Abstract: The present invention relates to an additive manufacturing system and its methods. The system includes a material conveyor, an energy source, and a micro-forging device. The material conveyor is configured to convey material. The energy source is configured to direct an energy beam toward the material, the energy beam fuses at least a portion of the material to form a solidified portion. The micro-forging device is movable along with the material conveyor for forging the solidified portion, wherein the micro-forging device comprises a first forging hammer and a second forging hammer, the first forging hammer is configured to impact the solidified portion to generate a first deformation, and the second forging hammer is configured to impact the solidified portion to generate a second deformation greater than the first deformation.

Abstract: A forging head for additive manufacturing, comprising a base portion and a forging portion. The forging portion extends from the base portion for forging a cladding layer during formation of the cladding layer by additive manufacturing. The forging head further comprising a through hole which is formed through the base portion and the forging portion, for at least one of an energy bean and an additive material to pass through during formation of the cladding layer.

Abstract: An additive manufacturing system, comprises an energy source device for providing a first energy beam and a second energy beam; and a forging device comprising a forging head. The first energy beam and a substrate are configured to move relative to each other to fuse at least a portion of a material added to the surface of the substrate for forming a cladding layer on the substrate. The forging head is configured to forge the cladding layer during formation of the cladding layer. The second energy beam is configured to heat a forging area of the cladding layer.

Abstract: A temperature control method for additive manufacturing includes directing an energy beam of a first energy source toward a material and fusing at least a portion of the material to form a cladding layer, forging the cladding layer with a micro-forging device, and detecting a first internal effect parameter of the cladding layer at a forging position where is forged by the micro-forging device. The first internal effect parameter includes at least one of a stress or a strain of the cladding layer. The method also includes calculating a first calculated temperature of the cladding layer at the forging position based on the first internal effect parameter and adjusting the at least one of the first energy source and the micro forging device if the first calculated temperature does not fall within a desired temperature range.

Abstract: The invention relates to a temperature control system for additive manufacturing and method for same. The temperature control system comprises: a cladding device configured to fuse a material and form a cladding layer, the cladding device comprising a first energy source; a micro-forging device coupled to the cladding device for forging the cladding layer; a detecting device; a control module; and an adjusting module coupled to at least one of the first energy source and the micro-forging device.

Abstract: A method for removing oxide materials from a crack of a metallic workpiece comprises: infiltrating an alkali solution into the crack in a pressurized atmosphere or an ultrasonic environment; applying an energy to the crack to react the oxide materials with the alkali solution and form a resultant material; and rinsing the resultant material with an acid solution to remove the resultant material from the crack. The method is easier to penetrate into the inside of the cracks, in particular suitable for cleaning narrow and deep cracks.

Abstract: An ultrasonic roller burnishing system comprises a roller and a controller. The roller is configured to be pressed against a surface of a workpiece to a pressing depth, roll on the surface at a feed rate, and vibrate at an ultrasonic frequency under a back pressure. The roller is pressed and rolled by a motion unit which is driven by a drive motor. The vibrating of the roller is driven by an ultrasonic vibration unit with an input current inputted thereinto. The controller is configured to adjust at least one of the pressing depth, the back pressure, the input current and the feed rate based on an expected residual compressive stress and a real time output power of the drive motor, to generate a residual compressive stress in the workpiece which is in an expected range predetermined based on the expected residual compressive stress.

Abstract: The present invention relates to an additive manufacturing system and its methods. The system includes a material conveyor, an energy source, and a micro-forging device. The material conveyor is configured to convey material. The energy source is configured to direct an energy beam toward the material, the energy beam fuses at least a portion of the material to form a solidified portion. The micro-forging device is movable along with the material conveyor for forging the solidified portion, wherein the micro-forging device comprises a first forging hammer and a second forging hammer, the first forging hammer is configured to impact the solidified portion to generate a first deformation, and the second forging hammer is configured to impact the solidified portion to generate a second deformation greater than the first deformation.

Abstract: A method for removing oxide materials from a crack of a metallic workpiece comprises: infiltrating an alkali solution into the crack in a pressurized atmosphere or an ultrasonic environment; applying an energy to the crack to react the oxide materials with the alkali solution and form a resultant material; and rinsing the resultant material with an acid solution to remove the resultant material from the crack. The method is easier to penetrate into the inside of the cracks, in particular suitable for cleaning narrow and deep cracks.

Abstract: An additive manufacturing system, comprises an energy source device for providing a first energy beam and a second energy beam; and a forging device comprising a forging head. The first energy beam and a substrate are configured to move relative to each other to fuse at least a portion of a material added to the surface of the substrate for forming a cladding layer on the substrate. The forging head is configured to forge the cladding layer during formation of the cladding layer. The second energy beam is configured to heat a forging area of the cladding layer.

Abstract: An ultrasonic roller burnishing system comprises a roller and a controller. The roller is configured to be pressed against a surface of a workpiece to a pressing depth, roll on the surface at a feed rate, and vibrate at an ultrasonic frequency under a back pressure. The roller is pressed and rolled by a motion unit which is driven by a drive motor. The vibrating of the roller is driven by an ultrasonic vibration unit with an input current inputted thereinto. The controller is configured to adjust at least one of the pressing depth, the back pressure, the input current and the feed rate based on an expected residual compressive stress and a real time output power of the drive motor, to generate a residual compressive stress in the workpiece which is in an expected range predetermined based on the expected residual compressive stress.

Abstract: The invention relates to a temperature control system for additive manufacturing and method for same. The temperature control system comprises: a cladding device configured to fuse a material and form a cladding layer, the cladding device comprising a first energy source; a micro-forging device coupled to the cladding device for forging the cladding layer; a detecting device; a control module; and an adjusting module coupled to at least one of the first energy source and the micro-forging device.

Abstract: A forging head for additive manufacturing, comprising a base portion and a forging portion. The forging portion extends from the base portion for forging a cladding layer during formation of the cladding layer by additive manufacturing. The forging head further comprising a through hole which is formed through the base portion and the forging portion, for at least one of an energy bean and an additive material to pass through during formation of the cladding layer.

Abstract: A component treatment processes and treated gas turbine components are disclosed. The gas turbine treatment process includes laser-removing coating from a substrate of a turbine component to form laser-induced plasma, spectroscopically analyzing the laser-induced plasma, and discontinuing the laser-removing in response to the spectroscopic analyzing. The treated gas turbine component includes a laser-affected surface, the laser-affected surface having one or both of modified dimensions and modified microstructure due to being exposed to the laser-removing of the coating. The laser-affected surface has a depth corresponding to the laser-removing being discontinued based upon the spectroscopic analyzing of the laser-induced plasma formed from the laser-removing.

Abstract: A method for removing oxide from a metallic substrate is described. The method includes providing a stream of boron trifluoride; heating the metallic substrate at a first temperature; and heating the metallic substrate at a second temperature different from the first temperature. An associated apparatus is also described.

Abstract: The present invention discloses a mold core assembly. The mold core assembly includes at least one core. The core comprises a main body member and a high temperature-resistant material with a melting point over 1500° C., the length-diameter ratio of the main body member is greater than 50, and the main body member includes a high melting point metal with a melting point over 1500° C. The mold core assembly also includes a shell mold, wherein the shell mold encloses the core to form a cavity between the shell mold and the core, so as to accommodate a molten casting metal. The present invention further discloses an investment casting method.

Abstract: A method for removing oxide from a metallic substrate is described. The method includes providing a stream of boron trifluoride; heating the metallic substrate at a first temperature; and heating the metallic substrate at a second temperature different from the first temperature. An associated apparatus is also described.

Abstract: A powder micro-spark deposition system is provided. The deposition system includes an electrode and a powder feed channel configured within or at least partially surrounding the electrode for guiding powder comprising electrically conductive material into a gap between the electrode and the substrate. A powder micro-spark deposition method is also provided.