Abstract: Improved devices and methods for additive manufacturing of implant components are disclosed, including improvements relating to utilizing support structures, aligning implant designs within the manufacturing apparatus, and making patient-adapted implants.

Abstract: The invention refers to a method for manufacturing a three-dimensional metallic article/component made of a Ni-, Co-, Fe-based superalloy or combinations thereof, entirely or partly, by a powder based additive manufacturing process. During the step of performing powder melting by scanning a dual laser setup is used, where two laser beams of different beam properties are combined in the same machine and by adjusted beam profiling and integration of a suitable beam switch in a controlled manner a switching between two different laser beam diameters is performed. In each layer the laser beam with the smaller diameter scans the whole area and in every kth layer, with k>1, the laser beam with the larger diameter scans the area where a coarse grain size is needed thereby remelting the area with fine grain sizes. With such a manufacturing method higher lifetime and operation performances of metallic parts and prototypes can be reached.

Abstract: A a titanium alloy can be applied on a substrate by one of melting, welding, and depositing said titanium alloy on said substrate and solidifying said deposited or molten titanium alloy. Further, 0.01-0.4 weight % Boron can be added to said titanium alloy before or during said melting, welding or depositing said titanium alloy on said substrate.

Abstract: A method of manufacturing an article including taking an article in an initial state formed using an additive manufacturing process, the article including at least one set of mounting features; performing a second manufacturing process to transform the article into a second state, which includes mounting, via the at least one set of mounting features, the article in a holding device of a machine for operating on the article, wherein the position and orientation of the article in three linear and three rotational degrees of freedom within the machine operating volume is known and defined by virtue of the interaction of the mounting features with the holding device, and processing at least one feature on the article. The at least one mounting feature includes kinematic mount features which engage with corresponding kinematic mount features on the holding device of the machine.

Abstract: Laser cladding filler material is introduced in a pattern on a on a substrate by a filler distribution apparatus having a linear or polygonal array of dispensing apertures for uniform distribution in advance of or during a laser beam transferring optical energy to the substrate. The distribution apparatus includes a housing (or assembly of coupled housings) that defines the distribution aperture array and an internal chamber in communication with the apertures that is adapted for retention of filler material. A mechanical feed mechanism, such as an auger, is adapted for feeding filler material from the internal chamber through the distribution apertures. A feed mechanism drive system is coupled to the mechanical feed mechanism, adapted for selectively varying filler material feed rate. The distribution aperture array may be selectively reconfigured to vary selectively the filler material distribution pattern.

Abstract: The present invention relates to a method for forming a three-dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table. Said method comprising the steps of: providing at least a first and second powder tank, providing a first type of powder in said first powder tank having a first particle size distribution, providing a second type of powder in said second powder tank having a second particle size distribution, providing a first sub-layer of said first type of powder on said work table, providing a second sub-layer of said second type of powder on top of said first layer of said first type of powder, fusing said first and second sub-layers simultaneously with a high energy beam from a high energy beam source for forming a first cross section of said three-dimensional article.

Abstract: A three-dimensional printing process, a swirling device, and a thermal management process are disclosed. The three-dimensional printing process includes distributing a material to a selected region, selectively laser melting the material, and forming a swirling device from the material. The swirling device is printed by selective laser melting. The thermal management process includes providing an article having a swirling device printed by selective laser melting, and cooling a portion of the article by transporting air through the swirling device.

Abstract: An example multi-dimensional component building system includes a first chamber having at least one base disposed therein, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber is configured to receive the at least one base via a first transfer mechanism if the fluid parameters of the first chamber are approximately equal to the fluid parameters of the second chamber. The second chamber includes a directed heat source and a build-up material configured to form a component on the at least one base by melting or sintering. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position.

Abstract: A method of refurbishing a bearing is disclosed. The method includes providing a bearing having a tube structure and inner and outer surfaces. The bearing is mounted onto a mounting unit and a cladding head of a laser cladding unit is positioned within a bore of the bearing. The cladding head forms laser cladding layers disposed on the inner surface of the bearing. The cladding layers increase a thickness of the bearing and reduce an internal diameter of the bearing.

Abstract: The laser welding apparatus includes a welding head and a welding head scanning apparatus. A collimate lens installed on a head body of the welding head is arranged opposite to an end face of optical fibers. The welding head includes only the collimate lens as a lens and the length is shortened. A laser generated by a laser oscillator is introduced into the optical fiber, enters the collimate lens, and then is converted to a parallel beam by the collimate lens. The laser of a parallel beam is irradiated on a surface a welding portion of the welding object through a laser path and the surface of the welding portion is melted. Metallic powder is jetted from powder feed paths formed in a head body to the melted portion and build-up welding is performed on the surface of the welding portion.

Abstract: A powder rapid prototyping method includes steps of forming a thin layer 35a of a powder material, irradiating a heating energy beam to a specific region of the thin layer 35a of the powder material to thereby form a preliminary heating layer 35c whose temperature is elevated, and irradiating the heating energy beam to an inside region of the preliminary heating layer 35c whose temperature is elevated to melt and then solidify the thin layer 35a of the powder material to thereby form a solidified layer, wherein the respective steps are repeatedly implemented to fabricate a rapid prototyping model 51, 52.

Abstract: Superalloy components, such as service-degraded turbine blades and vanes, are clad by laser beam welding. The welding/cladding path, including cladding application profile, is determined by prior, preferably real time, non-contact 3D dimensional scanning of the component and comparison of the acquired dimensional scan data with specification dimensional data for the component. A welding path for cladding the scanned component to conform its dimensions to the specification dimensional data is determined The laser welding apparatus, preferably in cooperation with a cladding filler material distribution apparatus, executes the welding path to apply the desired cladding profile. In some embodiments a post-weld non-contact 3D dimensional scan of the welded component is performed and the post-weld scan dimensional data are compared with the specification dimensional data.

Abstract: The invention relates to a method of forming a coating or of three-dimensional structural elements on substrate surfaces which is/are formed by TiAl, Said coating/Said three-dimensional structural elements is/are manufactured by laser build-up welding. The procedure is followed in the method in accordance with the invention that titanium and aluminum are supplied into the region of influence of at least one laser beam in wire and/or band form in a pure or alloyed form in each case as a single wire or a single band. They are melted by the thermal input and in this respect the materials are mixed with one another. The coating or three-dimensional structural elements are thereby formed with TiAl on the substrate surface.

Abstract: A method of manufacturing an orthopedic implant is provided. The method includes creating a 3D model of an orthopedic implant having a solid portion and a porous portion and selectively adjusting a physical property of at least one of porosity of the porous portion, lattice thickness of the porous portion, beam profile of the porous portion, and topography of the 3D model. The entire implant is then additively manufactured based on the 3D model.

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: A method for hardfacing a surface including: depositing a powder (68) having alloy particles onto a surface (70) of a substrate (66); rastering a laser beam (60) across the surface to melt the powder and to form a weld pool (78) having a width (64); directing particles (74) of a material exhibiting a different property than the substrate into the weld pool in a spray pattern having a width less than the width of the weld pool; and establishing the rastering and directing steps such that material circulation within the weld pool is effective to distribute the particles in the weld pool into a pattern having a width greater than the width of the spray pattern prior to re-solidification of the weld pool.

Abstract: An additive layer manufacture machine generates a first electron beam for scanning a powder layer to be melted in a selective melting process. Backscatter electrons from the interaction between the first electron beam and the powder layer is detected by a backscatter detector. Any defects in the powder layer can then be identified, or inferred, from the detected backscatter electrons. If necessary, any defects can be removed from the powder layer before selective melting. Once the powder layer has been inspected and if necessary improved, selective melting of the layer is performed in order to produce a layer of the component. The process may be repeated to generate a finished component with good mechanical properties.

Abstract: A method of manufacturing an assembly (10), including: positioning a first component (12) and a second component (14) in a desired positional relationship with each other; and building-up a locking component (16) by depositing layer after layer of material onto a surface (24, 26) of the assembly until a completed locking component is formed in-situ that holds the first component and the second component in the desired positional relationship.

Abstract: An additive layer manufacture (ALM) machine generates a first electron beam for selectively melting a layer of metal powder, and a second electron beam for detecting defects in the selectively melted layer once it has solidified. The second electron beam has a lower power than the first electron beam so as to be used to identify any defects without performing further melting. If any defects are detected, they can be removed, for example by re-melting, before the next layer of powder is supplied. The process may be repeated to generate a finished component with good mechanical properties.

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 object holder (100) for a lithographic apparatus has a main body (400) having a surface (400a). A plurality of burls (406) to support an object are formed on the surface or in apertures of a thin-film stack (410, 440, 450). At least one of the burls is formed by laser-sintering. At least one of the burls formed by laser-sintering may be a repair of a damaged burl previously formed by laser-sintering or another method.

Abstract: Methods and apparatuses to fabricate additive manufactured parts with in-process monitoring are described. As parts are formed layer-by-layer, a 3D measurement of each layer or layer group may be acquired. The acquisition of dimensional data may be performed at least partially in parallel with the formation of layers. The dimensional data may be accumulated until the part is fully formed, resulting in a part that was completely inspected as it was built. The as-built measurement data may be compared to the input geometrical description of the desired part shape. Where the part fails to meet tolerance, it may be amended during the build process or rejected.

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: A machine part for agricultural, turf, mining or construction equipment for processing material is provided. The machine part comprises a base material. A clad material is deposited on the base material to form at least one blunt edge along the body. The clad material comprises a second hardness greater than the first hardness.

Abstract: A manufacturing method of a three-dimensional shaped object is capable of suitably forming a solidified layer by subsequent formation of a powder layer. The manufacturing method according to an embodiment of the present invention is performed by repetition of a powder-layer forming and a solidified-layer forming, the repetition including forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein a light-beam condition for an irradiation path with an unirradiated portion on both adjacent sides thereof is different from that for another irradiation path with an irradiated portion at an adjacent region.

Abstract: Apparatus for mulching organic matter such as brush and trees are disclosed. The apparatus have cutting teeth that include cladding for increasing the wear-resistance of the teeth. Cutting heads and vehicles that incorporate such teeth are also disclosed.

Abstract: Disclosed is a method for generatively producing components by layer-by-layer building from a powder material by selective material bonding of powder particles by a high-energy beam. An eddy current testing is carried out concurrently with the material bonding. Also disclosed is an apparatus which is suitable for carrying out the method.

Abstract: A method of manufacturing a turbo-machine impeller, which includes a hub and a plurality of blades, using powder material in an additive-manufacturing process. The method includes: applying energy to the powder material by way of a high energy source, and solidifying the powder material. At least one bulky portion of the hub is irradiated such that the powder material solidifies in a lattice structure surrounded by an outer solid skin structure enclosing the lattice structure.

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: The invention described herein generally pertains to a welding device that deposits a material onto a workpiece, the welding device having with an electrode head and a contact assembly coupled thereto. The contact assembly can house electrodes that allow deposition of material on a workpiece. At least a first set of electrodes and a second set of electrodes can be driven at different speeds. Moreover, welding arcs for one or more electrodes can be established based upon a predetermined order in which the predetermined order can be based on at least one of a location of the electrode head on the workpiece, a start of a welding process, and/or a stopping of a welding process.

Abstract: A composite wire for use with a wire arc spray system and related methods. The composite wire can include: a low melting point material at a core region thereof and a cladding including a metal surrounding the core region, the low metal point material having a melting point less than that of the metal, wherein the low melting point material includes a polymer in the form of a powder having particles having a size of from approximately 1 nanometer to approximately 100 nanometers.

Abstract: A roll (1) for supporting and conveying hot material, including a roll element that has a roll jacket (2) made of a basic material and a wear coat which is applied to the basic material by means of a surface welding process (4) using a welding additive which surrounds the surface of the roll jacket. In order to increase the service life of the wear coat, improve the resistance to wear, and reduce the cost for producing the welded-on surface. The basic material of the roll jacket (2) is steel and contains up to 0.45 percent of C. The welded-on surface (4) is designed as a single-layer weld, and the wear coat contains 12.5 to 14.0 percent of Cr at least in an external zone that surrounds the surface of the roll jacket. Also disclosed are a method for producing the roll (1), a method for repairing a used roll (1), a welding additive and a welding rod for producing the welded-on surface.

Abstract: According to one embodiment, a valve apparatus includes a movable member operating in conjunction with opening and closing of a valve, and a stationary member in sliding or abutting contact with the movable member. The valve apparatus includes a cladding portion that is integrally formed on a sliding-contact surface or an abutting contact surface of at least one of the movable member or the stationary member. The cladding portion is formed by inducing a pulsed discharge between an electrode, which is formed of a molded body consisting mainly of a metal, and a treatment target portion of the movable member or the stationary member, so as to weld and deposit a material of the electrode on a surface of the treatment target portion.

Abstract: A method of applying a laser metal formed build layer on a surface of an article. The surface of the article is melted locally using a light source to form a melt pool. Powdered metal is injected into the melt pool. The melt pool is solidified to form the build layer having a desired microstructure and geometry on the surface of the article.

Abstract: A method of applying a laser metal formed build layer on a surface of an article is disclosed. A laser deposition head including a light source and a nozzle is positioned relative to the surface of the article by a distance that is about normal to the surface. The surface of the article is melted locally using the laser light source to form a melt pool. Powdered metal is injected into the melt pool using the nozzle. The melt pool is solidified to form the build layer having a desired microstructure on the surface of the article.

Abstract: Some embodiments include a reinforced face of a club head. Other embodiments for related reinforced faces of club heads and related methods are also disclosed.

Abstract: A cladding system and method for applying a cladding to a power generation system component including a first weld bead, a second weld and a filler bead. The first weld is deposited on the surface with a first energy source and solidified to form a first weld bead. The second weld is deposited on the surface adjacent to the first weld bead with the first energy source, wherein depositing the second weld creates a surface depression between the first weld bead and second weld. The filler bead is simultaneously deposited in the surface depression with a second energy source while depositing the second weld bead. The second weld and the filler bead are solidified to form the cladding bead.

Abstract: In a two-electrode welding method of the present invention, a leading electrode is used to perform gas-shielded arc welding and a trailing electrode is an energized filler. A trailing electrode wire protrudes from a guide lead or guide tip and is energized from an energizing tip. The distance between a welding surface and the energizing tip is 100 mm or more and 1500 mm or less. The distance between electrodes is 10 mm or less. The electric current of the leading electrode is 250 A or more, and the electric current of the trailing electrode is 10 A or more and 50% or less of the electric current of the leading electrode. The feeding speed of the trailing electrode wire is 20% or more and 50% or less of the feeding speed of the leading electrode wire.

Abstract: A wire arc spray system use at least one first wire and second wire that include a composite wire including a first material at a core region thereof and a cladding including a second material surrounding the core region. A controller controls operation to propel heated material created by the arcing of the first wire and the second wire at the arc point to a surface to be coated. A wire arc spray methodology for creating a porous metal coating with all-metal wires is also provided.

Abstract: A method of manufacturing an annular wall (46) of a combustion chamber (15) comprises depositing layers of a metal sequentially one upon the other to form layers of a spiral wall (45) of the combustion chamber (15). Each layer of metal is deposited in a spiral pathway (122). The ends (E1, E2) of the spiral wall (45) of the combustion chamber (15) are joined together to form the annular wall (46) of the combustion chamber (15). The ends (E1, E2) of the spiral wall (45) of the combustion chamber (15) are at the opposite ends of the spiral pathway (122).

Abstract: A pulverant material supply system has an outer shell, an inner shell, and a plurality of openings to a passage within the inner shell to allow a reducing fluid into the pulverant material contained therein. The liner is made from a non-evaporable getter alloy.

Abstract: The invention described herein generally pertains to a welding device that deposits a material onto a workpiece, the welding device having with an electrode head and a contact assembly coupled thereto. The contact assembly can include a rectangular-shaped first contact bar and a rectangular-shaped second contact bar that can be affixed to one another with an assembly connective means in order to encase a plurality of electrodes therebetween. The second contact bar can include a set of grooves in which each groove can correspond to an electrode to provide guidance during a welding procedure.

Abstract: The application of a peripheral weld before the removal of material produces an enlarged face for the subsequent build-up welding. A process for build-up welding on an outer face having an edge region of a component which is adjoined by a side face is provided.

Abstract: A microchannel cooled turbine component includes a first portion of the microchannel cooled turbine component having a substrate surface. Also included is a second portion of the microchannel cooled turbine component comprising a substance that is laser fused on the substrate surface. Further included is at least one microchannel extending along at least one of the first portion and the second portion, the at least one microchannel formed and enclosed upon formation of the second portion.

Abstract: A process for the thermal deposition coating of a workpiece is provided that comprises the steps of: thermally depositing a coating on a metallic surface of a workpiece from a deposition head wherein at least one condition selected from the group of: coating deposition rate onto said surface, relative motion between the surface and said deposition head, and cryogenic coolant application rate onto said workpiece is controllable; substantially simultaneously measuring temperatures at a plurality of locations over the metallic surface of the workpiece; determining an average temperature of the temperatures measured in step (b); comparing the average temperature to a preselected minimum temperature and a preselected maximum temperature for the workpiece; and adjusting at least one of the controllable conditions if said average temperature is not between the preselected minimum temperature and the preselected maximum temperature for the workpiece.

Abstract: A method and system to start and use a combination wire feed and energy source system for any of brazing, cladding, building up, filling, and hard-facing overlaying applications. High intensity energy is applied onto a workpiece to heat the workpiece. One or more resistive filler wires are fed toward the workpiece at or just in front of the applied high intensity energy. Sensing of when a distal end of the one or more resistive filler wires makes contact with the workpiece at or near the applied high intensity energy is accomplished. Electric heating current to the one or more resistive filler wires is controlled based on whether or not the distal end of the one or more resistive filler wires is in contact with the workpiece. The applied high intensity energy and the one or more resistive filler wires are moved in a same direction along the workpiece in a fixed relation to each other.

Abstract: A welding device for powder welding is described, which comprises a welding head for transportation of at least one welding electrode to a welding area, and a powder transportation device for transportation of powder from a container to the welding area. The powder transportation device comprises at least a first pipe which at a first end has an opening which is arranged to be placed in the container in order to transport fluxing agent from the container. The powder transportation device comprises at least a first ejector which is connected to the second end of the first pipe and which is arranged to transport powder from the container via the first pipe using pressurized gas.

Abstract: Disclosed are methods and systems for improving the quality, throughput and efficiency of Solid Free Form manufacture of implant components.

Abstract: The present invention is a device for coating surfaces of metallic work pieces with an electrically conductive material by employing short duration high current packets of pulses in which the work piece forms the cathode and the consumable coating material forms the anode, which are connected to a generator for generating pulses by charging and discharging a bank of capacitors using a MOSFET. The invention is also a device for controlling the on and off time of a metal oxide semiconductor field effect transistor (MOSFET).

Abstract: Superalloy components, such as service-degraded turbine blades and vanes, are clad by laser beam welding. The welding/cladding path, including cladding application profile, is determined by prior, preferably real time, non-contact 3D dimensional scanning of the component and comparison of the acquired dimensional scan data with specification dimensional data for the component. A welding path for cladding the scanned component to conform its dimensions to the specification dimensional data is determined. The laser welding apparatus, preferably in cooperation with a cladding filler material distribution apparatus, executes the welding path to apply the desired cladding profile. In some embodiments a post-weld non-contact 3D dimensional scan of the welded component is performed and the post-weld scan dimensional data are compared with the specification dimensional data.