Abstract: A method of making a component using additive manufacturing (AM) techniques that selecting an AM manufacturing process suitable for making the component; selecting a material for the component that is compatible with the AM manufacturing component; selecting and programming AM process steps into a selected AM apparatus; and building the component on the selected AM apparatus using the selected AM process steps. The AM process steps are selected to produce a plurality of melt pools that reduce material segregation in the finished part. The component exhibits reduced material segregation compared to making the material with a consumable electrode remelting process. The component made with AM techniques includes a region exhibiting reduced material segregation compared to making the material with a consumable electrode remelting process.

Abstract: A method of weld repairing a cast component includes identifying a repair zone on the cast component. The repair zone represents a region of a cast substrate of the cast component requiring a directed energy deposition repair operation. A surface preparation operation is performed on the repair zone before performing the directed energy deposition repair operation. The surface preparation operation imparts a pre-selected level of compressive residual stress to the repair zone. The directed energy deposition repair operation is performed on the repair zone without formation of microcracks in a heat affected zone adjacent to the repair zone. The directed energy deposition repair operation includes formation of a directed energy deposition deposit on the cast substrate.

Abstract: Composite materials comprising ferroelastic ceramic particulates dispersed in a metal matrix are capable of vibration damping. When the ferroelastic ceramic particulates are subjected to stress, such as the cyclic stress experienced during vibration of the material, internal stresses in the ceramic cause the material to deform via twinning, domain rotation or domain motion thereby dissipating the vibrational energy. The ferroelastic ceramic particulates may also act as reinforcements to improve the mechanical properties of the composites. The composite materials may be used in various structural components in vehicles, aircraft, spacecraft, buildings and tools.