Abstract: The present invention discloses a rare earth permanent magnet material and a preparation method thereof. The method includes a sintering treatment step performed by laying a composite powder for diffusion on the surface of a neodymium iron boron magnetic powder layer and carrying out spark plasma sintering treatment to obtain a neodymium iron boron magnet with a diffusion layer solidified on the surface thereof, and diffusion heat treatment and tempering steps. The method of the present invention has high efficiency, good diffusion effects, and reduced quantities of heavy rare earth elements.

Abstract: The invention relates to a computer-assisted method for generating a control data set for an additive layer manufacturing device. In a first step, a layer data set is accessed, wherein points are marked in the data model which correspond to an object cross-section and at which the bid-up material should be solidified. In a second step, the layer data set is modified in such a way that for at least a portion of the object cross-section, the number of beams required for solidifying the build-up material inside said portion is determined preferably automatically, according to quality specifications of the portion and/or a manufacturing time of the object. In a third step, the modified layer data set is provided as a control data set for the additive layer manufacturing device.

Abstract: A fabricating apparatus includes a powder layer forming device, a fabrication liquid discharge device, and processing circuitry. The powder layer forming device is configured to form a powder layer. The fabrication liquid discharge device is configured to discharge fabrication liquid onto the powder layer. The processing circuitry is configured to control the fabrication liquid discharge device to discharge the fabrication liquid with a first kinetic energy and then discharge the fabrication liquid with a second kinetic energy higher than the first kinetic energy.

Abstract: The application discloses a coating material for fabricating rare earth magnets and a method using the coating material to prepare neodymium-iron-boron (NdFeB) magnets having high coercive force. The coating material includes: alloy powder A and low-melting-point metal powder B. The alloy powder A is heavy rare earth element R powder, or rare earth-metal alloy (RM) powder, or rare earth-metal-hydrogen alloy (RMH) powder. The heavy rare earth elements are Dy and/or Tb, metal is Fe or Co, or an alloy of Fe and Co, and H is hydrogen element. The low-melting-point metal powder B is one or two of Zn, Al, and Ga. The preparation method includes the following steps: the coating material is mixed into a slurry, and the slurry is coated on the surface of NdFeB magnet, and then apply a two-stage diffusion heat treatment to the magnet, followed by an annealing process to obtain a high-coercivity NdFeB magnet.

Abstract: A method of producing multiple batches of objects by stereolithography, includes the steps of: (a) dispensing an initial or subsequent batch of dual cure resin into a stereolithography apparatus, the resin including a light polymerizable component and a heat polymerizable component; (b) producing an intermediate object by light polymerization of the resin in the apparatus, wherein the intermediate object retains excess resin on a surface thereof; then (c) separating excess resin from the intermediate object; (d) blending the excess resin with additional dual cure resin to produce a subsequent batch of dual cure resin; (e) repeating steps (a) through (c), and optionally repeating step (d), to produce additional object(s); and (f) baking the objects, together or separately, to produce multiple batches of objects.

Abstract: Provided is a hard particle in which Cr and W, that are quickly diffused in Mo, are present at the same time as Ni and Mn. Specifically, the hard particle contains Cr: 5% by mass to 20% by mass, W: 2% by mass to 19% by mass, Mo: 25% by mass to 40% by mass, Ni: 10% by mass to 22% by mass, Mn: 10% by mass or less, C: 2.0% by mass or less, Si: 2.0% by mass or less, and a remainder: Fe and unavoidable impurities.

Abstract: Disclosed is a switching system for a facility for 3D printing by spraying at least a first powder, including a body defining: at least one first upstream gas conduit configured to receive a gas; at least one first upstream powder conduit configured to receive the first powder; at least one first downstream discharge conduit for discharging the first powder; and a downstream work conduit configured in order to supply a nozzle designed for depositing at least the first powder. The system further includes a distributor that is movable with respect to the body, preferably in rotation about an axis, between a rest position, in which the first upstream powder conduit is fluidly connected, via the distributor, to the first downstream discharge conduit, and at least a first supply position, in which the first upstream powder conduit is fluidly connected, via the distributor, to the downstream work conduit.

Abstract: An injection molding mold apparatus including: a first mold and a second mold forming a cavity into which thermoplastic resin is configured to be injected; a slide mold provided on at least one of the first and second molds, capable of moving back and forth in a direction intersecting a mold opening and closing direction, and forming a part of the cavity while being in pressure contact with an insert member during molding; and a pressing member provided at a portion where the slide mold is not provided among portions of the first and second molds that face each other and at a position corresponding to a tip end portion of the slide mold, being movable in the mold opening and closing direction, and pressing and moving the tip end portion in the mold opening and closing direction when the first and second molds are closed.

Abstract: A rendering apparatus, in an example, comprises a rendering zone disposed between a rendering material deposition head and a substrate, a processing module to process the rendering material, a heat exchanger to transfer heat from the processing module to air to be re-distributed to the rendering zone, a distribution system for re-distributing heated air to the rendering zone, a valve located between the heat exchanger and the rendering zone, a temperature sensor located in the rendering zone to detect a temperature of the heated air that is re-distributed to the rendering zone, and a control module to adjust a temperature of the rendering zone by controlling an aperture of the valve using a feedback signal received from the temperature sensor.

Abstract: A method of producing multiple batches of objects by stereolithography, includes the steps of: (a) dispensing an initial or subsequent batch of dual cure resin into a stereolithography apparatus (11), the resin including a light polymerizable component and a heat polymerizable component; (b) producing an intermediate object by light polymerization of the resin in the apparatus (12), wherein the intermediate object retains excess resin on a surface thereof; then (c) separating excess resin from the intermediate object (13); (d) blending the excess resin with additional dual cure resin to produce a subsequent batch of dual cure resin (15); (e) repeating steps (a) through (c), and optionally repeating step (d), to produce additional object(s); and (f) baking the objects, together or separately, to produce multiple batches of objects (14).

Abstract: A manufacturing method for a three-dimensional structure includes forming unit layers using at least one of a first flowable composition including first powder and a second flowable composition including second powder and solidifying at least one of the first flowable composition including the first powder and the second flowable composition including the second powder in the unit layers. In the forming the unit layers, both of the first flowable composition and the second flowable composition are caused to be present in plane directions crossing a thickness direction of the unit layers.

Abstract: A manufacturing method for a three-dimensional structure includes forming unit layers using at least one of a first flowable composition including first powder and a second flowable composition including second powder and solidifying at least one of the first flowable composition including the first powder and the second flowable composition including the second powder in the unit layers. In the forming the unit layers, both of the first flowable composition and the second flowable composition are caused to be present in plane directions crossing a thickness direction of the unit layers.

Abstract: A method of forming a component from a part in the green state, including selecting at least one first portion of the part to undergo a different local volume reduction from at least one second portion to obtain the component. The green part is provided with the first portion(s) having a first solid loading and the second portion(s) having a second solid loading different from the first solid loading, then debound and sintered to obtain the component. The different first and second solid loadings produce the different local volume reduction in the first portion(s). The first portion(s) can be selected by determining a resulting final shape obtained from debinding and sintering a green part having a uniform first volumetric proportion of binder, and selecting the first portion(s) requiring a different local deformation than that producing the resulting final shape to obtain a desired final shape.

Abstract: A composition of matter includes a substrate material (M) having a bulk portion and an outer surface integrated to the bulk portion. The outer surface includes a modified surface layer. The modified surface layer extends to a depth from the outer surface of at least 1 nm. The modified surface layer includes M and at least one other material (X) which is a metal or metal alloy. The modified surface layer has a 25° C. electrical conductivity which is at least 2.5% above or below a 25° C. electrical conductivity in the bulk portion of M. The composition of matter can be an article that includes a frequency selective surface-based metamaterial, and the plurality of modified surface portions can be a plurality of periodic surface elements that provide a resonant frequency.

Abstract: The invention relates to an oxygen-consuming electrode, in particular for use in chloralkali electrolysis, comprising a novel catalyst coating based on carbon nanotubes and a silver-based cocatalyst, and to an electrolysis device. The invention further relates to a method for producing said oxygen-consuming electrode and to the use thereof in chloralkali electrolysis or fuel cell technology.

Abstract: A method for manufacturing a rare earth permanent magnet includes manufacturing an NdFeB sintered magnet. A grain boundary diffusion material in the form of a mixed powder comprising an alloy powder containing Re1aMb or M; and Re2 hydride or Re2 fluoride is disposed on a surface of the NdFeB sintered magnet. The grain boundary diffusion material is heated to diffuse at least one of Re1, Re2 and M into a grain boundary part inside the sintered magnet or a grain boundary part region of a sintered magnet main phase grain. Re1 and Re2 are each rare earth elements selected from the group consisting of dysprosium, terbium, neodymium, praseodymium, and holmium, M is a metal compound consisting of copper, zinc, tin, and aluminum, 0.1<a<99.9, and a+b=100.

Abstract: Disclosed herein is a method for manufacturing an R-T-B permanent magnet and the magnet made with the method. The method may include preparation of strip pieces by melting and casting, preparing coarse powder by hydrogen decrepitation of the strip pieces; milling the powder into fine powder; pressing the fine powder is pressed to form a compact, pre-sintering the compact in vacuum or inert gas, machining the pre-sintered block to a desired shape; and dispersing the heavy rare earth compound powder into an organic solvent to prepare a slurry and a second sintering step.

Abstract: A method of manufacturing a heat exchanger comprising a body and a support embedded within the body. The support comprises a different material and/or a different material structure to the body and hence has at least one material property which is different to that of the body. The method comprises; forming at least a first portion of the support with a first material and a first material structure using a first additive manufacturing step; and forming at least a first portion of the body with a second material and a second material structure using a second additive manufacturing step. The first material is different to the second material and/or the first material structure is different to the second material structure.

Abstract: An exemplary method for determining a set of additive manufacturing parameters includes, a) determining a nominal parameter of at least one surface of a component, b) determining at least a second order variation in the nominal parameter, c) predicting an actual resultant dimension based at least in part on the nominal parameter and the second order variation, and d) adjusting at least one additive manufacturing process parameter in response to the predicted actual resultant dimension.

Abstract: The present invention relates to a gas diffusion electrode that includes an electrically conductive carrier, and a porous coating based on an electrochemically active catalyst and a hydrophobic material, wherein the electrode has a first side facing an oxygen-containing gas and a second side facing an alkaline electrolyte, wherein the catalyst comprises a noble metal as a catalytically active component, wherein the hydrophobic material comprises a hydrophobic polymer, and wherein the coating comprising the catalyst has a pore volume from 10 to 500 mm3/g, and a pore diameter in the range from 100 to 10,000 nm.

Abstract: A production method for a rare earth permanent magnet, wherein: a sintered magnet body comprising an R1—Fe—B composition (R1 represents one or more elements selected from among rare earth elements, including Y and Sc) is immersed in an electrodeposition liquid obtained by dispersing a powder containing an R2 oxyfluoride and/or an R3 hydride (R2 and R3 represent one or more elements selected from among rare earth elements, including Y and Sc) in a solvent; an electrodeposition process is used to coat the powder onto the surface of the sintered magnet body; and, in the state in which the powder is present on the surface of the magnet body, the magnet body and the powder are subjected to a heat treatment in a vacuum or an inert gas at a temperature equal to or less than the sintering temperature of the magnet.

Abstract: A production method for a rare earth permanent magnet, wherein: a sintered magnet body comprising an R1—Fe—B composition (R1 represents one or more elements selected from among rare earth elements, including Y and Sc) is immersed in an electrodeposition liquid comprising a slurry obtained by dispersing a powder containing an R2 fluoride (R2 represents one or more elements selected from among rare earth elements, including Y and Sc) in water; an electrodeposition process is used to coat the powder onto the surface of the sintered magnet body; and, in the state in which the powder is present on the surface of the magnet body, the magnet body and the powder are subjected to a heat treatment in a vacuum or an inert gas at a temperature equal to or less than the sintering temperature of the magnet.

Abstract: A production method for a rare earth permanent magnet, wherein: a sintered magnet body comprising an R1—Fe—B composition (R1 represents one or more elements selected from rare earth elements including Y and Sc) is immersed in an electrodeposition liquid obtained by dispersing a powder containing an R2 oxide (R2 represents one or more elements selected from rare earth elements including Y and Sc) in a solvent; an electrodeposition process is used to coat the powder to the surface of the sintered magnet body; and, in the state in which the powder is present on the surface of the magnet body, the magnet body and the powder are subjected to heat treatment in a vacuum or an inert gas at a temperature equal to or less than the sintering temperature of the magnet.

Abstract: An apparatus and method for manufacturing and authenticating a three-dimensional article including the steps of (1) successively building up the article from a metal powder by an additive manufacturing process by scanning a selected portion of the metal powder with electromagnetic radiation, (2) forming an anti-counterfeiting mark in the article during the additive manufacturing process, and (3) determining whether the article includes the anti-counterfeiting mark.

Abstract: A method of forming an overhanging structure at a discharge end of a cooling hole that passes through a component. The method includes the step of using an additive manufacturing process to fuse material to a face to build up an edge of the discharge end of the cooling hole to form an overhanging tab.

Abstract: A method for forming a composite article includes providing a metallic substrate and a preform adjacent the metallic substrate. The preform includes an unfused metallic powder material with an organic binder dispersed through the powder material. The metallic substrate and the preform are then subjected to a monocyclic heating process. The monocyclic heating process causes removal of the organic binder from the preform, fusing of the metallic powder material and metallurgical bonding of the metallic powder to the metallic substrate.

Abstract: An airfoil includes a body that includes leading and trailing edges joined by spaced apart pressure and suction sides to provide an exterior airfoil surface. A cooling passage is arranged interiorly of the exterior airfoil surface and provides an interior surface. The interior cooling surface includes micro-bumps that protrude from the interior cooling surface into the cooling passage. The micro-bumps are discrete from and noncontiguous relative to one another in multiple directions along the interior cooling surface. The micro-bumps may be provided while forming the airfoil or using correspondingly shaped micro-depressions on an airfoil core.

Abstract: A process for fabricating a wiring board is provided. In the process, a wiring carrying substrate including a carry substrate and a wiring layer is formed. Next, at least one blind via is formed in the wiring carrying substrate. Next, the wiring carrying substrate is laminated to another wiring carrying substrate via an insulation layer. The insulation layer is disposed between the wiring layers of the wiring carrying substrates and full fills the blind via. Next, parts of the carry substrates are removed to expose the insulation layer in the blind via. Next, a conductive pillar connected between the wiring layers is formed. Next, the rest carry substrates are removed.

Abstract: A method and an apparatus (10) for generating a three-dimensional work piece containing an information code are provided. The method comprises the steps of applying a raw material powder (18) onto a carrier (14) by means of a powder application device (16), irradiating electromagnetic or particle radiation (22) onto the raw material powder (18) applied onto the carrier (14) by means of an irradiation device (20), and controlling the operation of the powder application device (16) and the irradiation device (20) so as to generate an information code pattern (36) on or in the work piece (12), wherein the information code pattern (36) is defined by the microstructure (34) of the work piece (12).

Abstract: The invention relates to a sintering method for manufacturing structures by sintering. In addition, the invention relates to a sintered product, an electronic module, and new uses. In the method, a particle material containing conductive or semiconductive encapsulated nanoparticles is sintered, in order to increase its electrical conductivity, by applying a voltage over the particle material. In the method, a substrate is typically used, one surface of which is at least partly equipped with a layer containing nanoparticles. The method is based on thermal feedback between the voltage feed and the nanoparticles. The invention permits the manufacture of conductive and semiconductive structures and pieces by sintering at room temperature and at normal pressure.

Abstract: An orthopaedic prosthesis and a method for rapidly manufacturing the same are provided. The orthopaedic prosthesis includes a solid bearing layer, a porous bone-ingrowth layer, and an interdigitating layer therebetween. A laser sintering technique is performed to manufacture the orthopaedic prosthesis.

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: This publication discloses a method and apparatus for functionalizing nanoparticle systems. The method comprises treating a nanoparticle-containing layer so as to produce a pattern of structurally transformed zones, the treatment comprising applying an electric field through the nanoparticle layer. According to the invention an AC-field capacitively coupled to the nanoparticle-containing layer is used as said electric field. The treatment preferably results in at least partly sintered structures, which can be used as conductors, for example. The document discloses several realizations for utilization of the disclosed functionalization in mass-fabrication lines.

Abstract: The present invention makes it possible to increase the thickness of a sintered body. Thus, the present invention provides a production method that is suitable for the production of anode electrode materials with high capacitance useful for medium- to high-voltage aluminum electrolytic capacitors, that does not involve an etching treatment, and that enables desired formation of the resulting electrode material for aluminum electrolytic capacitor into the desired shape. Specifically, the present invention provides a method for producing an electrode material for aluminum electrolytic capacitor, comprising the steps of: (1) forming, in a sintering mold, an unsintered laminate in which a substrate is held between compositions comprising a powder of at least one member selected from the group consisting of aluminum and aluminum alloys; and (2) sintering the unsintered laminate in the sintering mold, wherein the method does not comprise an etching step.

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: In a process, a thermally stable diamond table body and a substrate are stacked on each other at an interface which includes a layer of a imbibiting material interposed between a bottom surface of the body and an upper surface of the substrate. The stack is subjected to a suitable thermal cycle, constituted by heating, temperature maintenance and cooling, which brings at least some of the imbibiting material into the liquid state for migration into the thermally stable diamond table body and substrate at and about the interface so as to join the thermally stable diamond table body to the substrate. The substrate may be produced as a block of dense material constituted by hard particles dispersed in a binder phase, wherein the dense material has been enriched locally with binder phase by imbibition.

Abstract: The invention relates to a powder of an alloy comprising uranium and molybdenum in ?-metastable phase, a composition of powders comprising this powder, and the uses of said alloy powder and of said composition of powders. The alloy powder comprising uranium and molybdenum in ?-metastable phase according to the invention is formed of particles comprising a nucleus which consists of said alloy, and which is covered with a layer of alumina positioned in contact with this nucleus. Applications: manufacture of nuclear fuel elements and, in particular, of fuel elements for experimental nuclear reactors; manufacture of targets intended for production of radioelements, which are useful in particular for medical imaging, such as technetium 99m.

Abstract: The present invention provides a bonding material and a method of bonding for metal bonding at a bonding interface capable of a higher bonding strength at a lower temperature without application of pressure, compared to a bonding material of metal particles having an average particle size of not greater than 100 nm. An electrically conductive bonding material including (A) silver particles, (B) silver oxide, and (C) a dispersant including organic material containing not more than 30 carbon atoms as essential components, wherein a total amount of (A) the silver powder, (B) the silver oxide powder, and (C) the dispersant including an organic material containing not more than 30 carbon atoms is in a range of 99.0% to 100% by weight, is provided. In other words, no resin binder is contained.

Abstract: In one aspect, methods of making cladded articles are described herein. A method of making a cladded article, in some embodiments, comprises disposing over a surface of a metallic substrate a sheet comprising organic binder and powder metal or powder alloy having a solidus temperature at least 100° C. less than the metallic substrate and heating the powder metal or powder alloy to provide a sintered metal or sintered alloy cladding metallurgically bonded to the metallic substrate.

Abstract: A thermal barrier tile (34) with a braze layer (46) co-sintered to a ceramic layer (48) is brazed to a substrate (26) of a component for fabrication or repair of a thermal barrier coating (28) for example on a gas turbine ring segment (22, 24). The tile may be fabricated by disposing a first layer of a metal brazing material in a die case (40); disposing a second layer of a ceramic powder on the metal brazing material; and co-sintering the two layers with spark plasma sintering to form the co-sintered ceramic/metal tile. A material property of an existing thermal barrier coating to be repaired may be determined (90), and the co-sintering may be controlled (93) responsive to the property to produce tiles compatible with the existing thermal barrier coating in a material property such as thermal conductivity.

Abstract: Forming a wear- and corrosion-resistant coating on an industrial component such as a chemical processing or nuclear power valve component by applying a cobalt-based dilution buffer layer to an iron-based substrate by slurry coating, and then applying by welding a cobalt-based build-up layer over the cobalt-based dilution buffer layer. An industrial component having a dilution buffer layer and a welding build-up layer thereover.

Abstract: A method of forming a fully consolidated joint between first and second components comprising the steps of forming a slot in the first component; inserting at least part of the second component into the slot; inserting a powder material into the slot; heating the powder material to form a pressure tight skin; and applying hot isostatic pressure to the pressure tight skin to form a fully consolidated joint. Also a method of repairing a component.

Abstract: The invention refers to a method for manufacturing a hybrid component including the following steps of manufacturing a preform as a first part of the hybrid component, then successively building up on that preform a second part of the component from a metallic powder material by means of an additive manufacturing process by scanning with an energy beam, thereby establishing a controlled grain orientation in primary and in secondary direction of at least a part of the second part of the component. The controlled secondary grain orientation is realized by applying a specific scanning pattern of the energy beam, which is aligned to the cross section profile of the component or to the local load conditions for the component.

Abstract: The invention relates to a method for fabricating an open-porous metal foam body with a nickel base alloy, to a metal foam body fabricated this way as well as advantageous applications for the separation of specific components and pollutants from fluid flows. On the occasion, according to the set object open-porous metal foam bodies which have improved mechanical properties, and in addition an enlarged specific surface and/or increased surface roughness are to be provided. During fabricating it is proceeded such that an open-porous base foam body made of nickel or a nickel base alloy is coated with a liquid binding agent. Subsequent to this, a mixture of a powdery nickel base alloy and an organic component the temperature of phase transformation of which is at least 30 degrees centigrade from its solid phase to the liquid phase is deposited. The temperature should then be below the respective temperature of phase transformation.

Abstract: A method for producing a housing structure at least partially enclosing at least one component, wherein the housing structure is produced with a construction process utilizing at least one of repeated layered deposition and solidification of material, which is interrupted at least once before completion of the housing structure, and during at least one interruption at least one component, which is not produced by the construction process, is joined to or disposed in a partially finished housing structure, and the construction process is then continued after the interruption until the housing is completed, wherein at least one of an actuator and sensor comprising at least partially a transformer material selected as the at least one component to be joined to or disposed in the housing structure.

Abstract: A multiphase composite system is made by binding hard particles, such as TiC particles, of various sizes with a mixture of titanium powder and aluminum, nickel, and titanium in a master alloy or as elemental materials to produce a composite system that has advantageous energy absorbing characteristics. The multiple phases of this composite system include an aggregate phase of hard particles bound with a matrix phase. The matrix phase has at least two phases with varying amounts of aluminum, nickel, and titanium. The matrix phase forms a bond with the hard particles and has varying degrees of hard and ductile phases. The composite system may be used alone or bonded to other materials such as bodies of titanium or ceramic in the manufacture of ballistic armor tiles.

Abstract: The invention relates to a method of manufacturing a molding element for a tire mold. The molding element comprises a sintered part and a non-sintered part attached to the sintered part. The sintered part comprises a shell and a core internal to the shell and formed as one piece with the said shell. The core comprises a meshed structure comprising a plurality of cavities. The method of manufacture comprises a step of manufacturing the sintered part of the molding element from a metallic powder deposited on a flat surface of a support plate and fused layer by layer, the sintered part being attached to the support plate by fused metallic powder. The method also comprises a step of machining the support plate to form the non-sintered part of the molding element.

Abstract: A rotary implement includes a metallic body that is rotatable around an axis. The metallic body includes a tapered leading edge having an interface surface and an opposite, free surface. The metallic body has a first composition. A metallic layer has a first side surface that is attached to the interface surface and a free, second side surface opposite from the first side surface. The metallic layer has a second, different composition from the first composition. A rotary machine can include an actuator and the rotary implement operably coupled to the actuator. A method for making a rotary implement includes providing the metallic body that has the tapered leading edge having the interface surface and the opposite, free surface. The metallic layer is then attached to the interface surface of the metallic body.

Abstract: A removed damaged portion of a fully consolidated turbine engine component is replaced with a powder coupon that includes powder particles that are at most partially sintered or are bonded together with a binder. A bonding agent is applied to the component and/or the powder coupon. The powder coupon is then positioned over the component and heat is applied to fully sinter the powder particles, thus causing the powder coupon to shrink onto the component. The heat also activates the bonding agent to bond the shrunken powder coupon to the component, but the heat does not sinter the material forming the fully consolidated component.

Abstract: In accordance with an exemplary embodiment, a method of manufacturing a stator airfoil assembly includes forming an interior wall of a stator airfoil using an additive manufacturing technique, forming an exterior wall of the stator airfoil using the additive manufacturing technique, and forming a plurality of internal ribs between the interior wall and the exterior wall using the additive manufacturing technique. A cooling air circuit is formed in a space between the interior wall and the exterior wall. Further, the interior wall, the exterior wall, and the internal ribs are formed simultaneously as an integral structure by using the additive manufacturing technique.