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: A feedstock for a cold spray process includes a plurality of globule bodies. The globule bodies include a plurality of discrete particles bonded to one another to define porous globule bodies. The bonds between the particles are of sufficient strength such that the globule bodies can retain both the body integrity as well as the body shape when the body experiences acceleration from a conveying gas in a cold spray technique. Methods of making the feedstock and globule bodies are also described.

Abstract: A method of making a sheath for an airfoil may include the steps of forming an upper sleeve and a lower sleeve, and forming a central portion bonded to the upper sleeve and the lower sleeve. The central portion may be formed by depositing a material on the upper sleeve and the lower sleeve. A portion of the material may be removed from at least one of the central portion, the upper sleeve, or the lower sleeve. The sheath may include a first flank, a central portion bonded to the first flank, and a second flank bonded to the central portion. The central portion may have a substantially uniform microstructure resulting from additive manufacturing.

Abstract: Manufacturing methods are disclosed that can electropolish a metal surface by disposing an electrode over the metal surface, and a permeable dielectric spacer between the metal surface and the electrode. An electrolyte is infiltrated into the permeable dielectric spacer, and an electrical voltage differential is applied to the electrode and the metal surface.

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 making a ceramic matrix composite (CMC) brake component may include the steps of applying a pressure to a mixture comprising ceramic powder and chopped fibers, pulsing an electrical discharge across the mixture to generate a pulsed plasma between particles of the ceramic powder, increasing a temperature applied to the mixture using direct heating to generate the CMC brake component, and reducing the temperature and the pressure applied to the CMC brake component. The ceramic powder may have a micrometer powder size or a nanometer powder size, and the chopped fibers may have an interphase coating.

Abstract: A additive manufacturing system includes a containment housing operable to form a containment chamber with a low pressure operating atmosphere and an additive manufacturing build housing within said containment housing.

Abstract: An example embodiment of a method is disclosed for making a component including a high entropy alloy (HEA). The method includes combining a reaction component with a powdered HEA precursor to form a solid HEA feedstock. The solid HEA feedstock is converted into a powder suitable for use as a powder feedstock in an additive manufacturing device and capable of sustaining a self-propagating high-temperature synthesis (SHS) reaction. At least a portion of the powder feedstock is additively manufactured into a preformed shape approximating a desired shape of the component. The preformed shape is filled with the HEA powder feedstock. The powdered HEA precursor in the preformed shape are ignited to induce the self-propagating high-temperature synthesis (SHS) reaction, thereby forming a stable HEA component approximating the desired shape.

Abstract: An example method of making a component includes providing a digital model of a component to a software program, the software program operable to slice the digital model into digital layers and raster each digital layer into digital segments, the digital segments delineated by digital raster lines. The method further includes depositing a first layer of powdered material onto a platform, compacting the first layer of powered material into a first compacted layer, sintering the first compacted layer along lines corresponding to the digital raster lines using a laser, wherein the laser operates at a first power and a first scan speed, and sintering the first compacted layer along a perimeter of the first compacted layer using the laser to form a first unitary layer, wherein the laser operates at a second power and a second scan speed, wherein the ratio of the first power to the second power is less than about 3. An apparatus for making a component is also disclosed.

Abstract: A build plate for an additive manufacturing system is disclosed. The build plate includes a support structure, a sub-plate, and one or more transducers. The support structure is configured to support a stack of sintered layers of a pulverant material. Further, the support structure extends orthogonally to a build direction. The sub-plate is arranged along the support structure, and defines a transducer cavity. One or more transducers are arranged in the transducer cavities. The one or more transducers are operable to cause vibration of the support structure and the stack parallel to the build direction. Such vibration relieves internal stresses caused by sintering of the stack.

Abstract: A method of altering an additively manufactured part can include orienting a surface of the additively manufactured part toward a rotational center that may be independent of a rotational axis defined by the additively manufactured part, flowing an abrasive media past the surface, rotating the additively manufacturing part about the rotational center; urging abrasive particles in the abrasive media past the surface abrasive media to impinge the surface with centrifugal force generated by the rotating, and improving surface finish of the surface.

Abstract: A support structure for an additive manufacturing system includes a support body with a support body material and an interface disposed on the support body with an interface material. The interface material has a ductile-to-brittle transition temperature that is higher than the ductile-to-brittle temperature of the support body material for selectively fracturing the interface material to separate an additively manufactured article from the support body.

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 rotating tool system attachment on the spindle of a computer numerical control (“CNC”) machine includes a rotating assembly mounted on a static assembly. The rotating assembly provides a continuous supply of a wire material for deposition on a substrate during an additive manufacturing process. The rotating assembly includes a material supply housing a feedstock of wire mounted on a rotating spindle and a wire feeder configured to draw the wire from the wire supply and provide the wire for application during the additive manufacturing process. The tool system can be attached to the spindle of CNC machine to provide additive manufacturing capabilities to the CNC machine.

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 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 build plate for an additive manufacturing system is disclosed. The build plate includes a support structure, a sub-plate, and one or more transducers. The support structure is configured to support a stack of sintered layers of a pulverant material. Further, the support structure extends orthogonally to a build direction. The sub-plate is arranged along the support structure, and defines a transducer cavity. One or more transducers are arranged in the transducer cavities. The one or more transducers are operable to cause vibration of the support structure and the stack parallel to the build direction. Such vibration relieves internal stresses caused by sintering of the stack.

Abstract: A method of manufacturing a component is described comprising building a preform from a powdered first material, the preform having residual porosity, applying a coating of a second material to a porous surface of the preform by a cold spray powder deposition process to form a coated preform having a gas-tight surface, and then consolidating the coated preform to produce a component. The component may comprise a duct system.

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 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.