Abstract: A method of depositing an extrudate onto a substrate, the method including steps of rotating a stirring tool about an axis of rotation while urging a tool distal end of the stirring tool against the substrate, and wherein the stirring tool defines a bore, extending therethrough; positioning a die adjacent to the stirring tool, such that the stirring tool rotates relative to the die; and passing feedstock through the bore toward the tool distal end.

Abstract: A method is provided for manufacturing an article. The method comprises depositing by additive friction stir deposition a wear-resistant material on a surface of a preform to provide an intermediate article. The preform comprises a first composition and the wear-resistant material comprises a second composition. The second composition is substantially different from the first composition. The method also comprises machining the intermediate article to remove therefrom at least a portion of the wear-resistant material.

Abstract: Implementations provide gas atomized metal matrix composite (“GAMMC”)-based feedstock for cold spray additive manufacturing (“CSAM”) enabling complex structural repairs. The feedstock is prepared by arranging a metal matrix composite (MMC) material in a gas atomization system, wherein the MMC material includes metal particles and ceramic particles. The feedstock is further prepared by performing gas atomization of the MMC material using the gas atomization system to atomize the MMC material, and producing a feedstock powder comprised of metal particles that are embedded with the ceramic particles from the atomized MMC material. The GAMMC-based feedstock comprises metallic (for binding to the substrate of the damaged part) and ceramic (for reinforcement) particles bonded together such that the ceramic particles bond directly to and within the metallic particles.

Abstract: Implementations provide gas atomized metal matrix composite (“GAMMC”)-based feedstock for cold spray additive manufacturing (“CSAM”) enabling complex structural repairs. The feedstock is prepared by arranging a metal matrix composite (MMC) material in a gas atomization system, wherein the MMC material includes metal particles and ceramic particles. The feedstock is further prepared by performing gas atomization of the MMC material using the gas atomization system to atomize the MMC material, and producing a feedstock powder comprised of metal particles that are embedded with the ceramic particles from the atomized MMC material. The GAMMC-based feedstock comprises metallic (for binding to the substrate of the damaged part) and ceramic (for reinforcement) particles bonded together such that the ceramic particles bond directly to and within the metallic particles.

Abstract: A method for loading feedstock bars into an additive friction stir deposition machine (AFSD) is described. The method comprises containing a plurality of feedstock bars in a container disposed adjacent to a spindle of the additive friction stir deposition machine. The method further comprises moving one feedstock bar of the plurality of feedstock bars into axial alignment with the spindle of the additive friction stir deposition machine.

Abstract: A method of depositing an extrudate onto a substrate, the method including steps of rotating a stirring tool about an axis of rotation while urging a tool distal end of the stirring tool against the substrate, and wherein the stirring tool defines a bore, extending therethrough; positioning a die adjacent to the stirring tool, such that the stirring tool rotates relative to the die; and passing feedstock through the bore toward the tool distal end.

Abstract: An additive manufacturing system for depositing an extrudate onto a substrate comprises a deposition head. The deposition head comprises a stirring tool, rotatable about an axis of rotation AR and comprising a tool distal end and a tool proximal end, axially opposing the tool distal end along the axis of rotation AR. The stirring tool defines a bore, extending from the tool proximal end to the tool distal end. The bore is configured to receive feedstock, biased toward the tool distal end. The deposition head also comprises a die, which is positioned adjacent to the stirring tool, defines a die axis AD1, and comprises a die distal end and a die proximal end, axially opposing the die distal end along the die axis AD1. The die axis AD1 is parallel with the axis of rotation AR of the stirring tool.

Abstract: A method is provided for manufacturing an article. The method comprises depositing by additive friction stir deposition a wear-resistant material on a surface of a preform to provide an intermediate article. The preform comprises a first composition and the wear-resistant material comprises a second composition. The second composition is substantially different from the first composition. The method also comprises machining the intermediate article to remove therefrom at least a portion of the wear-resistant material.

Abstract: Methods of using micro-specimens for testing an additive manufactured material or a part made from the additive manufactured material. The methods include testing small and large test specimens taken from an additive manufactured part and from a blank constructed from the additive manufactured material. Correction factors based on the test specimens are calculated and applied to a calculated material property of the additive manufactured material.

Abstract: Implementations provide gas atomized metal matrix composite (“GAMMC”)-based feedstock for cold spray additive manufacturing (“CSAM”) enabling complex structural repairs. The feedstock is prepared by arranging a metal matrix composite (MMC) material in a gas atomization system, wherein the MMC material includes metal particles and ceramic particles. The feedstock is further prepared by performing gas atomization of the MMC material using the gas atomization system to atomize the MMC material, and producing a feedstock powder comprised of metal particles that are embedded with the ceramic particles from the atomized MMC material. The GAMMC-based feedstock comprises metallic (for binding to the substrate of the damaged part) and ceramic (for reinforcement) particles bonded together such that the ceramic particles bond directly to and within the metallic particles.

Abstract: A method and apparatus for joining workpieces is described. The apparatus comprises a clamp configured to restrain a first workpiece against a second workpiece and an additive friction stir deposition (AFSD) machine comprising a spindle. The first workpiece is clamped to the second workpiece, and feedstock material is deposited, via rotation of the spindle, into an aperture extending through one or both of the first workpiece and the second workpiece. The deposited feedstock material forms a weld nugget that joins the first workpiece to the second workpiece.

Abstract: A test fixture configured to attach to and apply a tensile force to a test specimen. The test fixture may include a first clevis section and a second clevis section that are each configured to be attached to the test specimen. Each of the first and second clevis sections may include a fixed block and a movable block. Connectors connect the clevis sections together and hold the test specimen. The first and second clevis sections may be moved apart to apply a force to the attached test specimen to test one or more properties of the test specimen.

Abstract: A method for loading feedstock bars into an additive friction stir deposition machine (AFSD) is described. The method comprises containing a plurality of feedstock bars in a container disposed adjacent to a spindle of the additive friction stir deposition machine. The method further comprises moving one feedstock bar of the plurality of feedstock bars into axial alignment with the spindle of the additive friction stir deposition machine.

Abstract: A test fixture configured to attach to and apply a tensile force to a test specimen. The test fixture may include a first clevis section and a second clevis section that are each configured to be attached to the test specimen. Each of the first and second clevis sections may include a fixed block and a movable block. Connectors connect the clevis sections together and hold the test specimen. The first and second clevis sections may be moved apart to apply a force to the attached test specimen to test one or more properties of the test specimen.

Abstract: Methods of using micro-specimens for testing an additive manufactured material or a part made from the additive manufactured material. The methods include testing small and large test specimens taken from an additive manufactured part and from a blank constructed from the additive manufactured material. Correction factors based on the test specimens are calculated and applied to a calculated material property of the additive manufactured material.

Abstract: An additive manufacturing system (110) for depositing an extrudate (112) onto a substrate (114) comprises a deposition head (116). The deposition head (116) comprises a stirring tool (118), rotatable about an axis of rotation AR and comprising a tool distal end (120) and a tool proximal end (122), axially opposing the tool distal end (120) along the axis of rotation AR. The stirring tool (118) defines a bore (124), extending from the tool proximal end (122) to the tool distal end (120). The bore (124) is configured to receive feedstock (126), biased toward the tool distal end (120). The deposition head (116) also comprises a die (128), which is positioned adjacent to the stirring tool (118), defines a die axis AD1, and comprises a die distal end (130) and a die proximal end (132), axially opposing the die distal end (130) along the die axis AD1, and wherein the die axis AD1 is parallel with the axis of rotation AR of the stirring tool (118).