Abstract: A method of evaluating and validating additive manufacturing operations includes generating a multidimensional space defined by a plurality of bounds, determining a coordinate position of at least one additive manufacturing operation within the multi-dimensional coordinate system, and categorizing the operation as flaw free when the coordinate position is within the multi-dimensional space. Each of the bounds is defined on a distinct parameter of an additive manufacturing process, each of said parameters being a dimension in a multi-dimensional coordinate system.

Abstract: A method of evaluating and validating additive manufacturing operations includes generating a multidimensional space defined by a plurality of bounds, each of the bounds being defined on a distinct parameter of an additive manufacturing process and each of the bounds being directly related to the occurrence of a downskin roughness flaw, each of the parameters being a dimension in a multi-dimensional coordinate system, determining a coordinate position of at least one additive manufacturing operation within the multi-dimensional coordinate system, and categorizing the operation as free of downskin roughness flaws when the coordinate position is within the multi-dimensional space.

Abstract: A weld clad layer having a substantially equiaxed grain microstructure may be formed by forming a repair area in a substrate, depositing a first layer of laser deposition spots in the repair area, and depositing a second layer of laser deposition spots over the first layer of laser deposition spots. The first layer of laser deposition spots may comprise a first laser deposition spot and a second laser deposition spot adjacent to the first laser deposition spot. The first laser deposition spot may solidify prior to deposition of the second laser deposition spot. The first layer of laser deposition spots may comprise titanium or titanium alloy.

Abstract: A method for forming a reinforced metallic structure includes providing a tool having a formation surface corresponding to a desired structure shape of the reinforced metallic structure. The method also includes positioning a plurality of fibers on the formation surface of the tool. The method also includes depositing a layer of material on the plurality of fibers using a cold-spray technique. The method also includes removing the layer of material with the plurality of fibers from the tool to create the reinforced metallic structure.

Abstract: A method for forming a sheet structure includes depositing at least one layer of material on a main formation surface of a main tool using a cold-spray technique, the main tool having a plurality of tool portions that each have a formation surface such that the formation surface of each of the plurality of tool portions forms the main formation surface corresponding to a desired structure shape of the sheet structure. The method also includes removing the at least one layer of material from the main formation surface to create the sheet structure.

Abstract: A method for forming a metallic structure having a secondary component includes positioning the secondary component on a main formation surface of a main tool, the main formation surface corresponding to a desired shape of a first layer of material. The method also includes depositing a layer of material on the secondary component and the main formation surface using a cold-spray technique such that the layer of material bonds to the secondary component. The method also includes removing the layer of material and the secondary component to form the metallic structure.

Abstract: A method for forming a metallic structure having a non-linear aperture includes providing a main tool having a formation surface corresponding to a desired structure shape of the metallic structure. The method also includes attaching a removable tool having a shape corresponding to a desired aperture shape of the non-linear aperture to the main tool. The method also includes depositing a layer of material on the formation surface using a cold-spray technique. The method also includes removing the removable tool from the layer of material such that the layer of material defines the non-linear aperture.

Abstract: A method for forming a reinforced metallic structure includes depositing a mixture of metallic particles and reinforcing particles on a formation surface of a tool by cold-spraying the metallic particles to form a layer of mixed material, the formation surface corresponding to a desired shape of the reinforced metallic structure.

Abstract: A method for forming a metallic structure having multiple layers includes providing a main tool having a main formation surface corresponding to a desired shape of a first layer of material. The method also includes depositing the first layer of material on the main formation surface using a cold-spray deposition technique. The method also includes positioning a secondary tool having a secondary formation surface in a portion of a first volume defined by a first surface of the first layer of material. The method also includes depositing a second layer of material on the secondary formation surface using the cold-spray deposition technique. The method also includes removing the secondary tool such that the first volume is positioned between the first layer of material and the second layer of material.

Abstract: A method for forming a sheet structure includes providing a tool having a formation surface corresponding to a shape of the sheet structure. The method also includes depositing at least one layer of material on the formation surface using a cold-spray deposition technique. The method also includes removing the at least one layer of material from the formation surface to create the sheet structure.

Abstract: A method is provided that involves a component including a first fastener aperture that extends through the component. During the method, the component is machined to enlarge the first fastener aperture to provide an enlarged aperture. The component is friction plug welded to plug the enlarged aperture with friction plug welded material. A second fastener aperture is machined in the friction plug welded material, where the second fastener aperture extends through the component.

Abstract: A testing apparatus may include a stand having an aperture and a platform adjacent to the aperture, a clamp adjacent to the platform and configured to hold a coupon, and an actuator within the aperture. The actuator is configured to impart a first force on the platform and the coupon at a specified frequency. The testing apparatus may also include a displacement sensor adjacent to the stand and configured to measure a displacement of the coupon and circuitry connected to the actuator and the displacement sensor with the circuitry configured to collect data from the actuator and the displacement sensor.

Abstract: A method of evaluating and validating additive manufacturing operations includes generating a multidimensional space defined by a plurality of bounds, each of the bounds being defined on a distinct parameter of an additive manufacturing process and each of the bounds being directly related to the occurrence of a vertical lack of fusion flaw, each of the parameters being a dimension in a multi-dimensional coordinate system, determining a coordinate position of at least one additive manufacturing operation within the multi-dimensional coordinate system, and categorizing the operation as free of vertical lack of fusion flaws when the coordinate position is within the multi-dimensional space.

Abstract: A method of evaluating and validating additive manufacturing operations includes generating a multidimensional space defined by a plurality of bounds, determining a coordinate position of at least one additive manufacturing operation within the multi-dimensional coordinate system, and categorizing the operation as flaw free when the coordinate position is within the multi-dimensional space.

Abstract: A method of evaluating and validating additive manufacturing operations includes generating a multidimensional space defined by a plurality of bounds, each of the bounds being defined on a distinct parameter of an additive manufacturing process and each of the bounds being directly related to the occurrence of a balling flaw, each of the parameters being a dimension in a multi-dimensional coordinate system, determining a coordinate position of at least one additive manufacturing operation within the multi-dimensional coordinate system, and categorizing the operation as free of balling flaws when the coordinate position is within the multi-dimensional space.

Abstract: A method of evaluating and validating additive manufacturing operations includes generating a multidimensional space defined by a plurality of bounds, each of the bounds being defined on a distinct parameter of an additive manufacturing process and each of the bounds being directly related to the occurrence of a downskin roughness flaw, each of the parameters being a dimension in a multi-dimensional coordinate system, determining a coordinate position of at least one additive manufacturing operation within the multi-dimensional coordinate system, and categorizing the operation as free of downskin roughness flaws when the coordinate position is within the multi-dimensional space.

Abstract: A method of evaluating and validating additive manufacturing operations includes generating a multidimensional space defined by a plurality of bounds, each of the bounds being defined on a distinct parameter of an additive manufacturing process and each of the parameters affecting the occurrence of a keyhole porosity flaw, each of the parameters being a dimension in a multi-dimensional coordinate system, determining a coordinate position of at least one additive manufacturing operation within the multi-dimensional coordinate system, and categorizing the operation as free of keyhole porosity flaws when the coordinate position is within the multi-dimensional space.

Abstract: A method of evaluating and validating additive manufacturing operations includes generating a multidimensional space defined by a plurality of bounds, each of the bounds being defined on a distinct parameter of an additive manufacturing process and each of the parameters being directly related to the occurrence of a horizontal lack of fusion flaw, each of the parameters being a dimension in a multi-dimensional coordinate system, determining a coordinate position of at least one additive manufacturing operation within the multi-dimensional coordinate system, and categorizing the operation as free of horizontal lack of fusion flaws when the coordinate position is within the multi-dimensional space.

Abstract: A testing apparatus may include a stand having an aperture and a platform adjacent to the aperture, a clamp adjacent to the platform and configured to hold a coupon, and an actuator within the aperture. The actuator is configured to impart a first force on the platform and the coupon at a specified frequency. The testing apparatus may also include a displacement sensor adjacent to the stand and configured to measure a displacement of the coupon and circuitry connected to the actuator and the displacement sensor with the circuitry configured to collect data from the actuator and the displacement sensor.

Abstract: Systems and methods are disclosed herein for repairing components. A material layer may be deposited on a surface of a component. The material layer may cover a cooling hole. A pulsed heat source may heat the component and the material layer. An infrared camera may take a series of images of the component. A location of the cooling hole may be identified based on thermal properties of the component. A removal tool may remove a portion of the material layer in order to expose the cooling hole.