Abstract: A workpiece manufactured from an additive manufacturing system (AMS) having a particle separator and a method of operating includes modeling the workpiece into layers and modeling the layers into a plurality of regions. The AMS then deposits one of a plurality of particle types into a respective one of the plurality of regions. In this way, the surface finishes of the component may be controlled and material densities from one region to the next and from one layer to the next are also controlled.

Abstract: An additive manufacturing system includes a build platform and an illuminator disposed on opposite sides of a powder carrier relative to gravity. The powder carrier has a movement envelop that intersects the beam path and includes a material that is translucent to radiation emitted by the illuminator such that the emitted radiation traverses the powder carrier and fuses powder from a powder bed carried by the powder carrier with a substrate overlying the powder carrier and suspended from the build platform.

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 for making an article is described that includes generating a digital model of the article that comprises an internal cavity. The digital model is inputted into an additive manufacturing apparatus or system comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a metal powder, which fuses the powder to form incremental portions of the metal powder according to the digital model to form the article with the internal cavity. Abrasive magnetic particles are disposed in the internal cavity, and a magnetic field is applied to the magnetic particles in the internal cavity. Repeated relative movement is imparted between the magnetic field and the article to hone a fused metal powder surface of the internal cavity.

Abstract: A method includes additively manufacturing an article in an inert environment, removing the article from the inert environment and placing the article in a non-inert environment, allowing at least a portion the article to oxidize in the non-inert environment to form an oxidized layer on a surface of the article, and removing the oxidized layer (e.g., to smooth the surface of the article). The method can further include relieving stress in the article (e.g., via heating the article after additive manufacturing).

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 producing a heat exchanger includes designing the heat exchanger to include a wall with a target thickness. A model is created relating process parameters to geometry of a single track melt pool and relating the single track melt pool geometry to a heat exchanger wall thickness. At least one variable process parameter is defined. The model, heat exchanger wall target thickness, and variable process parameters are used to identify a set of process parameters to produce the heat exchanger wall target thickness. The melt pool geometry is predicted based on the model and process parameters. The heat exchanger wall target thickness is predicted based on the melt pool geometry. The process parameters that will produce the heat exchanger wall target thickness are identified. The additive manufacturing process is controlled based upon the identified set of process parameters to create the heat exchanger wall target thickness.

Abstract: A hybrid airfoil according to an exemplary aspect of the present disclosure includes, among other things, a leading edge portion made of a first material, a trailing edge portion made of a second material, and an intermediate portion between the leading edge portion and the trailing edge portion made of a non-metallic material. A rib is disposed between the leading edge portion and the intermediate portion. A protrusion of one of the rib and the intermediate portion is received within a pocket of the other of the rib and the intermediate portion.

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 selecting an alloy for additive manufacturing includes melting a first material and a second material together to create a material melt, spinning the material melt to create melt spun ribbons, welding the ribbons together to produce a weld, and determining a weld quality of the weld.

Abstract: An example multi-dimensional component building system includes a first chamber having at least one base disposed therein, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber is configured to receive the at least one base via a first transfer mechanism if the fluid parameters of the first chamber are approximately equal to the fluid parameters of the second chamber. The second chamber includes a directed heat source and a build-up material configured to form a component on the at least one base by melting or sintering. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position.

Abstract: A pulverant material supply system has an outer shell, an inner shell, and a plurality of openings to a passage within the inner shell to allow a reducing fluid into the pulverant material contained therein. The liner is made from a non-evaporable getter alloy.

Abstract: A method of forming an object includes installing multiple foil drums within a processing chamber of an ultrasonic consolidation system. The multiple foil drums each include different materials than the other foil drums. The multiple foil drums are positioned so that one of the foils is selected to be placed on top of the build platform. The selected foil is welded onto the build platform or onto a previously processed layer. A portion of the welded foil is then cut. The multiple foil drums are retracted away from the build platform. The portion of the welded foil that was just cut is then consolidated to the object. The build platform is incrementally lowered before the process is repeated to form the next layer of the object.

Abstract: A method includes issuing a state change fluid into an internal passage of an additively manufactured article and causing the state change fluid to change from a first state having a first viscosity to a second state that is either solid or has a second viscosity that is higher than the first viscosity within the internal passage. The method can also include causing the state change fluid to change back from the second state to the first state and flushing the state change fluid from the internal passage to remove residual powder from the additively manufactured article.

Abstract: A method for additively manufacturing an article includes applying energy to a powder to produce a weld pool of molten powder and applying an electromagnetic field to the weld pool to control one or more characteristics of the weld pool. Applying the electromagnetic field can include applying an electric field and/or a magnetic field to the weld pool.

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 for forming a part includes: forming a first portion of the part at a first level; forming a second portion of the part at a second level; wherein forming the first and second portions includes exposing the first and second levels to a sintering process and portions of the first and second levels to an electron beam; causing a magnetorheological (MR) fluid to move into a passage inside the first and second portions; exposing the first and second portions to a magnetic field causing motion of particles in the MR fluid to move and break up sintered material in the passage; and removing some or all of the sintered material in the passage.

Abstract: A powder bed deposition apparatus comprises a movable build plate, a powder delivery system, an energy beam apparatus capable of selectively steering at least one focused energy beam over successive quantities of metal powder, a non-metallic barrier layer, and an anchor removably secured to the build plate. The non-metallic barrier layer is disposed over a metal upper surface of the build plate. The anchor has a metal bonding surface flush with the non-metallic barrier layer, the non-metallic barrier layer and the anchor defining a removable build assembly with a powder bed working 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: A structure includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset.