Abstract: The present disclosure relates to net-shape or near-net shape articles of manufacture and methods for producing the same. For example, a method for manufacturing net-shape or near-net shape metallic article includes the steps of: forming, using an additive manufacturing process, a metal can comprising a hollow interior portion, filling the hollow interior portion with a metal powder, and subjecting the metal can filled with the metal powder to a hot isostatic pressing (HIP) process to densify the metal powder. As another example, a net-shape or near-net shape metallic article of manufacture includes a metallic outer shell portion having a layer-by-layer fused microstructure that exhibits anisotropic mechanical and physical properties and a metallic inner core portion having a pressure-densified microstructure that exhibits isotropic mechanical and physical properties.

Abstract: There is provided a method for fabricating a dual microstructure component that may in turn be machined to fabricate a rotary element such as an impeller characterized as capable of withstanding high heat conditions for use in a gas turbine engine. The method provides a nickel based superalloy suitable for application of an impeller in a gas turbine engine. The bore region is manufactured having a grain size finer than ASTM 10.0 and the body region is manufactured having a grain size coarser than ASTM 7.0. The bore region and the body region define a dual microstructure and an interface.