Abstract: An AM apparatus for an AM process is provided. The AM apparatus includes a build chamber with a build plate to support one or more parts built with a powder, during a build operation. The AM apparatus further includes a laser assembly operable to deliver a melting laser beam, to melt and fuse the powder used to build the one or more parts. The AM apparatus further includes a part detachment assembly, separate from the laser assembly and operable for a cutting operation. The part detachment assembly includes one or more laser beam delivery apparatuses, each operable to deliver a cutting laser beam, and a part holder apparatus. During the cutting operation, the part holder apparatus holds the one or more parts, and each of the laser beam delivery apparatus(es) delivers the cutting laser beam, to detach the one or more parts from the build plate within the AM apparatus.

Abstract: A steel alloy including, by weight percent: Ni: 18 to 19%; Co: 11.5 to 12.5%; Mo: 4.6 to 5.2%; Ti: 1.3 to 1.6%; Al: 0.05 to 0.15%; Nb: 0.15 to 0.30%; B: 0.003 to 0.020%; Cr: max 0.25%; Mn: max 0.1%; Si: max 0.1%; C: max 0.03%; P: max 0.005%; and S: max 0.002%, the balance being iron plus incidental impurities.

Abstract: There is provided an AM apparatus for an AM process. The AM apparatus has an AM assembly with a build chamber to support part(s) built with a powder, in a build operation. Unused powder accumulates in the build chamber during the build operation. The AM apparatus has a vacuum assembly with duct line(s) in flow communication with the build chamber, and a powder receptacle in flow communication with the duct line(s). The powder receptacle has coupling member(s) allowing the powder receptacle to be reversibly attached to the duct line(s). The vacuum assembly includes a vacuum apparatus coupled to, and in flow communication with, the powder receptacle, via vacuum duct line(s). The vacuum assembly pulls the unused powder from the build chamber to the powder receptacle, and provides an automated removal of the unused powder from the build chamber into the powder receptacle, to avoid manual removal of the unused powder.

Abstract: A laser deposition apparatus includes a sealed enclosure configured to hold a substrate, a powder source configured to hold a powder material, a peen source configured to hold a shot peen media, and a deposition system fluidly connected to the powder source and the peen source. The deposition system includes a laser configured to generate a laser beam. The deposition system is configured to deposit at least one layer on the substrate by injecting a stream of the powder material into the laser beam. The deposition system is configured to shot peen the at least one layer by propelling the shot peen media onto an exterior surface of the at least one layer.

Abstract: A method for manufacturing a component having a spatially graded property includes providing a first layer of particulate matter, the first layer having first material characteristics, and providing a second layer of particulate matter, the second layer having second material characteristics different from the first material characteristics. The method further includes providing an interlayer between the first layer and the second layer and heating the first layer, the second layer, and the interlayer to bond the first layer with the second layer.

Abstract: There is provided an AM apparatus for an AM process. The AM apparatus has an AM assembly with a build chamber to support part(s) built with a powder, in a build operation. Unused powder accumulates in the build chamber during the build operation. The AM apparatus has a vacuum assembly with duct line(s) in flow communication with the build chamber, and a powder receptacle in flow communication with the duct line(s). The powder receptacle has coupling member(s) allowing the powder receptacle to be reversibly attached to the duct line(s). The vacuum assembly includes a vacuum apparatus coupled to, and in flow communication with, the powder receptacle, via vacuum duct line(s). The vacuum assembly pulls the unused powder from the build chamber to the powder receptacle, and provides an automated removal of the unused powder from the build chamber into the powder receptacle, to avoid manual removal of the unused powder.

Abstract: An AM apparatus for an AM process is provided. The AM apparatus includes a build chamber with a build plate to support one or more parts built with a powder, during a build operation. The AM apparatus further includes a laser assembly operable to deliver a melting laser beam, to melt and fuse the powder used to build the one or more parts. The AM apparatus further includes a part detachment assembly, separate from the laser assembly and operable for a cutting operation. The part detachment assembly includes one or more laser beam delivery apparatuses, each operable to deliver a cutting laser beam, and a part holder apparatus. During the cutting operation, the part holder apparatus holds the one or more parts, and each of the laser beam delivery apparatus(es) delivers the cutting laser beam, to detach the one or more parts from the build plate within the AM apparatus.

Abstract: A laser deposition apparatus includes a sealed enclosure configured to hold a substrate, a powder source configured to hold a powder material, a peen source configured to hold a shot peen media, and a deposition system fluidly connected to the powder source and the peen source. The deposition system includes a laser configured to generate a laser beam. The deposition system is configured to deposit at least one layer on the substrate by injecting a stream of the powder material into the laser beam. The deposition system is configured to shot peen the at least one layer by propelling the shot peen media onto an exterior surface of the at least one layer.

Abstract: A steel alloy including, by weight percent: Ni: 18 to 19%; Co: 11.5 to 12.5%; Mo: 4.6 to 5.2%; Ti: 1.3 to 1.6%; Al: 0.05 to 0.15%; Nb: 0.15 to 0.30%; B: 0.003 to 0.020%; Cr: max 0.25%; Mn: max 0.1%; Si: max 0.1%; C: max 0.03%; P: max 0.005%; and S: max 0.002%, the balance being iron plus incidental impurities.

Abstract: Provided is a method for making a modified alloy. The method includes: providing at least one base alloy; providing at least one boride compound represented by the formula, MxBy; forming a melt pool comprising the base alloy and the at least one boride compound, and solidifying at least a portion of the melt pool. In the formula, M is a non-boron element, B is boron, x=1 or 2, and y=1 or 2.

Abstract: A method for manufacturing a component having a spatially graded property includes providing a first layer of particulate matter, the first layer having first material characteristics, and providing a second layer of particulate matter, the second layer having second material characteristics different from the first material characteristics. The method further includes providing an interlayer between the first layer and the second layer and heating the first layer, the second layer, and the interlayer to bond the first layer with the second layer.

Abstract: Provided is a method for modifying a metal alloy for use in additive manufacturing. The method includes providing a metal alloy; providing at least one grain refiner; forming a melt pool that includes the at least one metal alloy and the at least one grain refiner; and solidifying at least a portion the melt pool to form a modified alloy.