Abstract: A method according to an exemplary aspect of the present disclosure, includes, among other things, at least partially filling a vessel with an abrasive fluid, pressurizing the abrasive fluid, and vibrating a component within the vessel. Further, the method includes gradually adjusting a rate material is removed from the component.

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 method according to an exemplary aspect of the present disclosure, includes, among other things, at least partially filling a vessel with an abrasive fluid, pressurizing the abrasive fluid, and vibrating a component within the vessel. Further, the method includes gradually adjusting a rate material is removed from the component.

Abstract: According to one embodiment of this disclosure, a coating includes a plurality of elongated reinforcing materials. The coating includes a bond coat in which a first portion of a first elongated reinforcing material is embedded. The coating further includes a ceramic coat adjacent the bond coat in which a second portion of the first elongated reinforcing material is embedded.

Abstract: A method of manufacturing a rotor having a hub and a plurality of vanes extending therefrom includes providing the hub, the hub having an outer surface, and depositing a laser cladding on the hub outer surface to form the plurality of vanes.

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 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 globule for an additive manufacturing process includes a plurality of additive manufacturing stock particles respectively having a submicron size. A binder fixes the plurality of submicron size additive manufacturing stock particles to one another such that the particles form a globule having a size of less than fifty microns.

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 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 ceramic turbine component is formed by a process including mixing a ceramic powder with a metal binder powder mixture. The powder mixture is then formed into a turbine component that is subsequently densified by partial transient liquid phase sintering. In an embodiment, the turbine component may be formed by an additive manufacturing process such as selective laser sintering.

Abstract: A ceramic turbine component is formed by a process including mixing a ceramic powder with an inorganic binder powder. The powder mixture is then formed into a turbine component that is subsequently densified by transient liquid phase sintering. In an embodiment, the turbine component may be formed by an additive manufacturing process such as selective laser sintering.

Abstract: An additive manufacturing apparatus comprises a laser beam generator, a build surface spaced apart from the laser beam generator, and first and second adjacent optical elements disposed along a beam travel path between the laser beam generator and the build surface. The first optical element is continuously rotatable about a beam steering axis and the second optical element is continuously rotatable about the beam steering axis independently of the first optical element.

Abstract: An additive manufacturing system comprises a build chamber, a powder bed additive manufacturing device disposed in the build chamber, and a powder contamination detection system. The powder contamination detection system is in communication with an atmosphere in the build chamber.

Abstract: A solid freeform manufacturing system includes a manufacturing chamber containing a powder based additive manufacturing device. The manufacturing chamber is connected to an environmental control chamber. The environmental control chamber contains environmental control devices including fans, filters, and an inert gas source. An interconnection between the environmental control chamber and manufacturing chamber allows an inert, contaminant free manufacturing environment.

Abstract: A method of additive manufacturing of a component includes cutting a plurality of sheets, each sheet corresponding to a respective cross-section of the component, tack welding the sheets to one another to form a stack, arranging the stack in a mold, and spark plasma sintering the tack-welded stack of sheets to reduce vacancies and dislocations between adjacent sheets of the stack.

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 Blade Outer Air Seal (BOAS) includes a body manufactured of a metal alloy, the body includes a face opposite a forward interface and an aft interface, the face includes a cavity. A non-metallic insert within the cavity such that the insert is flush with the face.

Abstract: A method of forming a leading edge protection component includes depositing particles using a cold spray process on a mandrel to form a leading edge protection component; and removing the leading edge protection structure from the mandrel. The leading edge protection can be formed in one or more pieces and involve using one or more mandrels.

Abstract: A Blade Outer Air Seal (BOAS) includes a body manufactured of a metal alloy, the body includes a face opposite a forward interface and an aft interface, the face includes a cavity. A non-metallic insert within the cavity such that the insert is flush with the face.