Abstract: The present disclosure provides improved additive manufacturing methods and systems. More particularly, the present disclosure provides advantageous additive manufacturing methods and systems for the production of hierarchical design optimized components (e.g., composite or composite-like materials). The present disclosure provides a methodology to produce hierarchical design optimized additively manufactured parts/materials that include an inhomogeneous structure with variable local mechanical properties across the entire volume. Hierarchical inhomogeneous structure/composite materials can be produced through a laser powder bed fusion (LPBF) process. A novel LPBF method can be used to obtain location-specific properties through in-situ controlling of the local cooling rate during the additive manufacturing process.

Abstract: An analysis tool for multi-laser additive manufacturing including a build file module; a preprocessor in operative communication with the build file module; a prime module in operative communication with the preprocessor; and a defect code module in operative communication with the prime module.

Abstract: A system for deep rolling a fan blade including a shaft assembly disposed along a first axis; a hub connected to a distal end of the shaft assembly, the hub having an upper hub portion and a lower hub portion extending along a second axis, the second axis forming an angle relative to a first axis; a roller disk joined to the lower portion of the hub, the roller disk configured to contact a fan blade; a fixture supporting the fan blade; the fixture comprising a body supporting a pivot clamp attached to the body with a pivot; a support attached to the body, the support is configured to engage an airfoil portion of the fan blade; a receiver formed in the body for supporting a root of the fan blade; and a shoulder attached to the body configured to support a platform portion of the fan blade.

Abstract: Methods and systems for treating components are described. The methods include using a system having a controller, a laser applicator, a coating applicator, and a sensor array. The laser applicator, the coating applicator, and the sensor array are arranged on a treatment arm that is controlled by the controller. The method includes scanning a surface to be treated of the component using the sensor array, cleaning the surface to be treated using the laser applicator, defining surface texture patterns, applying laser texturing, and applying a new coating to the surface to be treated using the coating applicator.

Abstract: A mechanical surface treatment method for a workpiece includes using a multi-axis powered machine to actuate a deep rolling tool having a roller relative to the workpiece. The actuating includes applying the roller against a workpiece surface with a normal force sufficient to plastically deform the workpiece and translating the roller relative to the workpiece surface. The method includes concurrently applying an electrical current to the workpiece surface in a manner that produces an electroplastic effect at the workpiece surface and a near surface region. The electroplastic effect and the plastic deformation produce a refinement in a grain structure at the workpiece surface and near surface region and an increase in dislocation sources and tangles within the grain structure.

Abstract: A method of forming a metal workpiece is disclosed herein. The method includes applying an electrical current through a feedstock material, applying a vertical axis force to the feedstock material; applying a rotational force to the feedstock material, and producing a metallic component from the feedstock material based on the electric current, the vertical axis force, and the rotational force.

Abstract: Methods and systems for treating components are described. The methods include using a system having a controller, a laser applicator, a coating applicator, and a sensor array. The laser applicator, the coating applicator, and the sensor array are arranged on a treatment arm that is controlled by the controller. The method includes scanning a surface to be treated of the component using the sensor array, cleaning the surface to be treated using the laser applicator, defining surface texture patterns, applying laser texturing, and applying a new coating to the surface to be treated using the coating applicator.

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 system for deep rolling a fan blade including a shaft assembly disposed along a first axis; a hub connected to a distal end of the shaft assembly, the hub having an upper hub portion and a lower hub portion extending along a second axis, the second axis forming an angle relative to a first axis; a roller disk joined to the lower portion of the hub, the roller disk configured to contact a fan blade; a fixture supporting the fan blade; the fixture comprising a body supporting a pivot clamp attached to the body with a pivot; a support attached to the body, the support is configured to engage an airfoil portion of the fan blade; a receiver formed in the body for supporting a root of the fan blade; and a shoulder attached to the body configured to support a platform portion of the fan blade.

Abstract: A gas turbine engine article includes a substrate that has a pre-bond surface that includes a serpentine groove. A coating is disposed on the pre-bond surface and mechanically interlocks with the serpentine groove.

Abstract: A gas turbine engine article includes a substrate that has a pre-bond surface that includes a serpentine groove. A coating is disposed on the pre-bond surface and mechanically interlocks with the serpentine groove.

Abstract: A method of predicting the cutting speed for machining of titanium alloy comprising the steps of obtaining a first transfer function for a tool system, obtaining a second transfer function for a workpiece system, selecting from the first transfer function a first flexible mode, selecting from the second transfer function a second flexible mode, defining a natural frequency of the first flexible mode and the second flexible mode, calculating a tooth passing frequency using the defined natural frequency, accepting the calculated tooth passing frequency if the calculated tooth passing frequency differs from a second harmonic of a combined system formed of the tool system and the workpiece system and from at least one natural frequency corresponding to the tool system and the workpiece system, calculating a stable spindle speed, defining a cut depth using the calculated spindle speed.

Abstract: A method of predicting the cutting speed for machining of titanium alloy comprising the steps of obtaining a first transfer function for a tool system, obtaining a second transfer function for a workpiece system, selecting from the first transfer function a first flexible mode, selecting from the second transfer function a second flexible mode, defining a natural frequency of the first flexible mode and the second flexible mode, calculating a tooth passing frequency using the defined natural frequency, accepting the calculated tooth passing frequency if the calculated tooth passing frequency differs from a second harmonic of a combined system formed of the tool system and the workpiece system and from at least one natural frequency corresponding to the tool system and the workpiece system, calculating a stable spindle speed, defining a cut depth using the calculated spindle speed.

Abstract: A tool design methodology is provided for high speed machining tools for titanium alloys. The methodology includes providing a predetermined cutting criteria such as cutting speed and cutting depth. The geometry of the tool and work piece is modeled and discretized into desired sections. Cutting parameter such as instantaneous chip load per section and three dimensional forces per section are calculated. The heat parameters are calculated such as the heat generated on the shear and friction surfaces and the heat transfer across the work piece and tool interface. The temperature at the tool and work piece interface is calculated and the coolant parameters are adjusted to reduce the temperature at the interface. Coolant parameters may include the coolant flow angle relative to the interface, coolant impingement pressure at the interface, and the coolant flow rate at the interface.