Abstract: A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build.

Abstract: An additive manufacturing system includes a build platform, a plurality of particles positioned on the build platform defining a build layer, a first and second region within the build layer, and at least one consolidation device. The first region and the second region each including a portion of the plurality of particles. The at least one consolidation device is configured to consolidate the plurality of particles within the build layer into a solid, consolidated portion of said build layer. The consolidation device is further configured to consolidate at least one of the plurality of particles within the build layer and the solid, consolidated portion of the build layer into a molten volume of transfer material. The consolidation device is further configured to transfer a portion of the molten volume of transfer material within the first region from the first region to the second region.

Abstract: The disclosure relates to an apparatus for manufacturing a metallic component, and corresponding methods. The apparatus may include a build plate with a build surface and an aperture. The apparatus may also include an actuator operable to translate a metallic component such that an end portion of the metallic component is positioned within the aperture of the build plate and below the build surface. The apparatus may further include a seal coupled within the aperture of the build plate and configured to engage the end portion of the metallic component. The aperture of the build plate, the seal, and the end portion of the metallic component may cooperate to form a powder bed to hold metallic powder therein. The apparatus may also include an external heat control mechanism operable to form a predetermined temperature profile of the end portion of the component to prevent cracking of the component.

Abstract: A method of method of forming or repairing a superalloy article having a columnar or equiaxed or directionally solidified or amorphous or single crystal microstructure includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array corresponding to a pattern of a layer of the article onto a powder bed of the superalloy to form a melt pool; and controlling a temperature gradient and a solidification velocity of the melt pool to form the columnar or single crystal microstructure.

Abstract: A method of fabricating an airfoil includes forming a tip portion and imaging a second end of a body portion to obtain image data of one or more mortises formed therein. One or more tenons are formed on the first end of the tip portion using the image data of the second end of the body portion. The one or more tenons are manufactured using one of additive or subtractive manufacturing techniques. To complete assembly, the first end of the tip portion is positioned relative to the second end of the body portion such that each of the one or more tenons of the tip portion align with and are in sliding engagement with a respective one of the one or more mortises of the body portion. The body portion and the tip portion are coupled together such that the tip portion and the body portion form the airfoil. An airfoil formed by the method is also disclosed.

Abstract: An additive manufacturing system is configured to manufacture a component. The additive manufacturing system includes a laser device, a build platform, a first scanning device, and an air knife. The laser device is configured to generate a laser beam. The component is disposed on the build platform. The air knife is configured to channel an inert gas across the build platform. The first scanning device is configured to selectively direct the laser beam across the build platform. The laser beam is configured to generate successive layers of a melted powdered build material on the component and the build platform. The build platform is configured to rotate the component relative to the air knife.

Abstract: Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Abstract: Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Abstract: A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build.

Abstract: A system is configured for machining a workpiece of a lattice structure, the system includes an electrode of a lattice structure, an electrolyte supply, and a power supply. The workpiece and the electrode are intertwined with each other and electrically isolated from each other. The electrolyte supply is configured for circulating an electrolyte around and between the workpiece and the electrode. The power supply is configured for applying a voltage between the workpiece and the electrode to facilitate smoothing surfaces of the workpiece.

Abstract: A customizable powder bed containment system for use with a direct metal laser melting (DMLM) system includes a plurality of interlinkable containment walls mechanically couplable on a build plate of the DMLM system as well as mechanically coupleable to another interlinkable containment wall of the plurality of interlinkable containment walls, and at least one actuator mechanically coupled to at least one interlinkable containment wall of the plurality of interlinkable containment walls. The at least one actuator is operable to selectively raise the at least one interlinkable containment wall of the plurality of interlinkable containment walls axially relative to a build surface of the build plate.

Abstract: A powder bed containment system for use with a rotating direct metal laser melting (DMLM) system includes an annular build plate, which includes an inner wall, an outer wall concentric with the inner wall and spaced radially apart from the inner wall, and a substantially planar build surface extending between the inner wall and the outer wall, where the substantially planar build surface is arranged to receive a weldable powder for manufacture of an object.

Abstract: A direct metal laser melting (DMLM) system includes a rotatable base, and a build plate mounted on and supported by the rotatable base, where the build plate includes a build surface. The DMLM system also includes a first actuator assembly, a first powder dispenser disposed proximate the build plate and configured to deposit a weldable powder on the build surface of the build plate. In addition, the DMLM system includes a first powder spreader disposed proximate the build plate and configured to spread the weldable powder deposited on the build surface of the build plate, and a first laser scanner supported by the first actuator assembly in a position relative to the build plate, such that at least a portion of the build surface is within a field of view of the first laser scanner. The first laser scanner is configured to selectively weld the weldable powder. The first laser scanner is further configured to translate axially relative to the build surface on the first actuator assembly.

Abstract: The disclosure relates to an apparatus for manufacturing a metallic component, and corresponding methods. The apparatus may include a build plate with a build surface and an aperture. The apparatus may also include an actuator operable to translate a metallic component such that an end portion of the metallic component is positioned within the aperture of the build plate and below the build surface. The apparatus may further include a seal coupled within the aperture of the build plate and configured to engage the end portion of the metallic component. The aperture of the build plate, the seal, and the end portion of the metallic component may cooperate to form a powder bed to hold metallic powder therein. The apparatus may also include an external heat control mechanism operable to form a predetermined temperature profile of the end portion of the component to prevent cracking of the component.

Abstract: An additive manufacturing system is provided. The additive manufacturing system includes a build platform and at least one workstation. The build platform defines a continuous workflow path and is configured to rotate about a build platform axis. The workstation is spaced apart from the build platform along the third direction and at least one of the build platform and the workstation is configured to move along the third direction. The workstation includes at least one particle delivery device, at least one recoating device, and at least one consolidation device. The particle delivery device is configured to deposit particles on the build platform. The recoating device is configured to distribute the deposited particles to form a build layer on the build platform. The consolidation device is configured to consolidate at least a portion of the build layer.

Abstract: A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build.

Abstract: A turbine component includes: a metallic wall having opposed interior and exterior surfaces, the wall configured for directing a combustion gas stream in a gas turbine engine; and a metallic negative CTE structure rigidly attached to one of the surfaces.

Abstract: An additive manufacturing apparatus includes first and second spaced apart side walls defining a build chamber therebetween. The first and second spaced apart side walls are configured to rotate through an angle ?, about a z-axis along a pre-defined path. A build platform is defined within the first and second spaced apart side walls and is configured to rotate through an angle ? about the z-axis and vertically moveable along the z-axis. The apparatus further includes one or more build units mounted for movement along the pre-defined path. An additive manufacturing method is additionally disclosed.

Abstract: In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, a first plurality of particles positioned on the build platform, and a particle containment system positioned on the build platform. The particle containment system includes a particle containment wall. The particle containment wall at least partially surrounds the first plurality of particles and includes a second plurality of particles consolidated together. The particle containment wall includes a top end spaced apart from the build platform, an inner face positioned against the first plurality of particles and extending between the build platform and the top end, and an outer face that faces a substantially particle-free region, the outer face positioned opposite the inner face and extending between the build platform and the top end.

Abstract: An additive manufacturing system including a consolidation device, a build platform, an optical detector, and a controller is provided. The consolidation device is configured to form a build layer of a component. The build platform is configured to rotate about a build platform rotation axis extending along a first direction. The optical detector is configured to detect locations of at least two alignment marks. The controller is configured to receive locations of the at least two alignment marks from the optical detector. The controller is also configured to determine the locations of the build platform rotation axis and a build platform rotation center point based on a comparison between the at least two alignment marks, wherein the build platform rotation center point lies along the build platform rotation axis. The controller is further configured to control the consolidation device to consolidate a plurality of particles on the build platform.