Abstract: A method of forming a metallic coating a workpiece is disclosed herein. The method includes receiving a sacrificial deposition rod formed of a first material, receiving a workpiece of a second material, forming a coating of the first material from the sacrificial deposition rod onto the workpiece, the coating having a first thickness, and machining the coating to a second thickness that is less than the first thickness.

Abstract: A method of improving an internal surface topography of a manufactured workpiece includes filling a workpiece with an electrically conductive magnetorheological (MR) fluid. The workpiece includes at least one internal feature having an inner surface with at least one irregularity. The method further includes converting the MR fluid into a rigid MR material, applying a voltage to the rigid MR material, and ablating the inner surface in response to the voltage to remove the at least one irregularity.

Abstract: A method of titanium rod additive manufacturing may comprise: mixing a plurality of powdered metals comprising titanium, iron, vanadium, and aluminum to produce a powder blend; isostatic pressing the powder blend to form a billet having a cross-sectional profile; cutting the billet to form a rod feedstock having the first cross-sectional profile; loading the rod feedstock into an additive manufacturing machine configured to deposit the rod feedstock; and producing a metallic component from the rod feedstock.

Abstract: A heat exchanger includes a flow channel operatively connecting a channel inlet to a channel outlet to channel fluid to flow therethrough. The flow channel is defined at least partially by a shape change material. The shape change material changes the shape of the flow channel based on the temperature of the shape change material.

Abstract: An aluminum alloy comprising greater than 2.00 and less than 4.00 wt. % cerium, 0.25-3.00 wt. % silicon, 0.25-0.75 wt. % magnesium, 0-0.75 wt. % iron, 0-0.05 wt. % other alloying elements, and the balance of aluminum, based on the total weight of the aluminum alloy aluminum alloy.

Abstract: A method may comprise: placing a probe in a molten metal melt comprising a thixotropic metal alloy; injecting a gas into the molten metal melt to form a saturated slurry, the saturated slurry being at a temperature above a liquidus temperature of the thixotropic metal alloy after injecting the gas; removing the probe from the molten metal melt; and depositing the molten metal melt through an extruder of an additive manufacturing system.

Abstract: A metallic part is disclosed. The part may comprise a functionally graded monolithic structure characterized by a variation between a first material composition of a tubular preform and a second material composition of at least one of a secondary structural element wherein each of the first material composition and the second material composition comprises at least one of a titanium metal or an alloy of titanium. The first material composition may comprise an alpha-beta titanium alloy. The second material composition may comprise a beta titanium alloy.

Abstract: A composite component may be additively manufactured by a system that mixes a fiber and matrix and extrudes a body made of the fiber and matrix toward a work piece. The extruded body may be pressed against the work piece and the workpiece and/or extruded body may be moved relative to the other. The extruded body may at least partially melt and flow, uniting with the workpiece and additively manufacturing a layer of a feature thereon. In this manner, friction stir additive manufacturing of composite components having a fiber and matrix composite may be accomplished.

Abstract: An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.

Abstract: Methods, systems, and apparatuses for component manufacturing are provided. A component may be manufactured via an extrusion of loose substrate material into a unitary tubing. Features may be added to the tubing via friction stir additive manufacturing to manufacture a component. In this manner, a component may be manufactured from titanium alloys while processing challenges such as iron segregation or material loss through machining are ameliorated. Such a component may replace steel or other high strength components and further exhibits corrosion resistance.

Abstract: A method is provided for producing ultra-fine-grained materials using additive manufacturing. The method includes commanding, by a controller, a laser device to produce a plurality of optical pulses to a base material to add an additive material to the base material. The method further includes commanding, by the controller, a vibration mechanism to vibrate the base material as the plurality of optical pulses are being applied to the base material forming fine equiaxed grains with random crystallographic texture in the base material.

Abstract: A method of manufacturing a component includes making a preform from a powdered material, the preform having a density in a range from 70 to 95% of theoretical density of the material, The method also includes sintering the preform using a Field Assisted Sintering Technique (FAST) process to produce a component having a density of greater than 97% of the theoretical density of the material. Components, in particular low aspect components, formed by said method are also described.

Abstract: A method may comprise: placing a probe in a molten metal melt comprising a thixotropic metal alloy; injecting a gas into the molten metal melt to form a saturated slurry, the saturated slurry being at a temperature above a liquidus temperature of the thixotropic metal alloy after injecting the gas; removing the probe from the molten metal melt; and depositing the molten metal melt through an extruder of an additive manufacturing system.

Abstract: A method of titanium rod additive manufacturing may comprise: mixing a plurality of powdered metals comprising titanium, iron, vanadium, and aluminum to produce a powder blend; isostatic pressing the powder blend to form a billet having a cross-sectional profile; cutting the billet to form a rod feedstock having the first cross-sectional profile; loading the rod feedstock into an additive manufacturing machine configured to deposit the rod feedstock; and producing a metallic component from the rod feedstock.

Abstract: A method of fabricating a near net shape component includes forming a sacrificial shell from a pulverant material using an additive manufacturing process, the shell having an aperture. The method further includes filling the shell with a second pulverant material, subjecting the filled shell to a consolidation process, and removing the shell from the consolidated second pulverant material.

Abstract: An additive material manufacturing (AMM) system is provided to deposit powder to a build. The AMM system includes a powder supply, and a delivery mechanism. The powder supply receives a first electrical charge having first polarity. The delivery mechanism receives a second electrical charge having second polarity opposite first polarity. The build receives a third electrical charge having the first polarity. The third electrical charge of the build is greater than the second electrical charge of the delivery mechanism. The delivery mechanism receives the electrically charged powder where it is retained thereto based on electrostatic attraction generated between the first polarity of the electrically charged powder and the second polarity of the delivery mechanism. The electrocharged powder is from the delivery mechanism to the build based on electrostatic attraction generated between the first polarity of the electrically charged powder and the second polarity of the build.

Abstract: A method for making an article is disclosed. The method involves inputting a digital model of an article into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder includes an aluminum alloy having 2.00-10.00 wt. % cerium, 0.50-2.50 wt. % titanium, 0-3.00 wt. % nickel, 0-0.75 wt. % nitrogen, 0-0.05 wt. % other alloying elements, and the balance of aluminum, based on the total weight of the aluminum alloy.

Abstract: A method may comprise: placing a probe in a molten metal melt comprising a thixotropic metal alloy; injecting a gas into the molten metal melt to form a saturated slurry, the saturated slurry being at a temperature above a liquidus temperature of the thixotropic metal alloy after injecting the gas; removing the probe from the molten metal melt; and depositing the molten metal melt through an extruder of an additive manufacturing system.

Abstract: An additive manufacturing system includes an ultrasonic inspection system integrated in such a way as to minimize time needed for an inspection process. The inspection system may have an ultrasonic phased array integrated into a build table for detecting defects in each successive slice of a workpiece and such that each slice may be re-melted if and when defects are detected.

Abstract: A method of fabricating a near net shape component includes forming a sacrificial shell from a pulverant material using an additive manufacturing process, the shell having an aperture. The method further includes filling the shell with a second pulverant material, subjecting the filled shell to a consolidation process, and removing the shell from the consolidated second pulverant material.