Abstract: An additive manufacturing process is disclosed that involves positioning a metallic layer beneath a component substrate and welding the metallic layer to the component substrate using laser energy.

Abstract: A method of depositing powder in an additive manufacturing system includes driving a recoater along a drive axis and oscillating the recoater along an oscillation axis. The recoater is oscillated while the recoater is driven along the drive axis to overcome the effect of one or more particle movement restriction mechanisms for smoothing powder deposited in a build chamber of an additive manufacturing system.

Abstract: A method for making a component comprising a high entropy alloy (HEA) includes combining a reaction component with a powdered HEA precursor, igniting the combination of the reaction component and the powdered HEA precursor to induce a self-propagating high-temperature synthesis (SHS) reaction and to form a solid HEA feedstock, converting the solid HEA feedstock into a powder HEA feedstock, and additively manufacturing at least a portion of the powder feedstock into a HEA component or HEA preformed shape approximating a desired shape of the component.

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: The present disclosure relates to a method of manufacturing a powder for additive manufacturing. The method comprises steps of: vaporising a precursor metal material to form a metal vapor, wherein the precursor material includes a metal alloy and inclusions, and vaporising the alloy includes heating the precursor material to a temperature above the boiling point of the metal alloy and below the boiling point of the inclusions; condensing the metal vapor to form a molten metal; and atomizing the molten metal to form a metal powder. The present disclosure also relates to an apparatus for carrying out the method.

Abstract: An active clearance control valve (ACC Valve) includes a valve housing with a thermal shield provided externally to said housing, wherein said valve housing and said thermal shield have been integrally formed as one component. This may be achieved using additive manufacturing methods. Cooling channels and/or ribs may also be provided on or in the thermal shield.

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. The shape change material can include a shape-memory alloy, for example. The shape-memory alloy can include at least one of a nickel-titanium alloy (NiTi), Cu—Al—(X), Cu—Sn, Cu—Zn—(X), In—Ti, Ni—Al, Fe—Pt, Mn—Cu, or Fe—Mn—Si.

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: 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 system is provided for additively manufacturing a part. This additive manufacturing system includes a base, a solidification device and a detection device. The base is adapted to support material; e.g., powder material. The solidification device is adapted to solidify at least a portion of the supported material to form at least a portion of the part. The detection device is adapted to detect emissions produced by the solidification of at least a portion of the material.

Abstract: A method is provided for additive manufacturing. This method includes monitoring a current to a recoater blade. The monitored current is compared to a predetermined current. An operation is initiated in response to the monitored current exceeding the predetermined current. Another method for additive manufacturing includes comparing a movement of a recoater blade to an expected movement. A single exposure sequence is initiated in response to movement of the recoater blade being different than an expected movement. An additive manufacturing system is also provided which includes a recoated blade and a control. The control is operable to identify resistance to movement of the recoater blade.

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 2.00-9.00 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.

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 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 splatter shield system for an additive manufacturing machine includes one or more splatter shields configured to cover at least a portion of a build area during energy application such that the at least one splatter shield is positioned between an energy source of an additive manufacturing machine and the build area during energy application. The one or more splatter shields are transparent to an energy source (e.g., a laser) of the additive manufacturing system such that energy application occurs through the splatter shield.

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 process is provided for additively manufacturing at least one part. The processing includes depositing a substantially uniform layer of material over at least a portion of a support surface using a belt that contacts the material. The process also includes solidifying at least a portion of the layer of material using a solidification device to form at least a portion of the part.

Abstract: A splatter shield system for an additive manufacturing machine includes one or more splatter shields configured to cover at least a portion of a build area during energy application such that the at least one splatter shield is positioned between an energy source of an additive manufacturing machine and the build area during energy application. The one or more splatter shields are transparent to an energy source (e.g., a laser) of the additive manufacturing system such that energy application occurs through the splatter shield.

Abstract: A heat exchanger includes a core having a plurality of first layers for receiving a first fluid and at least one header arranged in fluid communication with the plurality of first layers. The at least one header is integrally formed ith the core via an additive manufacturing process. The header has a first microstructure and the core has a second, different microstructure.

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.