Abstract: An additively manufactured heat exchanger assembly formed of a lattice structure with a plurality of shell structure unit cells. The plurality of shell structure unit cells each include at least one junction and a plurality of connectors coupled to the junction. The junction and the plurality of connectors form an integral surface. The heat exchanger assembly further includes a fluid boundary wall defined within the lattice structure to define an active heat exchanger portion. The active heat exchanger portion includes at least one working fluid contained within the fluid boundary wall. Further, at least one of the plurality of shell structure unit cells extends through and beyond the fluid boundary wall. Further, the shell structure unit cells may be isotropic.

Abstract: A hybrid bonded semiconductor structure includes a first substrate and a second substrate each having an interface joined in a hybrid bond. Each substrate has a die portion and a crackstop structure adjacent the die portion. One or more voids in the first substrate and the second substrate are formed in or about a portion of a periphery of each crackstop structure. At least some of the one or more voids in the first substrate and the second substrate are substantially aligned to form a unified void with airgaps across the hybrid bond interface.

Abstract: An industrial asset item definition data store may contain at least one electronic record defining the industrial asset item. An automated support structure creation platform may include a support structure optimization computer processor. The automated support structure optimization computer processor may be adapted to automatically create support structure geometry data associated with an additive printing process for the industrial asset item. The creation may be performed via an iterative loop between a build process simulation engine and a topology optimization engine.

Abstract: A method, medium, and system to receive a specification defining a model of a part to be produced by an additive manufacturing (AM) process; execute an AM simulation on the model of the part to determine a prediction of thermal distortions to the part; execute a topology optimization (TO) to create TO supports that counteract the predicted thermal distortions; generate at least one rule-based support based on a geometry of the part to interface with the part at one or more regions other than the TO supports; combining the TO supports and the at least one rule-based support to generate a set of hybrid supports; save a record of the set of hybrid supports; and transmit the record of the set of hybrid supports to an AM controller to control an AM system to generate a support structure for an AM production of the part.

Abstract: An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component. The model includes a plurality of elements and at least one region of interest. The control system is also configured to apply a strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile for at least one element of the plurality of elements. The build characteristic contribution profile represents an effect of the strain load applied to the at least one element on a build characteristic of at least one location within the at least one region of interest. The control system is further configured to adjust a build parameter for a location within the component relating to the at least one element of the plurality of elements based on the build characteristic contribution profile.

Abstract: A method and system to receive a specification defining a model of a part to be produced by an additive manufacturing (AM) process; define a design space to enclose the part and a support structure for the part, the support structure to support the part and printed with the part during the AM process; execute an iterative topology optimization(TO) based at least in part on the specification for the part and the defined design space, to generate a TO support structure that counteracts predicted gravity-based distortions during the AM process; save a record of the generated TO support structure; and transmit the record of the TO support structure to an AM controller, the AM controller to control an AM system to generate an instance of the part and the TO support structure based on the record.

Abstract: A method, medium, and system to execute an additive manufacturing (AM) simulation on a model of a part; determine, based on the AM simulation, a prediction of a temperature and displacement distribution in the part at a particular time in the AM process; apply the predicted temperature and displacement distributions in the part as a boundary conditions on a support design space to determine a temperature distribution throughout the support design space; and execute a thermal-structural topology optimization based on the determined temperature and displacement distributions throughout the support design space to determine a distribution of material in the design space for a thermal support structure to interface with the part that optimally reduces a thermal gradient in the part with a minimum of material and results in the generation of an optimized AM support structure.

Abstract: A method includes assembling a setter assembly onto a binder-jet printed part, wherein the setter assembly includes a base, a top setter, a bottom setter positioned between the base and the top setter, and a support pin extending between the base and the top setter having a terminus that abuts an inward facing surface of the top setter, such that at least portion of the binder-jet printed part is nested between the top setter and the bottom setter. The method includes heating the binder-jet printed part and the setter assembly to debind or sinter the binder-jet printed part, wherein a length of the support pin decreases in response to the heating to move the top setter toward the base.

Abstract: A binder jet printed article includes a part having a top portion, a bottom portion, and an overhang extending from the top portion and a support structure formed around the part that may block deformation of the part during post-printing thermal processing. The support structure includes a skid positioned adjacent to the bottom portion that may support the part, a first plurality of support features disposed along an outer perimeter of the skid, and a second plurality of support features disposed on the top portion of the printed part. The first and second plurality of support features form a lattice around the printed part such that the printed part is nested within the support structure.

Abstract: A turbine shroud for turbine systems may include a unitary body including a support portion coupled directly to a turbine casing of the turbine system, and forward hook(s) and aft hook(s) formed integral with the support portion. The unitary body may also include an intermediate portion formed integral with and extending from the support portion. The intermediate portion may include a non-linear segment extending from the support portion, and a forward segment formed integral with the non-linear segment. The forward segment of the intermediate portion may be positioned axially upstream of the forward hook(s). Additionally the unitary body may include a seal portion formed integral with the intermediate portion, opposite the support portion. The seal portion may include a forward end formed integral with the intermediate portion. The forward end may be positioned axially upstream of the forward hook(s).

Abstract: A method, medium, and system to receive a specification defining a model of a part to be produced by an additive manufacturing (AM) process; execute an AM simulation on the model of the part to determine a prediction of thermal distortions to the part; execute a topology optimization (TO) to create TO supports that counteract the predicted thermal distortions; generate at least one rule-based support based on a geometry of the part to interface with the part at one or more regions other than the TO supports; combining the TO supports and the at least one rule-based support to generate a set of hybrid supports; save a record of the set of hybrid supports; and transmit the record of the set of hybrid supports to an AM controller to control an AM system to generate a support structure for an AM production of the part.

Abstract: A method, medium, and system to execute an additive manufacturing (AM) simulation on a model of a part; determine, based on the AM simulation, a prediction of a temperature and displacement distribution in the part at a particular time in the AM process; apply the predicted temperature and displacement distributions in the part as a boundary conditions on a support design space to determine a temperature distribution throughout the support design space; and execute a thermal-structural topology optimization based on the determined temperature and displacement distributions throughout the support design space to determine a distribution of material in the design space for a thermal support structure to interface with the part that optimally reduces a thermal gradient in the part with a minimum of material and results in the generation of an optimized AM support structure.

Abstract: A method includes assembling a setter assembly onto a binder-jet printed part, wherein the setter assembly includes a base, a top setter, a bottom setter positioned between the base and the top setter, and a support pin extending between the base and the top setter having a terminus that abuts an inward facing surface of the top setter, such that at least portion of the binder-jet printed part is nested between the top setter and the bottom setter. The method includes heating the binder-jet printed part and the setter assembly to debind or sinter the binder-jet printed part, wherein a length of the support pin decreases in response to the heating to move the top setter toward the base.

Abstract: A turbine shroud for turbine systems are disclosed. The shrouds may include a unitary body including a support portion coupled directly to a turbine casing of the turbine system, and forward hook(s) and aft hook(s) formed integral with the support portion. The unitary body may also include an intermediate portion formed integral with and extending from the support portion. The intermediate portion may include a non-linear segment extending from the support portion, and a forward segment formed integral with the non-linear segment. The forward segment of the intermediate portion may be positioned axially upstream of the forward hook(s). Additionally the unitary body may include a seal portion formed integral with the intermediate portion, opposite the support portion. The seal portion may include a forward end formed integral with the intermediate portion. The forward end may be positioned axially upstream of the forward hook(s).

Abstract: A setter assembly for use in additive manufacturing a binder-jet part includes a base, a first setter component having a first setter portion and a second setter portion that may be removably coupled to the first setter portion and a plurality of protrusions disposed on and extending away from a surface of the base. The plurality of protrusions may align the base with the first setter component and enable coupling of the first setter component to the base. The setter assembly also includes a second setter component positioned between the base and the first setter component. The second setter component is disposed on the surface and the first setter component, the second setter component, and the base can be assembled onto a printed part such that at least a portion of the printed part is nested between the first setter component and the second setter component.

Abstract: An X-ray source target includes a structure configured to generate X-rays when impacted by an electron beam. The structure has an X-ray generating layer comprising X-ray generating material, and a thermally-conductive layer is adjacent to and in thermal communication with the X-ray generating layer. A stress relieving layer is adjacent to the thermally-conductive layer. The thermally-conductive layer is sandwiched between the X-ray generating layer and the stress relieving layer.

Abstract: An airfoil for use in a turbomachine includes a pressure sidewall and a suction sidewall coupled to the pressure sidewall. The suction sidewall and the pressure sidewall define a leading edge and a trailing edge, the leading edge and the trailing edge define a chord distance. The airfoil includes a tip portion extending between the pressure sidewall and the suction sidewall. The tip portion includes a planar section and a recessed section. The recessed section extends adjacent to the planar section such that a thickness of the planar section is less than a thickness of the airfoil. The recessed section is offset a predetermined distance from the leading edge and the trailing edge along the chord distance.

Abstract: A setter assembly for use in additive manufacturing a binder-jet part includes a base, a first setter component having a first setter portion and a second setter portion that may be removably coupled to the first setter portion and a plurality of protrusions disposed on and extending away from a surface of the base. The plurality of protrusions may align the base with the first setter component and enable coupling of the first setter component to the base. The setter assembly also includes a second setter component positioned between the base and the first setter component. The second setter component is disposed on the surface and the first setter component, the second setter component, and the base can be assembled onto a printed part such that at least a portion of the printed part is nested between the first setter component and the second setter component.

Abstract: A binder jet printed article includes a part having a top portion, a bottom portion, and an overhang extending from the top portion and a support structure formed around the part that may block deformation of the part during post-printing thermal processing. The support structure includes a skid positioned adjacent to the bottom portion that may support the part, a first plurality of support features disposed along an outer perimeter of the skid, and a second plurality of support features disposed on the top portion of the printed part. The first and second plurality of support features form a lattice around the printed part such that the printed part is nested within the support structure.

Abstract: Coating systems for components of a gas turbine engine, such as a compressor blade tip, are provided. The coating system can include an abradable material disposed along the compressor blade tip and may be used with a bare compressor casing. The abradable coating is softer than the compressor casing and can reduce the overall rub ratio thereby increasing the lifetime of the compressor blade and casing. Methods are also provided for applying the coating system onto a compressor blade.