Abstract: A method includes flowing gas within a chamber for first process parameters at a predetermined point in a laser focal plane and simulating the step of flowing gas within the chamber based on the value of the flow characteristic of the gas at the predetermined point in the laser focal plane so that a value of a simulated-flow characteristic of the gas at a predetermined point away from the laser focal plane is identified. The method comprises comparing the value of the simulated-flow characteristic of gas at the predetermined point away from the laser focal plane to a desired value of the simulated-flow characteristic and flowing gas within the chamber for second differing process parameters, when the value of the simulated-flow characteristic of the gas at the predetermined point away from the laser focal plane differs from the desired value of the simulated-flow characteristic is outside a predetermined range.

Abstract: A method of configuring an additive-manufacturing machine comprises a chamber, a platform, movable inside the chamber and comprising a build-plane surface, and a laser, having a laser focal plane within the chamber. The method comprising steps of flowing a gas within the chamber in accordance with a first set of process parameters and identifying a value of a flow characteristic of the gas at a predetermined point in the laser focal plane while flowing the gas within the chamber in accordance with the first set of process parameters. The method also comprises additively manufacturing a test coupon using the laser while flowing the gas within the chamber in accordance with the first set of process parameters, wherein the test coupon has a test-coupon peripheral surface.

Abstract: A method of configuring an additive-manufacturing machine comprises a chamber , a platform, movable inside the chamber and comprising a build-plane surface, and a laser, having a laser focal plane within the chamber. The method comprising steps of flowing a gas within the chamber in accordance with a first set of process parameters and identifying a value of a flow characteristic of the gas at a predetermined point in the laser focal plane while flowing the gas within the chamber in accordance with the first set of process parameters. The method also comprises additively manufacturing a test coupon using the laser while flowing the gas within the chamber in accordance with the first set of process parameters , wherein the test coupon has a test-coupon peripheral surface.

Abstract: A computer-readable medium includes recorded instructions for performing a method of improving evacuation gas flow performance of an additive manufacturing build chamber. Instruction execution by a processor of a host computer device causes the processor to receive an input data set inclusive of flow field data of an inert gas through the build chamber, and an improvement metric operable to characterize flow improvements therein. The processor generates a flow field data set in response to the input data set, and extracts evacuation streamline data from the flow field data set. The streamline data describes expected flow paths of the inert gas through the modified build chamber. Instruction execution also causes the processor to generate an output data set using the streamline data, with the output data set including the flow improvements as characterized by the metric.

Abstract: Dual-walled fluid transportation systems and related methods. The systems comprise a dual-walled fluid conduit, comprising an outer duct comprising a pair of flared end regions and a central region extending therebetween that define an outer duct internal surface surrounding an outer duct internal volume, an inner duct defining a central conduit, extending within the outer duct internal volume, and comprising a pair of flared end regions and a central region extending therebetween that define an inner duct external surface. The inner duct and outer duct define interlocking geometries and are configured to be supported with an inner duct channel completely separating the inner duct external surface from the outer duct internal surface. The methods include additively forming an outer duct wall and additively forming an inner duct wall within an outer duct internal volume of the outer duct wall with an inner duct channel extending therebetween.

Abstract: An attachment system and method that includes first and second fittings, a first eccentric bushing positioned within the first fitting, and a second eccentric bushing positioned within the second fitting. The system may include a first friction washer positioned between the first bushing and first fitting and a second friction washer positioned between the second bushing and the second fitting. A coating on the exterior of the friction washers prohibits rotation of the bushings with respect to the fittings. The coating may be a nickel-diamond coating that prohibits rotation even in the presence of a lubricant. The first fitting may be a frame fitting connected to a fuselage of an aircraft and the second fitting may be a beam fitting connected to the floor of the aircraft. The system may include lock plates that engage lock stops to prohibit rotation of the bushings in combination with the coated friction washers.

Abstract: An attachment system and method that includes first and second fittings, a first eccentric bushing positioned within the first fitting, and a second eccentric bushing positioned within the second fitting. The system may include a first friction washer positioned between the first bushing and first fitting and a second friction washer positioned between the second bushing and the second fitting. A coating on the exterior of the friction washers prohibits rotation of the bushings with respect to the fittings. The coating may be a nickel-diamond coating that prohibits rotation even in the presence of a lubricant. The first fitting may be a frame fitting connected to a fuselage of an aircraft and the second fitting may be a beam fitting connected to the floor of the aircraft. The system may include lock plates that engage lock stops to prohibit rotation of the bushings in combination with the coated friction washers.

Abstract: An attachment system and method that includes first and second fittings, a first eccentric bushing positioned within the first fitting, and a second eccentric bushing positioned within the second fitting. The system may include a first friction washer positioned between the first bushing and first fitting and a second friction washer positioned between the second bushing and the second fitting. A coating on the exterior of the friction washers prohibits rotation of the bushings with respect to the fittings. The coating may be a nickel-diamond coating that prohibits rotation even in the presence of a lubricant. The first fitting may be a frame fitting connected to a fuselage of an aircraft and the second fitting may be a beam fitting connected to the floor of the aircraft. The system may include lock plates that engage lock stops to prohibit rotation of the bushings in combination with the coated friction washers.

Abstract: Structural components are disclosed that are fabricated from unidirectional carbon fiber composite materials into compound contour profiles along a longitudinal axis thereof without wrinkling of composite material plies oriented in various directions relative to the longitudinal axis. Methods of stacking, sequencing, and applying the material plies to fabricate the components are also disclosed.

Abstract: Structural components are disclosed that are fabricated from unidirectional carbon fiber composite materials into compound contour profiles along a longitudinal axis thereof without wrinkling of composite material plies oriented in various directions relative to the longitudinal axis. Methods of stacking, sequencing, and applying the material plies to fabricate the components are also disclosed.