Abstract: A method and apparatus for identifying porosity in a structure made by an additive manufacturing process in which a laser is scanned across layers of material to form the structure. Pyrometry data comprising images of the layers acquired during additive manufacturing of the structure is received. The pyrometry data is used to generate temperature data comprising estimated temperatures of points in the layers in the images of the layers. The temperature data is used to identify shapes fit to high temperature areas in the images of the layers. Conditions of the shapes fit to the high temperature areas in the images of the layers are identified. Outlier shapes are identified in the shapes fit to the high temperature areas in the images of the layers using the conditions of the shapes.

Abstract: Examples of a system for additive manufacturing are described. The system comprises a powder reservoir for storing the metal powder operatively coupled to a working chamber that includes a powder feeder with a housing that defines an inner cavity with an inlet and a number of nozzles in communication with the inner cavity of the powder feeder defining an outlet of the feeder. The number of nozzles are positioned around a center axis of a generated energy beam. A powder feeder's driver is configured to drive flow of the powder through the nozzles directly into a beam path such that an exact amount of the powder is placed into the beam path to be melted or sintered onto a powder bed.

Abstract: In a method of applying a weld to a target surface, a guide rail arrangement is attached to the target, the guide rail arrangement including at least one guide rail. A weld head carriage having a carriage housing, a rail follower assembly, and a sonotrode is movably mounted to the guide rail arrangement so that the follower assembly engages each guide rail for movement there-along. The weld head carriage is positioned adjacent the target surface, feedstock material is deposited onto the target surface, and the sonotrode is extended to engage the deposited feedstock material and apply a welding force to the feedstock material and the target. Relative movement between the carriage and the guide rail arrangement is initiated and ultrasonic vibrations are conducted into the feedstock material and the target, thereby welding the feedstock material to the target surface.

Abstract: A method of printing a hollow part with a robotic additive manufacturing system includes extruding thermoplastic material onto a build platform movable in at least two degrees of freedom in a helical pattern along a continuous 3D tool path with an extruder mounted on a robotic arm, to thereby print a hollow member having a length and a diameter. The method includes orienting the hollow member during printing by moving the build platform based on a geometry of the hollow member wherein the movement of the build platform and the movement of the robotic arm are synchronized to print the part without support structures.

Abstract: A steel track chain component, such as a track bushing, may be formed with a carburized portion, a hardface portion, and a core portion. The core portion may be softer than the carburized portion, which in turn, may be softer than the hardface portion. This configuration of the various portions of the component may allow for relatively high wear resistance of the component, as well as toughness. The core portion may be mostly ferrite crystal structure, while the carburized portion and the hardface portions may include martensitic and/or austenitic crystal structure. The carburized portion may be formed by carburizing the track chain component in a heated and carbon rich environment. The hardface portion may be formed by welding a hardface alloy over at least a portion of the carburized portion.

Abstract: A system and method of monitoring a powder-bed additive manufacturing process is provided where a layer of additive powder is fused using an energy source and electromagnetic emission signals are measured by a melt pool monitoring system to monitor the print process. The measured emission signals are analyzed to identify outlier emissions and clusters of outliers are identified by assessing the spatial proximity of the outlier emissions, e.g., using clustering algorithms, spatial control charts, etc. An alert may be provided or a process adjustment may be made when a cluster is identified or when a magnitude of a cluster exceeds a predetermined cluster threshold.

Abstract: A method of additive manufacture is disclosed. The method may include providing a powder bed and directing a shaped laser beam pulse train consisting of one or more pulses and having a flux greater than 20 kW/cm2 at a defined two dimensional region of the powder bed. This minimizes adverse laser plasma effects during the process of melting and fusing powder within the defined two dimensional region.

Abstract: A method of reworking or repairing a component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole; sealing the through hole with a backing; and at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.

Abstract: Systems, devices, and methods for additive manufacturing are provided that allow for components being manufactured to be assessed during the printing process. As a result, changes to a print plan can be considered, made, and implemented during the printing process. More particularly, in exemplary embodiments, a spectrometer is operated while a component is being printed to measure one or more parameters associated with one or more layers of the component being printed. The measured parameter(s) are then relied upon to determine if any changes are needed to the way printing is occurring, and if such changes are desirable, the system is able to implement such changes during the printing process. By way of non-limiting examples, printed material in one or more layers may be reheated to alter the printed component, such as to remove defects identified by the spectrometer data.

Abstract: A multiple axis robotic additive manufacturing system includes a robotic arm movable in six degrees of freedom. The system includes a build platform movable in at least two degrees of freedom and independent of the movement of the robotic arm to position the part being built to counteract effects of gravity based upon part geometry. The system includes an extruder mounted at an end of the robotic arm. The extruder is configured to extrude at least part material with a plurality of flow rates, wherein movement of the robotic arm and the build platform are synchronized with the flow rate of the extruded material to build the 3D part.

Abstract: A support assembly includes a part and a tension support rod. The part is additively manufactured on a base plate and includes a series of stacked layers of material fused together. The tension support rod is attached to the base plate at a first attachment location and is attached to the part at a second attachment location. At least one of the first attachment location or the second attachment location comprises a pivot joint to enable movement of the tension support rod at the pivot joint.

Abstract: An apparatus for fabricating a three-dimensional object from a representation of the object stored in memory. The apparatus includes an outer drum supported for rotation and an inner drum positioned within the outer drum and supported for rotation therewith. A powder receiving chamber is defined between the outer drum and the inner drum. A build platform is supported for linear movement within the powder receiving chamber from a first position adjacent a first end of the drums to a second position within the powder receiving chamber. The build platform is rotationally fixed relative to at least one of the inner or outer drums such that the build platform rotates with the drums. At least one directed energy source is positioned above the build platform and is configured to apply directed energy to at least a portion of the powder receiving chamber.

Abstract: Methods and systems for fabricating a component by consolidating a particulate include a build platform configured to receive a particulate, a particulate dispenser configured to deposit the particulate on the build platform, and at least one print head including at least one jet. The at least one print head is configured to dispense a binder through the at least one jet onto the particulate to consolidate at least a portion of the particulate and form a component. The methods and systems also include at least one actuator assembly configured to rotate at least one of the at least one print head and the build platform about a rotation axis extending through the build platform and move at least one of the at least one print head and the build platform in a build direction perpendicular to the build platform as part of a helical build process for the component.

Abstract: The invention relates to an additive production method involving the production of a layer of geometrically compact particles, having the following steps: a) providing a particle layer depositing arrangement, comprising a first and a second semi-chamber, wherein a partition separates the first semi-chamber from the second semi-chamber, and the partition is permeable for a dispersion medium and impermeable for particles dispersed in the dispersion medium; b) providing a particle dispersion comprising the dispersion medium and particles dispersed therein in the first semi-chamber, the particle dispersion being distributed substantially homogenously in the first semi-chamber; c) generating a pressure gradient between the first and the second semi-chamber such that the pressure gradient in the first semi-chamber causes a particle dispersion flow directed towards the partition; and d) depositing a particle aggregate material comprising geometrically compact particles on the partition by transporting a dispersion a

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: An additive manufacturing system includes a build plate; a deposition system operable to dispense material as a melt pool to grow a workpiece on the build plate; a sensor system operable to determine a temperature of the workpiece being grown on the build plate adjacent to the melt pool; and a heater system operable to selectively heat the workpiece between the melt pool and the build plate.

Abstract: According to one embodiment, a disk device includes a disk-shaped recording medium, a head which processes data on the recording medium, and a housing accommodating the recording medium and the head. The housing includes a base with a side wall, and a cover having a welded portion welded to the side wall by laser welding. The welded portion includes a first welded portion welded to a first region of the side wall and having weld beads with a first shape, and a second welded portion welded to a second region of the side wall and having welded beads with a second shape different from the first shape.

Abstract: Provided is a three-dimensional laminating and shaping apparatus 100 including a column unit 200 that is configured to output an electron beam EB and deflect the electron beam EB toward the front surface of a powder layer 32, an electron detector 72 that is configured to detect electrons that may be emitted in a predetermined direction from the front surface of the powder layer 32 when the powder layer 32 is irradiated with the electron beam EB, a melting judging unit 410 that is configured to generate a melting signal based on the strength of the detection signal from the electron detector 72, and a deflection controller 420 that is configured to receive the melting signal to determine the condition of the irradiation the electron beam.

Abstract: An additive manufacturing system including a build plate and at least two powder reservoirs. The at least two powder reservoirs including a first powder reservoir configured to store a first powder and deposit the first powder onto the build plate, wherein the first powder reservoir is configured to move relative to the build plate, and a second powder reservoir configured to store a second powder and deposit the second powder onto the build plate, wherein the second powder reservoir is configured to move relative to the build plate. The first powder has at least one predetermined characteristic that is different than that of the second powder.

Abstract: The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and/or software to form one or more three-dimensional objects, some of which may be complex. The three-dimensional objects may be formed by three-dimensional printing using one or more methodologies. In some embodiments, the three-dimensional object may comprise an overhang portion, such as a cavity ceiling, with diminished deformation and/or auxiliary support structures.

Abstract: The temperature of a molten pool is measured based on an image captured by an infrared camera or the like. A three-dimensional laminating and shaping apparatus include a material ejector that ejects a material of a three-dimensional laminated and shaped object. The three-dimensional laminating and shaping apparatus includes a light beam irradiator that irradiates the ejected material with a light beam. The three-dimensional laminating and shaping apparatus includes an image capturer that captures a molten pool of the material formed by irradiating the ejected material with the light beam. The three-dimensional laminating and shaping apparatus includes a temperature deriving unit that derives a temperature of the molten pool based on a luminance of an image of the molten pool captured by the image capturer.

Abstract: An additive manufacturing system including a build plate and a powder spreading unit having a plurality of recoater blades configured to spread powder onto the build plate. The powder spreading unit including a base member, and the plurality of recoater blades is coupled to the base member and configured to spread powder onto the build plate.

Abstract: A method for producing a layered object includes irradiating a surface layer of the object with an energy beam to create an interaction zone on the surface layer. The method also includes providing relative motion between the energy beam and the surface layer so as to control the interaction between the energy beam and the surface layer. The method also includes introducing feedstock into the interaction zone so that the feedstock melts and forms a hot solidified surface after leaving the interaction zone. The method also includes applying mechanical energy to the hot solidified surface.

Abstract: An additive manufacturing system including a build plate, and at least one powder reservoir configured to store and deposit powder onto the build plate, the at least one powder reservoir including a powder dispensing aperture having a variable size. The powder dispensing unit includes a base member, and the least one powder reservoir coupled to the base member.

Abstract: An additive manufacturing system including a build plate, at least one recoater blade configured to spread powder onto the build plate, and at least one vibration mechanism coupled to one or more of the build plate and the at least one recoater blade. A controller coupled to the at least one vibration mechanism is configured to control actuation of the at least one vibration mechanism so that vibratory pulses are induced within the powder to effect compaction of the powder on the build plate.

Abstract: The invention relates to additive manufacturing field and laser shock peening (LSP) field, in particular to a combined apparatus for layer-by-layer interactive additive manufacturing with laser thermal/mechanical effects. In the apparatus, a LSP module and a SLM module operate in alternate so as to perform LSP for the formed part in the forming process of the formed part, and thereby a better strengthening effect of the formed part is achieved. The invention effectively overcomes the challenges of “shape control” against deformation and cracking of the formed parts incurred by internal stress and “property control” against poor fatigue property of the formed parts incurred by metallurgical defects during additive manufacturing, improves fatigue strength and mechanical properties of the faulted parts, and realizes high-efficiency and high-quality holistic processing of the formed parts.

Abstract: A method is described for manufacturing a three-dimensional product, in particular a hydraulic element, the method encompassing at least the following method steps: Providing a first section of the product to be manufactured, which includes at least one first connection point for a second section of the product to be manufactured; and producing the second section by an additive manufacture in which the at least one first connection point of the first section is used as a substrate for the additive manufacture of the second section.

Abstract: An additive manufacturing system includes at least one imaging device configured to direct electromagnetic radiation towards a build layer of a component positioned within a powder bed of the additive manufacturing system. The additive manufacturing system also includes at least one detector configured to detect the electromagnetic radiation that reflects from the build layer.

Abstract: An additive manufacturing apparatus and corresponding method for building an object by layerwise consolidation of material wherein the apparatus includes a build enclosure containing a build support for supporting the object during the build, a material source for providing material to selected locations for consolidation, a radiation device for generating and directing radiation to consolidate the material at the selected locations and an acoustic sensing system. The acoustic sensing system may be arranged to detect acoustic signals generated in the build enclosure by consolidation of the material with the radiation. The acoustic sensing system may be a passive acoustic sensing system arranged to detect acoustic signals generated in the build enclosure that are indicative of at least one condition of the building process and/or the object.

Abstract: A component is produced in layers by laser melting. A molten pool is created in a bed of powder by a working laser beam. Further auxiliary laser beams are set to a power density that merely slows down the cooling of the material in one zone, but do not cause any renewed melting. In this way, the cooling rate of the microstructure can be set so that an advantageous structural formation develops. This allows for example the mechanical properties of the component produced to be advantageously improved without downstream heat treatments.

Abstract: A robot includes a first member, a second member provided to be capable of turning with respect to the first member, and a gear device configured to transmit a driving force from one side to the other side of the first member and the second member. The gear device includes internal teeth and external teeth provided halfway in a transmission path of the driving force and configured to mesh with each other and lubricant disposed between the internal teeth and the external teeth. An average grain size of a constituent material of the external teeth is smaller than an average grain size of a constituent material of the internal teeth.

Abstract: A method of manufacturing a terminal-formed electric wire includes a welding member placing process in which at least one welding member formed of metal having a melting point lower than that of a plurality of metal strands included in a core wire is arranged to the core wire of at least a terminal-forming target portion of the electric wire, and a terminal forming process in which the exposed terminal-forming target portion is interposed between first and second electrodes having a shape corresponding to a desired terminal shape, at least the welding member in the terminal-forming target portion is melted by electrically conducting the first and second electrodes while pressing the terminal-forming target portion with the first and second electrodes, and the melted metal is then solidified, so that the terminal-forming target portion is formed as a terminal portion having a desired terminal shape.

Abstract: A water jet peening device includes a sealed vessel provided to cover a surface of a welded portion, and adapted to be in a sealed state where an internal pressure is higher than an outside, a jet nozzle adapted to jet high-pressure water to create a cavitation bubble toward the surface of the welded portion, inside the sealed vessel, and a pressure control hole adapted to be able to adjust the internal pressure of the sealed vessel. The water jet peening device can efficiently reform a tensile residual stress on the surface of the welded portion to a compressive residual stress.

Abstract: A tool welding system is disclosed that includes a table that heats a tool. A multi-axis robot includes a welding head that is moved relative to the table in response to a command. A controller is in communication with the robot and generates the command in response to welding parameters. The weld parameters are based upon a difference between an initial tool shape and a desired tool shape. The difference between the initial tool shape and the desired tool shape corresponds to a desired weld shape. The desired weld shape is adjusted based upon initial tool shape variations, which includes thermal growth of the tool. The tool is welded to provide the desired weld shape to achieve a desired tool shape.

Abstract: A welding wire feeder having a multiple motor drive standard is provided. The welding wire feeder may be coupled to one of a plurality of electric motor assemblies, and a user may select the electric motor assembly to be used from a menu of electric motor assemblies on a user interface or may enter customized configuration parameters for the electric motor assembly on the user interface. The control circuitry of the welding wire feeder may then be properly configured backed upon which electric motor assembly is selected or based upon the customized configuration parameters entered.

Abstract: Methods of forming a blade and rendering a blade resistant to erosion includes positioning a backing plate(s) or elongated backing plate(s) adjacent at least one side of a forward face of a leading edge surface of the blade. The methods include depositing an erosion resistant material in a plurality of layers by fusion bonding the erosion resistant material to the forward face of the leading edge surface of the blade. The backing plates providing a template or guide for depositing the plurality of layers of erosion resistant material. The plurality of layers of erosion resistant material form an erosion shield and a leading edge of the blade. Methods include removing the backing plate.

Abstract: A process for closing an opening in a surface of a component, and components formed thereby. The process entails forming a channel in the component surface so that the channel at least partially surrounds an opening at the component surface. An alloy is then deposited in the channel to form a crack-free deposit in the channel. A step is then machined that intersects the opening and is at least partially formed in the deposit. The step defines a recess that is at least partially surrounded by a peripheral portion of the deposit and has a surface recessed into the component surface. A cap is placed in the recess and welded to the peripheral portion of the deposit to define a weld joint that completely closes the opening. The surface of the weld joint is then machined to form a machined surface that is substantially flush with the component surface.

Abstract: Cladding and remanufacturing a machine component includes directing cleaning and welding beams split from an incident laser beam toward the machine component, and moving the machine component relative the cleaning and welding beams such that the welding beam trails behind the cleaning beam along a common travel path. A surface of the machine component is decontaminated by the cleaning beam, whilst a cladding material is melted via the welding beam such that upon solidifying the cladding material forms a coating metallurgically bonded to base material and previously deposited cladding material of the machine component.

Abstract: A repairing method includes heating a base material by a heater, and irradiating a laser beam to a repair region of the base material by using a laser oscillator unit, after the base material is heated. In the method, generation of a crack and a break can be suppressed, and the repair region can be repaired more appropriately.

Abstract: A welding head is provided. The welding head includes a bracket and a plurality of blocks coupled to the bracket. Each of the plurality of blocks has a contact tip. The contact tips are adapted to receive an electrode. Further, at least one of the plurality of blocks is capable of variable positioning relative to the bracket.

Abstract: An additive layer manufacture (ALM) machine comprises an energy source (180) for selectively melting a layer of metal powder (500), and an electron beam (110) for determining the shape of the selectively melted solid layer (320) once it has solidified. The shape is determined by detecting backscattered electrons (130) from the interaction between the electron beam (110) and the solid layer (320). If the shape of the solid layer (320) is outside a determined tolerance, it may be corrected before proceeding. The process may be repeated to generate a finished component (300) with good mechanical properties and accurate geometry.

Abstract: An apparatus for cladding the interior surfaces of a curved pipe section includes a flexible track that is positioned longitudinally within the curved pipe and supported at opposite ends to corresponding opposite ends of the curved pipe. The flexible track is caused to bend and conform to the radius of curvature of an interior surface of the curved pipe. A robotic crawler is supported on the track section and carries a material applicator head. The robotic crawler is driven back-and-forth across the track section while the material applicator head applies an overlay material to the interior surface of the curved pipe. In a method, the position of the curved pipe in space, the travel direction and speed of the crawler and the position of the application head are all coordinated to maintain the application of the overlay material in the “flat plane” position.

Abstract: There is provided a transmission device comprising a rigid casing configured to be mounted perpendicularly on a pair of parallel rotatable driving and driven shafts. Annular driving and driven gears are provided in the casing. The annular driving gear is adapted for rotating simultaneously with the driving shaft, and is also adapted for forwarding rotational motion of the inner section to a transmission device. The annular driven gear is adapted for engaging and rotating simultaneously with the driving shaft and sliding over the same, and for forwarding to the inner section rotational motion received from the transmission device. The transmission device is rotatively connected to the annular driving and driven gears for transmitting rotational movement of the driving shaft to the driven shaft. There is also provided a portable boring-welding apparatus using this transmission device and a method for rotating a driven shaft using a parallel driving shaft.

Abstract: An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material of the plurality of metallic anchoring materials.

Abstract: Methods and systems to manufacture gun suppressors using laser metal melting (LMM) are disclosed, together with gun suppressors manufactured according to the methods and systems. In preferred forms the LMM process involves deposition of a metal powder such as titanium oxide.

Abstract: A method for forming a component includes providing a first layer of a mixture of first and second powders. The method includes determining the frequency of an alternating magnetic field to induce eddy currents sufficient to bulk heat only one of the first and second powders. The alternating magnetic field is applied at the determined frequency to a portion of the first layer of the mixture using a flux concentrator. Exposure to the magnetic field changes the phase of at least a portion of the first powder to liquid. The liquid portion couples to at least some of the second powder and subsequently solidifies to provide a composite component.

Abstract: Disclosed is a method for affixing a metal cladding to a metal base. The method includes: heating the metal cladding and a surface of the metal base with a heating device to create a molten metal pool having molten metal cladding layered upon molten metal base material in the metal base; stabilizing a temperature gradient of the molten metal pool with a laser beam directed into the molten metal pool; and cooling the molten metal pool to affix solidified cladding to the metal base.

Abstract: A method for re-melting and refilling a defect (7) in a surface (19) of a substrate (4) by re-melting the defect (7) causing a hollow (28) to be produced above the re-melt, and the hollow (28) is refilled. A nickel- or cobalt-based substrate (4) is re-melted by a laser re-melting method. Subsequently, the hollow (28) that is produced is refilled by a laser application method, in particular by soldering. Also, a component having a re-melted region (25) and a solder region (31) thereover is disclosed.

Abstract: A heater tube is provided for use in a method of producing a diamond or cubic boron nitride (CBN) tipped cutting tool by sintering a mass of crystalline particles to a metal carbide. The heater tube has a cylindrical shape and is comprised of a plurality of windings of an expanded graphite foil which are compressed together. In the method, a heater tube assembly is formed which comprises the metal carbide substrate positioned within the heater tube and a mass of diamond or CBN particles positioned within the heater tube adjacent the substrate. The method includes simultaneously applying sufficient levels of pressure to the heater tube assembly and sufficient levels of electrical current to the heater tube assembly for a sufficient amount of time to cause sintering of the crystalline particles and bonding to the substrate to form a diamond or CBN tipped cutting tool.

Abstract: A multi-hole probe has a kernel that includes a forward surface that includes at least a first, second, and third pressure sensing ports. The multi-hole probe kernel further includes an upper surface, generally orthogonal to the forward surface, and including at least a first, second, and third stem ports. Still further, the multi-hole probe kernel includes first, second, and third tubes running between and providing a fluid connection with the first, second, and third pressure sensing ports and the first, second, and third stem ports, respectively.