exterior surface, an interior surface, and one or more material delivery channels, where the exterior surface includes fluting. In some examples, a system may include a fluted material deposition head, a fluidized powder source, and an energy source.