СПОСОБ ИЗГОТОВЛЕНИЯ БУРОВОГО ИНСТРУМЕНТА С ТОЧНЫМ РАСПОЛОЖЕНИЕМ И ОРИЕНТАЦИЕЙ ПАЗА ПОД РЕЖУЩИЙ ЭЛЕМЕНТ

Группа изобретений относится к способам изготовления бурового инструмента. Технический результат заключается в обеспечении точности расположения и/или угловой ориентации пазов под режущие элементы. Способ изготовления бурового инструмента включает изготовление корпуса инструмента, содержащего множество обратных пазов под режущие элементы, сформированных в лопасти корпуса инструмента. По меньшей мере часть каждого из указанного множества обратных пазов под режущие элементы имеет профиль, совпадающий с профилем соответствующего реального режущего элемента, подлежащего закреплению внутри паза под режущий элемент, выполняемого путем последующей механической обработки паза из указанного множества обратных пазов под режущие элементы. Способ изготовления бурового инструмента также включает нанесение на участки лопасти корпуса инструмента первого упрочняющего материала, окружая им наружную кромку каждого из множества обратных пазов под режущие элементы, нанесение второго отличающегося упрочняющего ...

СВАРКА АЛИТИРОВАННЫХ КОМПОНЕНТОВ И АЛИТИРОВАННЫЙ КОМПОНЕНТ

Изобретение относится к способу ремонта компонента газовой турбины и компоненту газовой турбины, подвергнутому ремонту указанным способом. Проводят алитирование субстрата (4) с образованием диффузионного слоя (6) глубиной от 150 до 300 мкм и покрывающего слоя (7) толщиной 100 мкм на диффузионном слое (6). Затем покрывающий слой по меньше мере частично удаляют до поверхности (13) диффузионного слоя (6) и в области (11) удаленного материала покрывающего слоя (7) выполняют наплавку. В частных случаях осуществления изобретения субстрат (4) представляет собой сталь, в частности молибденсодержащую сталь, преимущественно сталь 16Mo3. Субстрат (4) алитируют частично. По толщине покрывающего слоя (7) удаляют часть упомянутой толщины покрывающего слоя (7). Покрывающий слой (7) удаляют с поверхности (13) диффузионного слоя локально. В качестве материала для сварки наплавкой используют сталь, в частности молибденсодержащую сталь, преимущественно сталь 16Mo3. Ремонту подвергают компонент, субстрат ( ...

СПОСОБ НАНЕСЕНИЯ ПОКРЫТИЯ НА СКОЛЬЗЯЩУЮ ПОВЕРХНОСТЬ ЖАРОПРОЧНОГО ЭЛЕМЕНТА, ЖАРОПРОЧНЫЙ ЭЛЕМЕНТ И ЭЛЕКТРОД ДЛЯ ЭЛЕКТРОРАЗРЯДНОЙ ОБРАБОТКИ ПОВЕРХНОСТИ

Изобретение относится к способу нанесения покрытия на скользящую поверхность жаропрочного элемента, жаропрочному элементу и электроду для электроразрядной обработки поверхности и может быть использовано при изготовлении и ремонте лопаток газовых турбин. Используют электрод из неспеченной прессовки из материала, обладающего смазочными свойствами при высокой температуре, или смеси из жаропрочного твердого материала и материала, обладающего смазочными свойствами при высокой температуре. Покрытие наносят путем генерирования импульсного электрического разряда между электродом и скользящей поверхностью и формируют слой покрытия из материала электрода или продукта реакции материала электрода со скользящей поверхностью с использованием энергии электрического разряда. Жаропрочным твердым материалом является любой из числа cBN, TiC, TiN, TiAlN, TiB2, WC, Cr3С2, SiC, ZrC, VC, B4 C, Si3N4, ZrO2 и Al2О3 или их смесь. Материал, обладающий смазочными свойствами при высокой температуре, содержит хром, ...

СПОСОБ ВЫПОЛНЕНИЯ МЕТАЛЛИЧЕСКОГО УСИЛИТЕЛЬНОГО ЭЛЕМЕНТА ЛОПАТКИ ТУРБОМАШИНЫ

... 1. Способ выполнения металлического усилительного, элемента (30) передней кромки или задней кромки лопатки турбомашины, последовательно содержащий:этап (44) позиционирования заготовки (26, 70) посредством оснастки (60), позиционирующей упомянутую заготовку (26, 70) в такое положение, что упомянутая заготовка (26, 70) имеет на одном конце зону (28, 72), выполненную с возможностью приема присадочного металла;этап (46) построения основания (39) упомянутого металлического усилительного элемента (30) посредством наплавки присадочного металла в упомянутой зоне (28, 72) в виде валиков металла.2. Способ выполнения металлического усилительного элемента (30) лопатки турбомашины по п.1, отличающийся тем, что упомянутый этап (46) построения наплавкой присадочного металла осуществляют при помощи сварочного аппарата MIG, содержащего генератор пульсирующего тока и представляющего пульсирующий расход присадочной проволоки.3. Способ выполнения металлического усилительного элемента (30) лопатки турбомашины ...

СПОСОБ ВОССТАНОВЛЕНИЯ МЕТАЛЛИЧЕСКОГО ИЗДЕЛИЯ И СПОСОБ ВОССТАНОВЛЕНИЯ КОМПОНЕНТА ГАЗОТУРБИННОГО ДВИГАТЕЛЯ

... 1. Способ восстановления металлического изделия, включающий: обеспечение металлического изделия, имеющего дефект в виде разрыва; удаление материала из металлического изделия на участке,образованном дефектом в виде разрыва, с формированием выемки;помещение материала, применяемого для восстановления, в сформированную выемку;герметизацию и вакуумирование области соединения, определенной между металлическим изделием и материалом, применяемым для восстановления; иобработку материала, применяемого для восстановления, и металлического изделия с применением горячего изостатического прессования для проведения восстановления.2. Способ по п.1, в котором металлическое изделие включает компонент газотурбинного двигателя и в котором сформированная выемка имеет больший объем, чем объем дефекта в виде разрыва.3. Способ по п.1, в котором герметизацию области соединения проводят посредством герметизации поверхностного участка области соединения.4. Способ по п.3, в котором толщина герметизирующего материала ...

Способ аддитивного производства тонкостенного металлического изделия

Изобретение относится к технологиям аддитивного производства и может быть использовано для изготовления и восстановления тонкостенного металлического изделия путем электродуговой наплавки присадочной проволоки. После предварительной механической очистки и закрепления металлического основания осуществляют поэтапное электродуговое наплавление присадочной проволоки диаметром dпр 1,0-1,2 мм в среде защитного газа. На первом этапе наплавляют 1 или 2 слоя металла шириной от 3 до 5 мм с постоянной подачей присадочной проволоки на режиме с силой тока I, составляющей 130-170 А, и напряжением дуги U, составляющим 17-19 В. Проводят технологическую выдержку полученного слоя металла до температуры TO 70-80°С. На втором этапе проводят послойное наплавление металлического изделия до достижения требуемой его геометрии путем формирования слоев металла шириной 2-3 мм с импульсной подачей присадочной проволоки при силе тока I, составляющей 110-150 А, и напряжении дуги U, составляющем 11-13 В. Проводят технологическую ...

VERFAHREN UND VORRICHTUNG ZUR HERSTELLUNG DREIDIMENSIONALER KÖRPER

Verfahren zur Herstellung eines Zylinderblocks für einen Verbrennungsmotor

Verfahren zur Herstellung eines Zylinderblocks eines Verbrennungsmotors, welches folgende Schritte aufweist: Festlegen eines Parametersatzes für den Zylinderblock, wobei der Parametersatz zumindest eine Schichtdicke der verschleißfesten Schicht, eine zulässige Schweißspannung, eine erste Abmessung des Zylinders nach der Endbearbeitung, eine Druck-Richtung und eine Gegen-Druck-Richtung beinhaltet, Ausbilden eines dem Parametersatz entsprechenden Zylinderblocks, Bestimmen mindestens eines ersten und eines zweiten Auftragschweiß-Abschnitts entlang eines Zylinders des Zylinderblocks entsprechend der Druck- und der Gegen-Druck-Richtung, wobei der erste Auftragschweiß-Abschnitt ein erster Bereich ist, der sich von mindestens etwa ±5° bis etwa ±45° auf beiden Seiten der Druck-Richtung relativ zur Mittelachse des Zylinders erstreckt und der zweite Auftragschweiß-Abschnitt ein zweiter Bereich ist, der sich von mindestens etwa ±5° bis etwa ±45° auf beiden Seiten der Gegen-Druck-Richtung relativ zur ...

Weld head manipulator

REPAIR PROCEDURE FOR METALLIC CONSTRUCTION UNITS, IN PARTICULAR FOR SHOVELS OF GAS TURBINES

PROCEDURE FOR THE THERMAL TREATMENT OF A PACKED PRODUCT TOTALLY ENCLOSED IN A GRANULAR MATERIAL

VERFAHREN UND VORRICHTUNG ZUR HERSTELLUNG EINER SCHWEISSNAHT ODER EINER DREIDIMENSIONALEN STRUKTUR AN DER OBERFLÄCHE EINES METALLISCHEN WERKSTÜCKS

The invention relates to a method and an apparatus (1) for the production of a welding seam or a three-dimensional structure (26) on a surface of a metallic work piece (14) with the help of a welding torch (7) for carrying out a welding process with a welding wire (9) guided in a welding torch (7), whereby an electric arc (13) is ignited between the welding wire (9) and the work piece (14), and for stabilising the electric arc (13) a laser (27') for emitting a laser beam (27) with a maximum power of 2000W is arranged, with a point of impact being on that position of the work piece (14) where the welding seam or structure (26) is produced. An improvement of the stabilisation of the electric arc (13) is obtained if the laser (27') is connected to a means (28) for the control of the laser (27'), which control means (28) is designed to activate the laser beam (27) prior to the ignition of the electric arc (13).

PROCEDURE AND DEVICE FOR THE PRODUCTION OF THREE-DIMENSIONAL BODIES

PROCEDURE FOR THE PRODUCTION FROM METALLIC WORKPIECES WITH A WELDING JIG AND DEVICE TO THE EXECUTION OF THE SAME

METHOD AND DEVICE FOR MANUFACTURING TITANIUM OBJECTS

This invention relates to a method and reactor of manufacturing an object by solid freeform fabrication, especially an object made of titanium or titanium alloys. The reactor of production of an object of a weldable material by solid freeform fabrication comprises a reactor chamber which is closed to the ambient atmosphere, wherein the reactor is given a design such that all adjacent wall elements forming the reactor chamber are joined with an obtuse angle (larger than 90°), the actuator located below the reactor chamber is given a design such that the actuator protrudes into the reactor chamber through an opening at the bottom of the reactor chamber holding the support substrate inside the reactor chamber, the opening is sealed by at least one elastic gas impermeable membrane which is gas tight attached to the reactor wall at the opening and to the actuator, the actuator located outside the reactor chamber is given a design such that the actuator protrudes into the reactor chamber through ...

FASTENER RETENTION AND ANTI-CAMOUT TOOL BIT

A tool bit with a surface layer metallurgically bonded on a substrate layer using electrospark deposition (ESD) that allows the tool bit to reduce camout and engage a fastener head for one-handed starting and removal. The surface layer has a rougher finish, compared to conventional tool bits, and therefore better grips engagement surfaces of a mating recess of the fastener during use. The reduction of camout provides greater durability to the tool bit and resists erosion and wear of the engagement surfaces of the fastener.

SYSTEMS AND METHODS PROVIDING LOCATION FEEDBACK FOR ADDITIVE MANUFACTURING

A system and method to correct for height error during a robotic welding additive manufacturing process. One or both of a welding output current and a wire feed speed are sampled during a robotic welding additive manufacturing process when creating a current weld layer. A plurality of instantaneous contact tip-to-work distances (CTWD's) are determined based on at least one or both of the welding output current and the wire feed speed. An average CTWD is determined based on the plurality of instantaneous CTWD's. A correction factor is generated, based on at least the average CTWD, which is used to compensate for any error in height of the current weld layer.

IN-SPACE MANUFACTURING AND ASSEMBLY OF SPACECRAFT DEVICE AND TECHNIQUES

A system for producing an object is disclosed including a build device having a build area and a material bonding component to receive portions of a material that are used to produce the object, at least one gripper within the build area to contact the object to provide support and to provide for at least one of a heat sink for the object, a cold sink for the object, and electrical dissipation path from the object, and a movement mechanism to move the build device relative to the object to position the build device at a position to further produce the object. Another system and methods are also disclosed.

EARTH-BORING TOOLS WITH PRECISE CUTTER POCKET LOCATION AND ORIENTATION AND RELATED METHODS

A method of forming an earth-boring tool includes forming a tool body including at least one inverted cutting element pocket, at least a portion of the at least one inverted cutting element pocket having a profile substantially matching a profile of an actual cutting element to be secured within a cutting element pocket to be formed by subsequently machining the at least one inverted cutting element pocket. Hardfacing material may be applied to portions of the tool body. The actual cutting element pocket is formed by removing material of the tool body within the at least one inverted cutting element pocket subsequent to applying the hardfacing material to portions of the tool body. A cutting element is affixed within the actual cutting element pocket.

METHOD OF APPLYING A PROTECTIVE CLADDING, PARTICULARLY TO GAS-TIGHT MEMBRANES OF ENERGY BOILERS

A method of applying a protective cladding, particularly to gas-tight membranes of energy boilers involves coupling of two gas-tight membranes (2) together, and then soaking a pair of gas-tight membranes (2) coupled together at 300°C to 800°C, favorably at around 700°C; afterwards, the membrane (2) surface where a cladding (1) is to be applied is cleaned, a pair of gas-tight membranes (2) coupled together is mounted on a positioner and then preheated up to 80°C to 600°C, favorably to around 300°C-450°C, and then the cleaned and preheated surface of a pair of gas- tight membranes (2) coupled together is covered with a protective cladding (1), wherein a protective cladding is applied at a thickness of 0.1 mm to 3.00 mm, favorably around 0.6 mm, and then the entire pair of gas-tight membranes (2) coupled together with a cladding (2) is finally soaked at 300°C to 800°C, favorably at around 700°C, and the set temperature is maintained for 10 minutes to 600 minutes, favorably for 15 minutes to ...

Welding repair procedure, in particular for a turbine blade point.

Ein Schweiss-Reparaturverfahren verwendet einen Wolfram-Inertgas- oder Plasma-Lichtbogen-Schweissbrenner und einen passenden Füller. Die an den Schweissbrenner zugeführte Stromstärke und die Vorschubgeschwindigkeit des Schweissbrenners werden gesteuert, um eine Schweissraupe mit einer pilzförmigen Gestalt zu erzeugen. Die Schweissraupe wird von allen Seiten geschliffen, um zumindest die Hälfte der Dicke der Schweissraupe abzutragen, und eine weitere Schweissraupe wird gebildet. Die Technik erzeugt rissfreie Schweissnähte mit gerichtet verfestigtem Schweissmetall, das jenem des Grundmaterials ähnlich ist und somit vergleichbare mechanische Eigenschaften aufweist.

SUPPLY SYSTEM METAL WIRE AND CORRESPONDING METHOD

UNIT POWER SUPPLY TIP WITH LIQUID STNYM COOLING FOR BUILDING UP METAL

СПОСОБ И УСТРОЙСТВО ДЛЯ ИЗГОТОВЛЕНИЯ ИЗДЕЛИЙ ИЗ ТИТАНА

Изобретение относится к способу и реактору для изготовления изделия по технологии прямого получения изделий сложной формы, преимущественно изделия из титана или титановых сплавов. Реактор согласно изобретению, который содержит камеру реактора, изолированную от окружающей атмосферы, характеризуется тем, что имеет конструкцию, в которой все смежные стеновые элементы (6) стенок камеры реактора соединены друг с другом под тупым углом (превышающим 90°); первый приводной механизм (2), часть которого, введенная в камеру реактора снизу, через отверстие (7) в камере реактора, несет опору (3) подложки, находящейся внутри камеры реактора. Отверстие (7) загерметизировано посредством по меньшей мере одной эластичной газонепроницаемой мембраны (8), которая газонепроницаемым образом прикреплена к стенке реактора вблизи указанного отверстия и к первому приводному механизму. Реактор содержит также второй приводной механизм (4), часть которого входит внутрь камеры реактора через отверстие (9) в стенке камеры ...

SUPPLY SYSTEM METAL WIRE AND CORRESPONDING METHOD

Method for manufacturing barber scissors, and barber scissors

PROCESS OF REPAIR Of a BASIC PENETRATION OF TANK Of a Nuclear reactor

PUNCH PERFORATOR AND METHOD OF MANU INVOICE PUNCH PERFORATOR

Un punzón perforador que incluye un cuerpo principal del punzón, y un revestimiento pulverizado que se forma sobre una superficie del cuerpo principal del punzón e incluye hierro y óxido de hierro. Una composición química del revestimiento pulverizado que incluye, adicionalmente al hierro y el óxido de hierro, en % de peso, C: 0.015% a 0.6%, Si: 0.05% a 0.5%, Mn: 0.1% a 1.0%, y Cu: 0 a 0.3%.

METHOD FOR PRODUCING A COMPONENT OF A ROTARY MACHINE AND COMPONENT PRODUCED ACCORDING TO SUCH A METHOD

Three-dimensional parts and methods fabricating the same

In various embodiments, wire composed at least partially of arc-melted refractory metal material is utilized to fabricate three-dimensional parts by additive manufacturing.

Welding method using welding material of low transformation temperature

An arc welding method using a welding material having a low transformation temperature, characterized in that it is carried out by the use of a shielding gas consisting of a rare gas alone or a mixed gas of a rare gas and a small amount of an oxygen gas; and an additional welding method using a welding material having a low transformation temperature, characterized in that it is carried out while moving a weld line in the form of a straight line. The former method allows the enhancement of a Charpy value in combination with improved fatigue strength, and the latter allows the experience of heat history of the material having a low transformation temperature to be suppressed, resulting in the prevention of weld crack in combination with an improved fatigue strength.

Coating apparatus and processes for forming low oxide coatings

A local environmental cell for a welding spray gun includes an annular ring having a top surface and a bottom surface, wherein the annular ring is adapted for attachment to an outer perimeter of the spray gun; and a plurality of fluid passageways radially disposed about the annular ring having a plurality of openings in the bottom surface of the ring in fluid communication with a vacuum source for providing a vacuum thereto. The use of the local environmental cell permits deposition of local bond coats as well as minimizes the number of steps associated with welding repair processes. For example, the use of the local environmental cell permits welding and formation of a low oxide bond coat during the welding process, thereby eliminating the need for placing the substrate subsequent to a welding process in a separate spray cell to deposit the bond coating.

Earth-boring tools having particle-matrix composite bodies and methods for welding particle-matrix composite bodies

Methods for welding a particle-matrix composite body to another body and repairing particle-matrix composite bodies are disclosed. Additionally, earth-boring tools having a joint that includes an overlapping root portion and a weld groove having a face portion with a first bevel portion and a second bevel portion are disclosed. In some embodiments, a particle-matrix bit body of an earth-boring tool may be repaired by removing a damaged portion, heating the particle-matrix composite bit body, and forming a built-up metallic structure thereon. In other embodiments, a particle-matrix composite body may be welded to a metallic body by forming a joint, heating the particle-matrix composite body, melting a metallic filler material forming a weld bead and cooling the welded particle-matrix composite body, metallic filler material and metallic body at a controlled rate.

THIN-SKIN SIDE STAY BEAMS AND LANDING GEAR ASSEMBLIES

A thin-skin side-stay beam may include an upper arm with thin skin and a mating flange extending longitudinally from the thin skin. A lower arm may also have a thin skin and a mating flange extending longitudinally from the lower arm. A joint may include a pin and/or a bushing extending through the mating flanges to pivotally couple the upper arm to the lower arm. The upper arm and/or the lower arm may include one or more internal walls defining one or more internal cavities. 1. A thin-skin side-stay beam , comprising:an upper arm comprising a first thin skin and a first mating flange extending longitudinally from the first thin skin;a lower arm comprising a second thin skin and a second mating flange extending longitudinally from the second thin skin; anda joint comprising at least one of a pin or a bushing extending through the first mating flange and the second mating flange to pivotally couple the upper arm to the lower arm.2. The thin-skin side-stay beam of claim 1 , wherein the upper arm comprises a first internal wall extending longitudinally within the first thin skin claim 1 , wherein the first internal wall and the first thin skin define a first internal cavity having a first triangular geometry.3. The thin-skin side-stay beam of claim 2 , wherein the first internal wall is substantially flat.4. The thin-skin side-stay beam of claim 3 , wherein the first triangular geometry is convex along the first thin skin.5. The thin-skin side-stay beam of claim 2 , wherein a curved surface blends the first internal wall into the first thin skin.6. The thin-skin side-stay beam of claim 2 , wherein the upper arm further comprises a second internal wall extending longitudinally within the first thin skin claim 2 , wherein the first internal wall claim 2 , the second internal wall claim 2 , and the first thin skin define a second internal cavity having a rectangular geometry.7. The thin-skin side-stay beam of claim 6 , wherein the second internal wall and the first thin ...

Screw extruder coating process

Extruder screw reinforcement To reinforce an extruder screw, an initial hard layer is deposited on at least an edge of the screw peak and only over a fraction of the screw peak width. A second layer of hard material is deposited over the remainder of the screw peak, of a harder material than the first layer. The deposited layers are worked to give the required screw peak shape profile. The second layer is a metal with a nickel base or a very hard ceramic material. At least one of the reinforcement materials is deposited by welding. An Independent claim is included for an extruder screw with at least two layers of different materials deposited side by side at the screw peak surfaces (7). The reinforcement material deposited on and near at least one edge (8,9) of the screw peaks, and on a lateral wall (5,6) of the screw structure (4), has a hardness of max. 52 HRc and at least 5 HRc less than the other deposited material over the remainder of the peak surface. At least one deposited material ...

СПОСОБ ИЗГОТОВЛЕНИЯ КОМПОНЕНТА РОТАЦИОННОЙ МАШИНЫ И КОМПОНЕНТ, ИЗГОТОВЛЕННЫЙ С ИСПОЛЬЗОВАНИЕМ УПОМЯНУТОГО СПОСОБА

Группа изобретений касается способа изготовления компонента ротационной машины и самого компонента(1), имеющего по меньшей мере один внутренний проход (7), который продолжается от центра (6) до граничной поверхности (42) компонента и является по меньшей мере частично закрытым. Согласно способу предусматривают заготовку, которая содержит граничную поверхность (42) и верхнюю поверхность. Выполняют первый этап субтрактивной механической обработки, при котором путем механической обработки выполняют часть прохода (7), которая по меньшей мере содержит раскрыв (71) прохода (7) в граничную поверхность (42). Также выполняют вырез в верхней поверхности, после чего проход (7) завершают путем обработки наращиванием на заготовке. Изобретения направлены на создание компонента способом, обеспечивающим его надежность в рабочем состоянии. 2 н. и 13 з.п. ф-лы. 5 ил.

СПОСОБ УПРОЧНЕНИЯ ПОЧВООБРАБАТЫВАЮЩИХ РАБОЧИХ ОРГАНОВ

Изобретение относится к области сельскохозяйственного машиностроения. Способ упрочнения почвообрабатывающих рабочих органов включает формирование на поверхности деталей углублений с последующим заполнением их твердым сплавом методом электродуговой наплавки. После прерывистого нанесения на поверхности деталей рабочих органов твердого износостойкого сплава их охлаждают на воздухе до температуры +20°С, а затем подвергают воздействию холодом в диапазоне температур -78…-196°С в течение 72…76 часов с последующим отпуском при температуре +150°С в течение 3 часов. Обеспечивается увеличение долговечности почвообрабатывающих рабочих органов. 1 ил., 1 табл.

Способ изготовления компонента, в частности, компонента транспортного средства и соответствующим образом изготовленный компонент

БУРОВЫЕ ИНСТРУМЕНТЫ С ТОЧНЫМ РАСПОЛОЖЕНИЕМ И ОРИЕНТАЦИЕЙ ПАЗА ПОД РЕЖУЩИЙ ЭЛЕМЕНТ И СОПУТСТВУЮЩИЕ СПОСОБЫ

Verfahren und Vorrichtung zum Schweissplatieren

Verfahren zur Herstellung eines Laufrades

Verfahren zur Herstellung und Reparatur eines Laufrades für eine Wasserkraftwerk mit einer Roboter-Schweißvorrichtung wobei das Laufrad in Schichten aus Schweißmaterialbahnen sowie ohne eine stützende Hilfsvorrichtung aufgebaut wird, wobei mit einem Rechenprogramm das Volumenmodell des Laufrades in eine Vielzahl von Schichten zerlegt wird, welche mit Hilfe der Roboter-Schweißvorrichtung von der Oberfläche eines Basiskörpers ausgehend aufgetragen werden, so dass das Laufrad aus Schweißmaterial aufgebaut wird, wobei die Roboter-Schweißvorrichtung WIG-Heißdraht-Schweißen zum Auftragen der Schweißmaterialbahnen verwendet.

Device for manufacturing titanium objects

Apparatus,method,system and computer program for machining a workpiece

RENOVATION METHOD FOR FROGS BY ARC WELDING BUILD UP IN COMBI NATION WITH COOLING

PROCEDURE FOR THE PRODUCTION OF HAIRDRESSER SHEARS, AS WELL AS HAIRDRESSER SHEARS

Method for manufacturing or for repairing a component of a rotary machine as well as a component manufactured or repaired using such a method

Abstract: A method for manufacturing a component of a rotary machine is proposed, the component extending to an axial direction (A) as well as to a radial direction (R) 5 vertical thereto, and having at least one inner channel (7), which extends from a first end (72) of a core (K) of a center (6) of the component and to a second end (71) at a radial limiting surface (42) of the component and which is at least partially closed, characterized in that a blank (10) is provided, comprising the core (K) of the component and which blank (10) is limited by an outer surface (11) in the radi 10 al direction (R), wherein the blank (10) is subtractively processed that way in a first subtractive process step, that an outer contour (AK) is elaborated in the area of the outer surface (11), which outer contour extends at least in the radial direction (R), as well as a part of the channel (7) is manufactured, which radially extends, at least partially, in the blank (10) to the first end (72) and then the ...

METHOD OF REPAIRING A RAIL

A system or method of repairing railroad rails which includes a head, upright and base sections. The method includes at least the following steps: identifying and locating a defect in the rail, removing the defect by removing material from the rail surrounding the defect in at least the head section so as to form a void and a rail void interface while maintaining continuity of the rail, filling the void with molten metal having a high carbon content and causing the molten metal and the rail void interface to bond. The molten metal may be produced by gas shielded arc welding. The carbon content of the molten metal is near that of the rail to decrease carbon migration from the rails. High carbon welding electrode is used in the welding of high strength steel using gas shielded arc welding techniques whereby a plurality of beads of molten weld material join together rail ends or fill a slot in a rail for repair purposes, the high carbon electrode avoiding adjacent soft and brittle areas across ...

способ изготовления парикмахерских ножниц, а также парикмахерские ножницы

Изобретение касается способа изготовления парикмахерских ножниц (1), при котором заготовки полотен (23, 33) ножниц предварительно деформируют с предварительно определенной степенью кривизны в направлении, противоположном режущим кромкам. После этого осуществляют стадию наплавки твердосплавного материала в форме наплавленного валика на повернутых друг к другу торцевых поверхностях полотен (23, 33) ножниц для формирования режущих кромок (24, 34), причем предварительное искривление полотен (23, 33) компенсируется под воздействием тепла во время процесса наплавки. После этого наплавленные валики шлифуют для образования режущих кромок (24, 34), а половины (2, 3) ножниц предварительно рихтуют и закаляют. Потом парикмахерские ножницы (1) рихтуют в собранном состоянии. Кроме того, изобретение касается изготовленных таким способом парикмахерских ножниц (1). Они имеют режущие кромки (24, 34), выполненные из твердосплавного материала, нанесенного по всей толщине полотна (23, 33), благодаря чему возможна ...

UNIT CONTACT TIP FOR WELDING OF METALS METAL ELECTRODE IN INERT GAS

METHOD AND DEVICE FOR MANUFACTURING OF METAL OBJECTS WITH USE OF TECHNOLOGY OF MANUFACTURING OF SOLID BODY FREE MOULDING

Method for coating sliding surface of high temperature member, and high temperature member and electrode for electric discharge surface treatment

In-space manufacturing and assembly of spacecraft device and techniques

AUTOMATIC WELDING SYSTEM FOR ENGINE BLOCK REPRODUCTION

PURPOSE: An automatic welding system is provided to improve welding efficiency by employing a welding robot, to maximize the quality of a product and to prevent accidents probably occurring during engine block rotation. CONSTITUTION: An engine block is rotated to have a welding robot(10) weld upper and lower cylinder assembled portions on a concentric circle and a main bearing assembled portion. The settlement of the portions is controlled by the output of an approximate sensor with the rotation of a motor(21) by a controller(50). After the completion of welding in a part, the welding robot is moved and the engine block is rotated for other parts welding. By the repetition of the procedure, reproductive welding of the engine block is finished. Finally, the engine block is separated from a rotary roller(30) by holding with a hoist. COPYRIGHT 2001 KIPO ...

SCREW FEED ELEMENT AND METHOD FOR THE ADDITIVE MANUFACTURE OF SCREW FEED ELEMENTS

Method and apparatus for the production of a welding seam or a three-dimensional structure on a surface of a metallic work piece

The invention relates to a method and an apparatus (1) for the production of a welding seam or a three-dimensional structure (26) on a surface of a metallic work piece (14) with the help of a welding torch (7) for carrying out a welding process with a welding wire (9) guided in a welding torch (7), whereby an electric arc (13) is ignited between the welding wire (9) and the work piece (14), and for stabilizing the electric arc (13) a laser (27) for emitting a laser beam (27) with a maximum power of 2000 W is arranged, with a point of impact being on that position of the work piece (14) where the welding seam or structure (26) is produced. An improvement of the stabilization of the electric arc (13) is obtained if the laser (27) is connected to a means (28) for the control of the laser (27), which control means (28) is designed to activate the laser beam (27) prior to the ignition of the electric arc (13).

Flexible 3D Freeform Techniques

This invention relates to processes and systems of rapid prototyping and production. Its features includes flexible material deposition along tangential directions of surfaces of a part to be made, thereby eliminating stair-shape surface due to uniform horizontal layer deposition, increasing width of material deposition to increase build up rate, applying the principles of traditional forming/joining processes, such as casting, fusion welding, plastic extrusion and injection molding in the fabrication process so that various industrial materials can be processed, applying comparatively low cost heating sources, such as induction heating and arc-heating. Additional features include varying width and size of material deposition in accordance with geometry to be formed and applying a differential molding means for improved shape formation and surface finishing. 1. A system for dispensing and building up materials to make a three-dimensional article comprises:a dispensing head for dispensing said materials, said dispensing head comprising a material cell with a first elongated exit opening through which the materials are dispensed and a first gating mechanism for adjusting cross-sectional dimension of dispensed material, said first gating mechanism comprising a first movable gating member inside the material cell for adjusting dimension of the exit opening, the first movable gating member comprising a recess feature such that when the gating member is positioned to a fully-closed position said recess feature and said exit opening form a nozzle structure for dispensing materials in thin wire- and filament-shapes, the exit opening having a maximal cross-sectional area of at least an order of magnitude larger than cross-sectional area of said recess feature; anda material supply unit for supplying materials to said dispensing head, said material supply unit capable of adjusting material supply rate to match the dimension of the exit opening.2. The system of claim 1 , ...

METHOD FOR PRODUCING A COMPONENT, IN PARTICULAR VEHICLE COMPONENT, AND CORRESPONDINGLY PRODUCED COMPONENT

The disclosure relates to a method for producing a component, in particular a vehicle component or an engine component, such as a piston of an internal combustion engine. The method comprises forming a first body region, in particular by means of casting or forging. The method includes forming a second body region, which is connected to the first body region, from an aluminium alloy or an iron-based alloy or a copper-based alloy by means of an additive manufacturing method. The second body region is alloyed in such a manner that it has higher thermal stability, higher mechanical strength or higher wear resistance upon tribological stressing than the first body region.

Method of manufacturing an article

A gas turbine engine (10) fan outlet guide vane (34) is manufactured by diffusion bonding titanium alloy sheet metal workpieces (52, 54) together to form an in integral structure (66). A titanium alloy is weld deposited at predetermined positions (70, 72) and in a predetermined shape to build up bosses (42, 44) at the radially outer end (40) of the hollow integral structure (68). The integral structure (66) is inflated at high temperature to form a hollow integral structure (68) of predetermined aerofoil shape. Apertures (46, 48) are drilled through the bosses (42, 44) to enable the radially outer end (40) of the fan outlet guide vane (34) to be attached to a fan casing (32) of the gas turbine engine (10).

Gas turbine engine blade containment system

A gas turbine engine blade containment system is disclosed. The blade containment system may include a generally cylindrical casing being made of a first material, and a generally cylindrical ring being made of a second material coaxially surrounding the casing, at least some portion of the ring metallurgically bonded to the casing.

Method and arrangement for building metallic objects by solid freeform fabrication

A method and arrangement for manufacturing objects by solid freeform fabrication, especially titanium and titanium alloy objects, wherein the deposition rate is increased by supplying the metallic feed material in the form of a wire and employing two gas transferred arcs, one plasma transferred arc for heating the deposition area on the base material and one plasma transferred arc for heating and melting the feed wire.

Method and device for manufacturing shaped objects

A method for producing a built-up object, includes: producing maps beforehand, the maps indicating bead heights BH and bead widths BW corresponding to a base-surface inclination angle θ and a track inclination angle φ, in which the base-surface inclination angle is an angle between a base surface on which the weld beads are to be formed and a vertical direction, and the track inclination angle is an angle between a track direction of the torch and a vertical direction on the base surface; selecting a bead height BH0and a bead width BW0from the maps correspondingly to the base-surface inclination angle θ and the track inclination angle φ in forming a weld bead on the base surface; and forming the weld bead based on the selected bead height BH0and bead width BW0.

Screw extruder coating process

MANUFACTURING METHOD, MANUFACTURING SYSTEM, AND MANUFACTURING PROGRAM FOR ADDITIVE MANUFACTURED OBJECT

ПРОШИВНАЯ ОПРАВКА И СПОСОБ ЕЕ ИЗГОТОВЛЕНИЯ

Изобретение относится к оправке, используемой в прошивном стане, который прошивает и прокатывает заготовку. Прошивная оправка состоит из корпуса и напыленного на поверхность корпуса покрытия на основе железа и оксида железа, при этом напыленное покрытие имеет следующий состав, мас.%: C 0,015-0,6, Si 0,05-0,5, Mn 0,1-1,0, Cu 0-0,3, железо, оксид железа и примеси - остальное, причем содержании оксида железа в покрытии составляет от 55 до 80 об.%. Изобретение направлено на повышение эффективности производства полых трубных заготовок за счет получения оправок с качественным покрытием. 2 н. и 4 з.п. ф-лы, 2 табл., 3 ил., 1 пр.

Способ изготовления или ремонта детали ротационной машины, а также деталь, изготовленная или отремонтированная с использованием такого способа

FIELD: mechanical engineering.SUBSTANCE: invention relates to the field of mechanical engineering and can be used in the manufacture of a rotary machine parts. The part extends in the axial direction (A) and in the radial direction and has at least one inner channel (7). The said channel is partially closed and extends from the first end (72) in the center (6) of the part to the second end (71) in the radial bounding surface (42) of the part. A workpiece (10) is obtained with the center (6) of the part, which is bounded by the outer surface (11) in the radial direction (R). The maximum dimension (D1) of the outer surface (11) in the radial direction (R) is smaller than the dimension (D2) of the bounding surface (42) in the radial direction. Then, the first subtractive stage of the technological process is carried out, when a part of the channel (7) is produced by machining that extends from the first end (72) of the channel to the outer surface (11) of the workpiece (10). Then, the channel (7) is finished by building up on the workpiece (10).EFFECT: as a result, it is possible to obtain a part with an internal channel of various geometric shapes.14 cl, 5 dwg РОССИЙСКАЯ ФЕДЕРАЦИЯ (19) RU (11) (13) 2 743 542 C2 (51) МПК B23P 15/00 (2006.01) B23P 6/00 (2006.01) F01D 5/04 (2006.01) F04D 29/22 (2006.01) ФЕДЕРАЛЬНАЯ СЛУЖБА ПО ИНТЕЛЛЕКТУАЛЬНОЙ СОБСТВЕННОСТИ (12) ОПИСАНИЕ ИЗОБРЕТЕНИЯ К ПАТЕНТУ (52) СПК B23P 15/00 (2020.08); B23P 6/00 (2020.08); F01D 5/04 (2020.08); F04D 29/22 (2020.08) (21)(22) Заявка: 2017131415, 07.09.2017 (24) Дата начала отсчета срока действия патента: Дата регистрации: (73) Патентообладатель(и): ЗУЛЬЦЕР МЭНЭДЖМЕНТ АГ (CH) 19.02.2021 22.09.2016 EP 16190145.9 (43) Дата публикации заявки: 12.03.2019 Бюл. № 8 (56) Список документов, цитированных в отчете о поиске: JP 2004308647 A, 04.11.2004. RU 2169639 C2, 27.06.2001. RU 2427726 C2, 27.08.2011. RU 2274509 C2, 20.04.2006. FR 2901305 A1, 23.11.2007. (45) Опубликовано: 19.02.2021 Бюл. № 5 2 7 4 3 5 4 2 R U ( ...

СПОСОБ ИЗГОТОВЛЕНИЯ ИЛИ РЕМОНТА ДЕТАЛИ РОТАЦИОННОЙ МАШИНЫ, А ТАКЖЕ ДЕТАЛЬ, ИЗГОТОВЛЕННАЯ ИЛИ ОТРЕМОНТИРОВАННАЯ С ИСПОЛЬЗОВАНИЕМ ТАКОГО СПОСОБА

СПОСОБ РЕМОНТА СУПЕРСПЛАВОВ С ПОМОЩЬЮ ЛАЗЕРНОГО ПЕРЕПЛАВА С ИСПОЛЬЗОВАНИЕМ ФЛЮСА

СПОСОБ РЕМОНТА И ИЗГОТОВЛЕНИЯ КОМПОНЕНТОВ ГАЗОТУРБИННОГО ДВИГАТЕЛЯ И КОМПОНЕНТЫ ГАЗОТУРБИННОГО ДВИГАТЕЛЯ, ОТРЕМОНТИРОВАННЫЕ ИЛИ ИЗГОТОВЛЕННЫЕ С ЕГО ИСПОЛЬЗОВАНИЕМ

СПОСОБЫ ПОЛУЧЕНИЯ ИЗДЕЛИЙ ПОСРЕДСТВОМ АДДИТИВНОГО ПРОИЗВОДСТВА

Изобретение относится к области машиностроения и может быть использовано пари получении металлических изделий с использованием аддитивного производства (АП). Из исходного сырья для АП получают фасонную заготовку. При этом осуществляют планирование траектории наращивания непрерывно наносимых слоев расплавленного металла с обеспечением перекрытия между смежными непрерывно наносимыми слоями в вертикальном направлении, перпендикулярном плоскости нанесения. Каждый нанесенный АП-слой получают из непрерывно наносимых слоев, а между первым нанесенным АП-слоем и последующим нанесенным АП-слоем непрерывно наносимые слои последующего АП-слоя не полностью перекрываются с непрерывно наносимыми слоями первого АП-слоя. В результате получают фасонную металлическую заготовку со сглаженной внешней поверхностью, имеющей неступенчатые стенки. Затем осуществляют по меньшей мере одну операцию последующей обработки заготовки с получением готового формованного металлического изделия. В результате обеспечивается ...

Verfahren und Vorrichtung zum Versprühen von Metall auf eine Auftragfläche

Bei einem Verfahren und einer Vorrichtung zum Versprühen von Metall auf eine Auftragfläche (38) durch ein Abschmelzen eines Metalldrahtes (22) in einem elektrischen Lichtbogen (66), der aus einer mit dem Metalldraht elektrisch verbundenen Stromquelle (60) versorgt und in einem mit einem Schutzgas erhaltenen Plasma durchgeführt wird, wird der Lichtbogen zwischen dem Drahtende (35) und einem Substrat (44) aus einem hitzebeständigen, elektrisch leitfähigen Material aufrechterhalten, welches als Gegenelektrode zu dem Metalldraht mit der Stromquelle (60) elektrisch verbunden ist und ein mit dem Drahtende fluchtendes Fenster (48) aufweist, durch welches hindurch die von dem Drahtende abgeschmolzenen Metalltropfen (70) gegen die unterhalb des Substrats (40) angeordnete Auftragfläche versprüht werden, wobei die Stromversorgung des Lichtbogens periodisch zwischen zwei verschieden großen Stromstärken gepulst wird.

Renovation method for frogs by arc welding build up in combination with cooling

Welding torch

A method of manufacturing an article

Applying a cladding layer to a component

Weld head manipulator

PROCEDURE FOR THE WELDING REPAIRING OF A COMPONENT FOR A TURBINE MOTOR WITH A REFRAKTÄREN METALLIC DOCUMENT MATERIAL

Plasma Arc Weld Repair of High Nickel Metal Alloys

Method of repairing a rail

MULTI-MATERIAL WIRES FOR ADDITIVE MANUFACTURING OF TITANIUM ALLOYS

Wires for use in electron beam or plasma arc additive manufacturing of titanium alloys are disclosed. The wires have a first portion comprising a first material, and a second portion comprising a second material. The combination of the first and second materials results in a titanium alloy product of the appropriate composition.

SYSTEMATIC COLD WORKING OF WELDS

A method for welding a component (10) includes the steps of selecting a weld area (120) in the part which is located near a feature of interest; applying a weld (22) to a portion of the weld area (120), wherein solidification of the first weld (126, 158) causes deviation of the feature from a desired position; and cold working the first weld (126, 158) so as to impart plastic deformation therein to a degree that material is extruded outward from the first weld (126, 158). The deviation of the feature is at least partially reversed. The method may include the step of applying and cold working a series of spaced- apart tack welds (126) in a defect, and then applying and cold-working a series of welds between the tack welds (126).

A LOW COST PROCESS FOR THE MANUFACTURE OF NEAR NET SHAPE TITANIUM BODIES

METHOD AND APPARATUS FOR AUTOMATED APPLICATION OF HARDFACING MATERIAL TO ROLLING CUTTERS OF HYBRID-TYPE EARTH BORING DRILL BITS, HYBRID DRILL BITS COMPRISING SUCH HARDFACED STEEL-TOOTHED CUTTING ELEMENTS, AND METHODS OF USE THEREOF

The present invention relates to a system and method for automated or "robotic" application of hardfacing to the surface of a steel-toothed cutter of a standard earth-boring rock bit or a hybrid-type rock bit. In particular, the system incorporates a grounded adapter plate and chuck mounted to a robotic arm for grasping and manipulating a rock bit cutter beneath an electrical or photonic energy welding source, such as a plasma arc welding torch manipulated by a positioner. In this configuration, the torch is positioned substantially vertically and oscillated along a horizontal axis as the cutter is manipulated relative along a target path for the distribution of hardfacing. Moving the cutter beneath the torch allows more areas of more teeth to be overlayed, and allows superior placement for operational feedback, such as automatic positioning and parameter correction. In the preferred embodiment, sensors provide data to the control system for identification, positioning, welding program ...

WEAR-RESISTANT OVERLAY FORMING METHOD AND WEAR-RESISTANT COMPOSITE MEMBERS

A wear-resistant overlay forming method wherein hard particles are supplied to a molten weld pool that is formed on a base material by an arc generated from an arc electrode to form a wear-resistant overlay containing hard particles on the base material, and wherein the hard particles are supplied to part of molten metal of the molten weld pool, the part being raised by the arc or flowing down owing to gravity. A wear-resistant composite member for cutting and removing rock and sand is designed such that the hard-facing deposit layers containing the hard particles are formed on the base material in a stripe pattern so as to run in the direction of friction produced by rock and sand or such that the hard-facing deposit layers containing the hard particles and soft-facing deposit layers made from soft material are formed on the base material in a stripe pattern so as to run in the direction transverse to the direction of friction produced by rock and sand, being alternately aligned in the ...

METHOD AND DEVICE FOR ADDITIVE FABRICATION BY SUBMERGED ARC WELDING ROBOT WITH MATTER DELIVERY BY WELDING WIRE FOR THE MANUFACTURE OF METAL PARTS WITH VERY LOW THERMAL CONDUCTIVITY

METHOD FOR REPAIRING METAL PARTS OF A TURBOMACHINE MADE OF NICKEL BASED SUPERALLOY AND COBALT BY MIG WITH PULSED CURRENT AND FILLER WIRE

Repairing nuclear reactor tank base penetration, involves use of half inserts and automatic, remote controlled formation of model-derived solder strand in groove for repair

L'invention concerne un procédé de réparation d'une pénétration de fond de cuve d'un réacteur nucléaire, ladite pénétration comportant un tube (10) fixé sur la paroi interne du fond de cuve (1a) par un cordon de soudure (11) interne et débouchant à l'extérieur du fond de cuve en formant une gorge (15). Le procédé consiste, entre autres, à préparer une maquette représentative de la pénétration du fond de cuve à réparer et à déposer cette maquette sur site dans une zone hors irradiation, à fixer sur cette maquette dans la gorge deux demi-inserts (30a, 30b) ayant chacun un profil correspondant au demi-profil de la gorge, à réaliser toujours sur cette maquette de manière automatique avec commande à distance un cordon de soudure (35) dans la gorge (15), à effectuer un contrôle dimensionnel et, après validation de ce cordon de soudure (35), à effectuer les étapes de fixation de deux demi-inserts et de réalisation d'un cordon de soudure de manière automatique directement dans la gorge (15) de ...

SYSTEM AND METHOD FOR HIGH-SPEED CLADDING OF METALS

A metal cladding process using an automated welding tool, the tool comprising at least one torch for receiving two weld wires to produce a molten pool on the metal, the process having the steps of providing a set of instructions in a non-transitory computer readable medium, the instructions executable by a processor to control the travel speed of the at least one torch; and control the oscillation pattern and frequency of the at least one torch, the oscillation pattern comprising a pause at each of a center position, a lateral left position and a lateral right position relative to a weld reference line.

METHOD FOR PREPARATION OF A SUPERALLOY HAVING A CRYSTALLOGRAPHIC TEXTURE CONTROLLED MICROSTRUCTURE BY ELECTRON BEAM MELTING

The present disclosure provides a method of preparing superalloy metals having a crystallographic texture controlled micro structure by electron beam melting. 1. A process for the preparation of a superalloy metal comprising the steps ofproviding a metal alloy powder composition;providing a seed crystal;processing the metal alloy powder composition in the presence of the seed crystal toprovide a superalloy metal having a highly textured or single crystal microstructure.2. The process for the preparation of a superalloy metal according to claim 1 , further comprising:providing an inoculant prior to the processing step to provide a texture-free microstructure.3. The process for the preparation of a superalloy metal according to claim 1 , further comprising the step of:subjecting the superalloy metal to heat treatment.4. The process for the preparation of a superalloy metal according to claim 1 , further comprising the step of:subjecting the superalloy metal to hot isostatic pressing (HIP).5. The process for the preparation of a superalloy metal according to claim 1 , further comprising the steps of:subjecting the superalloy metal to heat treatment, andsubjecting the superalloy metal to hot isostatic pressing (HIP).6. The process for the preparation of a superalloy metal according to claim 1 , wherein the processing step is performed by electron beam melting claim 1 , electron beam solid freeform fabrication claim 1 , epitaxial laser beam formation claim 1 , laser engineered net shaping claim 1 , spray forming claim 1 , three-dimensional printing claim 1 , shaped metal deposition claim 1 , or metal inert gas welding.7. The process for the preparation of a superalloy metal according to claim 6 , wherein the processing step is performed by electron beam melting.8. The process for the preparation of a superalloy metal according to claim 1 , wherein the metal alloy powder composition comprises iron claim 1 , nickel claim 1 , chromium claim 1 , molybdenum claim 1 , niobium ...

Method and system for retreading track wheel

A wheel resurfacing method and system for resurfacing a worn track wheel to its original profile are disclosed. The system comprises a support for maintaining the worn railway wheel, a welding device, a controller, and a surface processing device. The worn railway wheel's circumferential surface defining a flange and a tread surface is reconstituted using a welding material. The welding device and the worn railway wheel rotate one relative to the other at a predetermined rate to adaptively aggregate annular welding beads along the circumferential surface to form a curvilinear profile slanted away from the flange. A surface processing device is then applied to the welded layer to form a substantially uniform surface to reconstitute the worn railway wheel to its original profile.

SYSTEM FOR AND METHOD OF PRODUCING A WELD ARC ADDITIVE MANUFACTURING PART WITH GRANULAR SUPPORT

The invention is a system for and method of manufacturing metallic parts through weld arc additive manufacturing with conductive granular media as support, to manufacture parts which have overhangs, hollow sections, a plurality of openings, a geometry having a discontinuous structure when formed by additive manufacturing steps that is joined, or a combination of geometries known in the art of manufacturing that could heretofore only be produced by cutting and assembling a variety of different parts. The system and method of the invention contemplate use of conductive granular media support material which may become at least partially incorporated in, or part of, a final part produced using the system or method of the invention.

Turbine rotor, manufacturing method thereof and steam turbine using turbine rotor

The present invention is a turbine rotor (20) which includes: a high temperature side rotor base material (21), and a low temperature side rotor base material (22). The high temperature side rotor base material (21) and the low temperature side rotor base material (22) respectively include concavities (26, 27) and grooves. The turbine rotor (20) has an enclosed space section formed by the concavity (26) of the high temperature side rotor base material (21) and the concavity (27) of the low temperature side rotor base material (22) being disposed opposingly, and a gap formed by the groove of the high temperature side rotor base material (21) and the groove of the low temperature side rotor base material (22) being disposed opposingly. The turbine rotor (20) contains a buildup welding section (23) formed between the high temperature side rotor base material (21) and the low temperature side rotor base material (22). The buildup welding section (23) has the same composition as that of the ...

PROCESS FOR THE MANUFACTURE OF TITANIUM ALLOY STRUCTURES

Method of weld repairing a component for a turbine engine with a refractory metal backing material

Reparing method of metallic elements

Process for repairing metallic parts of gas turbines comprises mechanically radiating the surfaces with a non-oxidic jet material, closing open groove ends, filling with a solder powder, heating and removing the solidified solder Process for repairing metallic parts of gas turbines comprises: (a) mechanically radiating the surfaces with a non-oxidic jet material; (b) closing open groove ends by build-up welding a welding material relative to the component material; (c) filling the groove closed on one end side with a solder powder with or without a filler; (d) heating the solder powder in a vacuum until it becomes liquid and metallurgically joins with the component material; and (e) removing the solidified solder. Preferred Features: The jet material is silicon carbide. After the solder has been liquefied and solidified in the groove, it is annealed in a vacuum.

A method of manufacturing an article

A gas turbine engine (10) fan outlet guide vane (34) is manufactured by diffusion bonding titanium alloy sheet metal workpieces (52,54) together to form an in integral structure (66). A titanium alloy is weld deposited at predetermined positions (70,72) and in a predetermined shape to build up bosses (42,44) at the radially outer end (40) of the hollow integral structure (68). The integral structure (66) is inflated at high temperature to form a hollow integral structure (68) of predetermined aerofoil shape. Apertures (46,48) are drilled through the bosses (42,44) to enable the radially outer end (40) of the fan outlet guide vane (34) to be attached to a fan casing (32) of the gas turbine engine (10).

Method for producing a metal reinforcement for a turbine engine blade

A method for making a metal reinforcement for the leading edge or trailing edge of a turbine engine blade, including: positioning a preform using an equipment positioning the preform in a position such that the preform, at one end thereof, has an area which is capable of receiving a filler metal; and, after the positioning, constructing a base for the metal reinforcement by hard-surfacing with filler metal in the area, in the form of metal beads.

METHOD FOR MANUFACTURING METAL PARTS AND MOLDS AND MICRO-ROLLER USED THEREFOR

A method for manufacturing parts and molds by: 1) slicing a three-dimensional CAD model of a part or mold; 2) planning a modeling path according to slicing data of the three-dimensional CAD model, whereby generating numerical control codes for modeling processing; and 3) performing fused deposition modeling of powders or wire material of metal, intermetallic compounds, ceramic and composite functional gradient materials by layer using a welding gun on a substrate layer via a numerical control gas shielded welding beam or laser beam according to a track specified by the numerical control code for each layer. A micro-roller or a micro-extrusion unit is installed at a contact area between melted and softened areas. The micro-roller or the micro-extrusion unit synchronously moves along with fused deposition area, which results in compressing and processing of the fused deposition area during the fused deposition modeling. 2. The method of claim 1 , wherein in said fused deposition modeling claim 1 , if a formed body cannot meet requirements for said dimension and surface accuracy requirements of said part or said mold claim 1 , grinding and polishing is performed on said formed body layer by layer or in a manner of segmentation during the modeling process claim 1 , until requirements for said dimension and surface accuracy of said part or said mold are met.3. The method of claim 1 , whereinsaid welding gun is a plasma gun, a gas shielded gun, or a laser welding head;said metal is metal or alloy material that can be used in gas shielded welding or laser welding;said intermetallic compound is an intermetallic compound material that can be used for surface cladding;said ceramic is a ceramic material that can be used for surface cladding; andsaid composite functional gradient material is a material integrating the metal, intermetallic compound and ceramic, or a material with gradient varied composition after integrating.4. The method of claim 2 , whereinsaid welding gun is ...

Localized repair of superalloy component

A method for repairing a damaged portion ( 144 ) of a brazed-on gas turbine engine seal ( 142 ) without the need to remove and to replace the entire seal. The damaged portion is removed to reveal a repair surface ( 146 ) of the underlying superalloy material, and a new seal structure ( 148 ) is formed by an additive manufacturing processes using a laser beam ( 124 ) to melt a powder ( 116 ) including superalloy material ( 116 ′) and flux material ( 116 ″). The flux material forms a protective layer of slag ( 132 ) over the melted superalloy material, thereby permitting the new seal structure to be formed directly onto the underlying superalloy material without the need for an intervening braze layer.

Turbine Rotor, Manufacturing Method Thereof and Steam Turbine Using Turbine Rotor

A turbine rotor includes a high- and low-temperature side rotor base materials. The high- and low-temperature materials include concavities and grooves. The turbine rotor has an enclosed space formed by the concavity of the high- and low-temperature materials being disposed opposingly, and a gap formed by the grooves of the high- and low-temperature materials being disposed opposingly. The turbine rotor contains a buildup welding section formed between the high- and low-temperature materials, which has the same composition as that of the high- or low-temperature material, and has a penetration bead on the enclosed space side, and the gap contains a weld metal filled therein. Thus, a stable penetration bead can be formed in a dissimilar material welded rotor combining two kinds of alloy materials with different thermal properties, and then generation of a non-welded portion of a butting section that becomes a start point of fracture can be suppressed. 1. A turbine rotor comprising:a high temperature side rotor base material; anda low temperature side rotor base material,the high temperature side rotor base material and the low temperature side rotor base material respectively including concavities and grooves,the turbine rotor having an enclosed space section formed by the concavity of the high temperature side rotor base material and the concavity of the low temperature side rotor base material being disposed opposingly, and a gap formed by the groove of the high temperature side rotor base material and the groove of the low temperature side rotor base material being disposed opposingly,the turbine rotor containing a buildup welding section formed between the high temperature side rotor base material and the low temperature side rotor base material,wherein the buildup welding section has the same composition as that of the high temperature side rotor base material or the low temperature side rotor base material, and has a penetration bead on the enclosed space ...

SYSTEM AND METHOD LOW HEAT WELD

A method for low heat welding includes providing short circuit pulse Metal Inert Gas (MIG) welding at less than a rate of about a twenty (20) inch a minute travel speed. 1. A method for low heat welding comprising:providing short circuit pulse Metal Inert Gas (MIG) welding at less than a rate of about a twenty (20) inch a minute travel speed.2. The method as recited in claim 1 , further comprising:providing an about 100% argon shielding gas for the short circuit pulse Metal Inert Gas (MIG) welding.3. The method as recited in claim 1 , further comprising:providing an about 99.75% argon and an about 0.25% carbon dioxide shielding gas for the short circuit pulse Metal Inert Gas (MIG) welding.4. The method as recited in claim 1 , further comprisingproviding short circuit pulse Metal Inert Gas (MIG) welding at a rate of 5-15 inch a minute travel speed.5. The method as recited in claim 1 , further comprisingproviding short circuit pulse Metal Inert Gas (MIG) welding at a rate of 5 inch a minute travel speed.6. A method for repairing an aerospace component comprising:removing material on an aerospace component to provide a consistent surface; andbuilding-up material on the consistent surface via short circuit pulse Metal Inert Gas (MIG) welding at less than a rate of a twenty (20) inch a minute travel speed to provide a weld buildup.7. The method as recited in claim 6 , further comprising:machining the weld buildup to original nominal dimensions of the aerospace component.8. The method as recited in claim 6 , wherein the aerospace component is a knife edge.9. The method as recited in claim 6 , further comprising:providing an about 100% argon shielding gas for the short circuit pulse Metal Inert Gas (MIG) welding.10. The method as recited in claim 6 , further comprising:providing an about 99.75% argon and an about 0.25% carbon dioxide shielding gas for the short circuit pulse Metal Inert Gas (MIG) welding.11. The method as recited in claim 6 , wherein the aerospace ...

METHOD AND ARRANGEMENT FOR BUILDING METALLIC OBJECTS BY SOLID FREEFORM FABRICATION

This invention relates to a method and arrangement for manufacturing objects by solid freeform fabrication, especially titanium and titanium alloy objects, wherein the deposition rate is increased by supplying the metallic feed material in the form of a wire and employing two gas transferred arcs, one plasma transferred arc for heating the deposition area on the base material and one plasma transferred arc for heating and melting the feed wire. 1. A system for building metallic objects by solid freeform fabrication , comprising:a first PTA torch electrically connected to a base material and a second PTA torch electrically connected to a feed wire; anda control system to control the first and second torches, and the feed wire to form an object by fusing successive deposits of a metallic material onto the base material.2. The system of claim 1 , wherein the electrical connection between the first PTA torch and the base material is achieved by a first power source claim 1 , and the electrical connection between the second PTA torch and the feed wire is achieved by a second power source.3. The system of claim 2 , wherein the first and second power sources are direct current.4. The system of claim 3 , wherein the first and second direct current power sources include independent controls.5. The system of claim 1 , wherein the first PTA torch preheats the base material at a position at which the metallic material is to be deposited.6. The system of claim 1 , wherein the second PTA torch melts the feed wire.7. The system of claim 1 , wherein at least one of the first and second PTA torches includes arc deflection control.8. The system of claim 1 , wherein the first PTA torch is a gas tungsten arc welding torch.9. The system of claim 1 , wherein at least one of first and second PTA torches is a gas metal arc welding torch.10. The system of claim 1 , further comprising an electrical connection between the second PTA torch and the base material.11. The system of claim 10 , ...

METHOD OF MANUFACTURING HIGH-CONDUCTIVITY WEAR RESISTANT SURFACE ON A SOFT SUBSTRATE

A method of forming a valve seat of an engine head formed from a first composition includes forming a groove at a predetermined valve seat location of a bore defined by the engine head. A source of directed heat energy preheats at least the valve seat location to about a temperature of the melting point of the first composition with the source of directed heat energy. The source of directed heat energy is infused with a material having a second composition generating a melt pool upon the groove by direct metal deposition with the melt pool including the second composition. The second composition includes a heat conductivity generally equal to a heat conductivity of the first composition for providing efficient transfer of heat energy from the first composition to the second composition. 1. A method of forming a valve seat of an engine head formed from a first composition includes the steps of:forming a groove at a predetermined valve seat location of a bore defined by said engine head;providing a source of directed heat energy;preheating at least said valve seat location to about a temperature of the melting point of the first composition with the source of directed heat energy;infusing the source of directed heat energy with a material having a second composition and generating a melt pool upon the groove by direct metal deposition, with the melt pool including the second composition; andsaid second composition including a heat conductivity generally equal to or greater than a heat conductivity of the first composition for providing efficient transfer of heat energy from the first composition to the second composition.2. The method set forth in claim 1 , wherein said step of infusing the source of directed heat energy with a material having a second composition is further defined by providing a second composition comprising:copper in the amount of 40-50 percent by weight;cobalt in the amount of 15-25 percent by weight;carbon in the amount of less than 0.1 percent ...

THIN-SKIN SIDE STAY BEAMS AND LANDING GEAR ASSEMBLIES

A thin-skin side-stay beam may include an upper arm with thin skin and a mating flange extending longitudinally from the thin skin. A lower arm may also have a thin skin and a mating flange extending longitudinally from the lower arm. A joint may include a pin and/or a bushing extending through the mating flanges to pivotally couple the upper arm to the lower arm. The upper arm and/or the lower arm may include one or more internal walls defining one or more internal cavities. 1. An arm of a thin-skin side-stay beam , comprising:a thin skin elongated in a longitudinal direction with a first mating flange extending from a first longitudinal end of the thin skin and a second mating flange extending from a second longitudinal end of the thin skin;a first internal wall extending longitudinally within the thin skin, wherein the thin skin and the first internal wall define a first triangular cavity; anda second internal wall extending longitudinally within the thin skin, wherein the thin skin, the first internal wall, and the second internal wall define a rectangular cavity, wherein the thin skin and the second internal wall define a second triangular cavity.2. The arm of claim 1 , wherein the thin skin has a thickness ranging from about 0.07 inches to about 0.125 inches.3. The arm of claim 2 , wherein the first internal wall has a thickness ranging from about 0.125 inches to about 0.25 inches.4. The arm of claim 3 , wherein the first internal wall is blended into the thin skin by a curved surface.5. The arm of claim 4 , wherein the curved surface has a radius of curvature ranging from about 0.5 inches to about 0.8 inches.6. The arm of claim 1 , wherein the first internal wall is aligned longitudinally with the first mating flange and the second mating flange.7. The arm of claim 1 , wherein the arm has a first height at the first longitudinal end of the thin skin and a second height at the second longitudinal end of the thin skin and the first height is greater than the ...

ELECTROSPARK DEPOSITION SYSTEM FOR REPAIR OF GAS TURBINE

A system and method for repairing a metal substrate includes an electrospark device and an electrode removably supported in the electrode holder. The electrospark device applies a coating of a material when placed into contact with the metal substrate. A cooling device to lowers the temperature of shielding gas flow below an ambient temperature. A conduit is arranged to direct a flow of the shielding gas to the interface of the electrode and the substrate to cool the area of the substrate receiving the coating. 1. A system for repairing a metal substrate comprising:an electrospark device including an electrode holder and a consumable electrode removably supported in the electrode holder, the electrospark device being arranged and disposed to establish a continuous spark between the consumable electrode and the substrate and continuously deposit an alloyed coating until a desired coating thickness is obtained;a cooling device configured to lower the temperature of a shielding gas flow below an ambient temperature; anda conduit arranged and disposed to receive the shielding gas flow from the cooling device and direct the shielding gas flow at an interface of the consumable electrode and the substrate.2. The system of claim 1 , wherein the interface is located at the point of contact of the consumable electrode with the substrate where an electrospark is generated.3. The system of claim 1 , wherein the consumable electrode is secured to a nozzle tip under an applied torque to establish the continuous spark between the consumable electrode and the substrate to build up a surface of the substrate.4. The system of claim 1 , wherein the substrate is mounted in a rotatable positioner.5. The system of claim 4 , wherein the rotatable positioner has a rotary speed adjustment.6. The system of claim 1 , wherein the electrode holder is rotatable.7. The system of claim 6 , wherein a rotational speed of the electrode holder is adjustable.8. The system of claim 1 , wherein the ...

CONTACT TIP CONTACT ARRANGEMENT FOR METAL WELDING

A contact tip assembly having an electric contact unit containing a contact tip with an electric energy source, where the electric contact unit is positioned at a distance away from the outlet opening of a guide. 1. A contact tip assembly , comprising:a guide having a longitudinal center axis, a first end, and an opposite second end, and a center bore extending and running along the longitudinal center axis of the guide from its first end to its second end;an electrically insulating lining inside of the center bore and extending at least from the first end to the second end of the guide; andan electric contact unit containing a contact tip in electric contact with an electric energy source, the electric contact unit arranged to contact a metal wire with the contact tip past the second end of the guide.2. The contact tip assembly of claim 1 , further comprising a wire pressing assembly for pressing the metal wire into contact with the contact tip of the electric contact element.3. The contact tip assembly of claim 1 , further comprising a contact element pressing assembly for pressing the contact tip of the electric contact element onto the metal wire.4. The contact tip assembly of claim 1 , further comprising a wire pressing assembly and a contact element pressing assembly.5. The contact tip assembly of claim 1 , where the electrically insulating lining:comprises a guide channel having an inlet opening at the first end and an outlet opening at the second end and running through the electrically insulating lining along the longitudinal center axis, andguides a metal wire being passed through the linear cylindrical guide channel from the inlet opening towards and further out of the outlet opening;6. The contact tip assembly of claim 1 , wherein the electric contact unit is positioned at a distance away from the outlet opening.7. The contact tip assembly of claim 1 , further comprising a bottom opening in the bottom of the guide.8. The contact tip assembly of claim 7 , ...

METAL WIRE FEEDING SYSTEM

Provided are a systems and methods for continuously providing a metal wire to a welding torch for manufacturing objects by solid freeform fabrication to provide continuous deposition of metal to the freeform object, especially objects made with titanium or titanium alloy wire. 1. A metal wire feeding system , comprising:a positionally adjustable wire supply spool;a cabinet comprising an entry wire position detector containing an aperture;a wire feeding device comprising a first motorized grooved roller, a first passive grooved roller, and a first motor attached to the first motorized grooved roller, wherein the first motorized grooved roller and the first passive grooved roller form a channel therebetween;a combination of at least three slack wire guides, wherein a first slack wire guide is positioned after the wire feeding device an in line therewith, a second slack wire guide positioned to the right of and below the first slack wire guide, and a third slack wire guide positioned to the left of and below the first slackwire guide;a slack wire pulling device comprising a second motorized grooved roller, a second passive grooved roller, and a second motor attached to the second motorized grooved roller, wherein the second motorized grooved roller and the second passive grooved roller form a channel therebetween; anda cabinet exit guide.2. The metal wire feeding system of claim 1 , where: a first dual grooved roller having a first and second groove, the roller being attached to a first arm pivotally connected to a back plate of the cabinet; and', 'a second dual grooved roller having a first and second groove, where the first groove of the first grooved roller and the first groove of the second grooved roller form a channel therebetween, and the first groove of the first dual grooved roller is biased by a spring on the first arm connected to a first support connected to the back plate of the cabinet;, 'the first slack wire guide comprises a third passive grooved roller ...

High-density, crack-free metallic parts

In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material.

THIN-SKIN SIDE STAY BEAMS AND LANDING GEAR ASSEMBLIES

A thin-skin side-stay beam may include an upper arm with thin skin and a mating flange extending longitudinally from the thin skin. A lower arm may also have a thin skin and a mating flange extending longitudinally from the lower arm. A joint may include a pin and/or a bushing extending through the mating flanges to pivotally couple the upper arm to the lower arm. The upper arm and/or the lower arm may include one or more internal walls defining one or more internal cavities. 1. A method of making an arm for a thin-skin side stay beam , comprising:selecting a metal;forming a thin skin of the arm from the metal using additive manufacturing, wherein the thin skin and the internal wall at least partially define a plurality of internal cavities; andforming an internal wall of the arm using additive manufacturing.2. The method of claim 1 , wherein the forming the thin skin of the arm comprises:depositing a first layer of the metal;removing an excess material from the first layer of the metal; anddepositing a second layer of the metal over the first layer of the metal.3. The method of claim 1 , wherein the forming the thin skin of the arm comprises:depositing a first layer of the metal;depositing a second layer of the metal over the first layer of the metal; andremoving an excess material from the first layer of the metal and the second layer of the metal.4. The method of claim 1 , wherein the internal wall and the thin skin define an internal cavity of the plurality of internal cavities claim 1 , wherein the cavity has a triangular geometry. This application is a divisional of, claims priority to and the benefit of, U.S. patent application Ser. No. 15/222,772, filed on Jul. 28, 2016, and entitled “THIN-SKIN SIDE STAY BEAMS AND LANDING GEAR ASSEMBLIES,” which is incorporated by reference in its entirety.The disclosure relates generally to aircraft landing gear, with various embodiments relating to thin-skinned landing gear structures.Aircraft designers have continuously ...

METHOD FOR FORMING A TURBINE COMPONENT

A method for forming a turbine component is disclosed, including applying a metal composition to a structure by an additive manufacturing technique and lengthening the structure by the additive manufacturing technique. The structure is a transition piece or a combustion liner-transition piece assembly. Lengthening the structure forms a structure extension. A picture frame is formed on an outer surface of the structure extension by the additive manufacturing technique. 1. A method for forming a turbine component , comprising:applying a metal composition to a structure by an additive manufacturing technique;lengthening the structure by the additive manufacturing technique, lengthening the structure forming a structure extension; andforming a picture frame on an outer surface of the structure extension by the additive manufacturing technique,wherein the structure is a transition piece or a combustion liner-transition piece assembly.2. The method of claim 1 , wherein the turbine component is a unibody.3. The method of claim 1 , wherein the additive manufacturing technique includes an additive welding technique.4. The method of claim 3 , wherein the additive welding technique is selected from the group consisting of gas metal arc welding claim 3 , gas tungsten arc welding with metal filler claim 3 , laser cladding with filler metal claim 3 , laser melting with filler metal claim 3 , electron beam melting with filler metal claim 3 , direct metal laser melting claim 3 , and combinations thereof.5. The method of claim 4 , wherein the additive welding technique is a robotic additive welding technique.6. The method of claim 1 , further including finishing the picture frame to net shape.7. The method of claim 1 , wherein forming the structure extension includes forming the structure extension to be between about 1 to about 2 inches in length.8. The method of claim 7 , wherein the structure extension is about 1.5 inches in length.9. The method of claim 1 , wherein lengthening ...

IN-SPACE MANUFACTURING AND ASSEMBLY OF SPACECRAFT DEVICE AND TECHNIQUES

A system for producing an object is disclosed including a build device having a build area and a material bonding component to receive portions of a material that are used to produce the object, at least one gripper within the build area to contact the object to provide support and to provide for at least one of a heat sink for the object, a cold sink for the object, and electrical dissipation path from the object, and a movement mechanism to move the build device relative to the object to position the build device at a position to further produce the object. Another system and methods are also disclosed. 1. A system for producing an object , the system comprising:a build device having a build area and a material bonding component to receive portions of a material that are used to produce the object;at least one gripper within the build area to contact the object to provide support and to provide for at least one of a heat sink for the object, a cold sink for the object, and electrical dissipation path from the object; anda movement mechanism to move the build device relative to the object to position the build device at a position to further produce the object.2. The system according to claim 1 , wherein the build area is an unlimited build area in at least one axis where the object is produced.3. The system according to claim 1 , further comprising radiators thermally coupled to the at least one gripper.4. The system according to claim 1 , further comprising a weaving component to create a mesh that applied over the object as the object is produced.5. The system according to claim 1 , further comprising an antennae element release mechanism to extrude an antennae element from the build device for engagement with the object at least one of as the object is produced and once the object is produced.6. The system according to claim 4 , wherein the mesh is a flexible conductive mesh.7. The system according to claim 1 , wherein a portion of the build area and the at ...

Systems and methods providing location feedback for additive manufacturing

A system and method to correct for deposition errors during a robotic welding additive manufacturing process. The system includes a welding power source to sample instantaneous parameter pairs of welding output current and wire feed speed in real time during a robotic welding additive manufacturing process while creating a current weld layer of a 3D workpiece part. An instantaneous ratio of welding output current and wire feed speed are determined for each instantaneous parameter pair. A short term running average ratio is determined based on the instantaneous ratios. A relative correction factor is generated based on at least the short term running average ratio and is used in real time while creating the current weld layer to compensate for deviations in a deposit level from a desired deposit level for the current weld layer.

WIRE ARC ACCURACY ADJUSTMENT SYSTEM

Provided are a systems and methods for continuously providing a metal wire to a welding torch in the correct orientation with respect to the heat source of the welding torch for manufacturing objects by solid freeform fabrication to provide continuous deposition of metal to the freeform object, especially objects made with titanium or titanium alloy, or nickel or nickel alloy, wire. 1. A metal wire positioning system , comprising:a plate containing an internally threaded opening, the plate fixedly attached to a main frame;a holding unit attached to the main frame, the holding unit comprising a rotatable support piston engaged with a pivot joint, and a connector connected to the rotatable support piston and pivotably supporting the rotatable support piston;an adjustable guide support frame rotatably connected to the main frame by the holding unit via the pivot joint and suspended by the rotatable support piston;a motor attached to the adjustable guide support frame, the motor attached to a threaded member that is engaged with the internally threaded opening in plate; anda detector that detects the position of an arc of welding torch.2. The system of claim 1 , further comprising a control system in communication with the motor claim 1 , the control system controls a rotation of the motor and thereby the movement of the threaded member.3. The system of claim 2 , wherein the control system controls an amount and a direction in which the threaded member is rotated.4. The system of claim 1 , wherein the threaded member is a screw or bolt.5. The system of claim 1 , wherein rotation of the threaded member by the motor in one direction repositions the adjustable guide support frame toward the main frame claim 1 , and rotation of the threaded member by the motor in the opposite direction repositions the adjustable guide support frame away from the main frame.6. The system of claim 1 , further comprising a movable sleeve that encircles the threaded member.7. The system of ...

GAS TURBINE ENGINE BLADE CONTAINMENT SYSTEM

A gas turbine engine blade containment system is disclosed. The blade containment system may include a generally cylindrical casing being made of a first material, and a generally cylindrical ring being made of a second material coaxially surrounding the casing, at least some portion of the ring metallurgically bonded to the casing. 1. A gas turbine engine blade containment system , comprising:a generally cylindrical casing being made of a first material; anda generally cylindrical ring being made of a second material coaxially surrounding the casing, at least some portion of the ring metallurgically bonded to the casing.2. The gas turbine engine blade containment system of claim 1 , further including a generally cylindrical second ring comprising a third material axially spaced apart from the ring claim 1 , at least some portion of the second ring metallurgically bonded to the casing.3. The gas turbine engine blade containment system of claim 2 , wherein the second material and third material are the same.4. The gas turbine engine blade containment system of claim 2 , wherein the second material and third material are different.5. The gas turbine engine blade containment system of claim 1 , further including a gap positioned between the casing and the ring.6. The gas turbine engine blade containment system of claim 1 , further including a sheet metal core positioned between the casing and the ring.7. The gas turbine engine blade containment system of claim 5 , further including a rib connected to at least some portion of the sheet metal core and extending through the ring.8. The gas turbine engine blade containment system of claim 1 , further including metallic foam positioned between the casing and the ring.9. A gas turbine engine claim 1 , comprising:a fan section;a compressor section downstream of the fan section;a combustor section downstream of the compressor section; anda turbine section downstream of the combustor section, the turbine section including a ...

ADDITIVE MANUFACTURING SYSTEMS AND METHODS

Present embodiments include an additive manufacturing tool configured to receive a metallic anchoring material and to supply a plurality of droplets to a part, wherein each droplet of the plurality of droplets comprises the metallic anchoring material and a mechanical oscillation system configured to mechanically oscillate a structural component of the additive manufacturing tool toward and away from the part, wherein the mechanical oscillation system comprises a motor, a cam coupled to the motor, and a piston coupled to the cam, wherein the piston is fixedly attached to the structural component. 1. A system , comprising:an additive manufacturing tool configured to receive a metallic anchoring material and to supply a plurality of droplets to a part, wherein each droplet of the plurality of droplets comprises the metallic anchoring material;a mechanical oscillation system configured to mechanically oscillate a structural component of the additive manufacturing tool toward and away from the part; anda controller configured to independently control the formation and application of each droplet of the plurality of droplets to the part, wherein the plurality of droplets is configured to build up the part.2. The system of claim 1 , wherein the structural component comprises an integrated tool head of the additive manufacturing tool claim 1 , and the metallic anchoring material extends through the integrated tool head.3. The system of claim 2 , comprising a liner disposed about the metallic anchoring material claim 2 , wherein the liner extends through the integrated tool head claim 2 , and the liner is fixed relative to the integrated tool head.4. The system of claim 1 , wherein the mechanical oscillation system comprises:a motor;a cam coupled to the motor; anda piston coupled to the cam, wherein the piston is fixedly attached to the structural component.5. The system of claim 4 , wherein oscillation of the piston has a fixed travel distance.6. The system of claim 1 , ...

Additive manufacturing of a component made from a metal matrix composite

The embodiments relate to a method for additive manufacturing of a component made from a metal matrix composite for a vehicle. In a step of the method, a plurality of elongated filaments is provided. In another step, metallic powder is provided. In a further step, the metal matrix composite component is additively manufactured by melting the metallic powder.

EARTH-BORING TOOLS HAVING PARTICLE-MATRIX COMPOSITE BODIES AND METHODS FOR WELDING PARTICLE-MATRIX COMPOSITE BODIES

Methods for welding a particle-matrix composite body to another body and repairing particle-matrix composite bodies are disclosed. Additionally, earth-boring tools having a joint that includes an overlapping root portion and a weld groove having a face portion with a first bevel portion and a second bevel portion are disclosed. In some embodiments, a particle-matrix bit body of an earth-boring tool may be repaired by removing a damaged portion, heating the particle-matrix composite bit body, and forming a built-up metallic structure thereon. In other embodiments, a particle-matrix composite body may be welded to a metallic body by forming a joint, heating the particle-matrix composite body, melting a metallic filler material forming a weld bead and cooling the welded particle-matrix composite body, metallic filler material and metallic body at a controlled rate. 1. A method of joining a particle-matrix composite body of an earth-boring tool to a metallic body , the method comprising: forming a first bevel portion and a second bevel portion in a face portion of a weld groove; and', 'forming an overlapping interface at least proximate a root portion of the weld groove;, 'forming a joint between a particle-matrix composite body of the earth-boring tool and a metallic body of the earth-boring tool, comprisingheating a volume of the particle-matrix composite body within the weld groove to an elevated first temperature below the melting temperature of the matrix material of the particle-matrix composite body;heating at least a portion of the volume of the particle-matrix composite body within the weld groove with a welding torch to a second temperature greater than the melting temperature of the matrix material of the particle-matrix composite body;melting a metallic filler material;forming a weld bead to weld the metallic filler to the particle-matrix composite body and to the metallic body at the joint;providing the welded particle-matrix composite body, metallic filler ...

ONE-PIECE PISTON FEATURING ADDITIVE MACHINING PRODUCED COMBUSTION BOWL RIM AND COOLING GALLERY

A piston capable of withstanding high temperatures and extreme conditions of a combustion chamber of an internal combustion engine and manufactured with reduced costs is provided. The method of manufacturing the piston includes casting or forging the bulk of the piston as a single-piece with an open cooling gallery from an economical first material, such as steel, cast iron, or aluminum. The method further includes forming a portion of a combustion bowl surface, which is a small area of the piston directly exposed to the combustion chamber, from a second material by additive machining. The second material has a higher thermal conductivity and higher resistance to oxidation, erosion, and oil coking, compared to the first material. The additive machining process is efficient and creates little waste, which further reduces production costs. 1. A piston for an internal combustion engine , comprising:a crown portion and a skirt portion formed from a first material;a combustion surface disposed along the crown portion, wherein at least a portion of the combustion surface is formed from a second material by an additive machining process; anda heat affected zone defined by a first edge along the first material and a second edge along the second material, wherein the first edge has a shape following the shape of the second edge.2. The piston of claim 1 , wherein a single piece of the first material forms the crown portion and the skirt portion; and the second material has at least one of a higher thermal conductivity claim 1 , higher erosion resistance claim 1 , higher resistance to coking adhesion claim 1 , and a higher oxidation resistance than the first material.3. The piston of claim 1 , wherein an underside of the combustion surface includes surface irregularities immediately following the additive machining process and prior to any subsequent machining; and the second material of the combustion surface includes martensite and tempered martensite in a crystalline ...

Method for manufacturing or for repairing a component of a rotary machine as well as a component manufactured or repaired using such a method

A method for manufacturing a component of a rotary machine, the component extends in an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end in a center of the component to a second end at a radial limiting surface of the component and which is partially closed. A blank includes the center of the component and is limited by an outer surface in the radial direction. The maximum dimension of the outer surface in the radial direction is smaller than the dimension of the limiting surface in the radial direction, A first subtractive process step is performed such that a part of the channel is manufactured by a machining process, with the part extending from the first end of the channel to the outer surface of the blank. Afterwards the channel is finished by a build-up process on the blank.

Fastener Retention and Anti-Camout Tool Bit

A tool bit with a surface layer metallurgically bonded on a substrate layer using electrospark deposition (ESD) that allows the tool bit to reduce camout and engage a fastener head for one-handed starting and removal. The surface layer has a rougher finish, compared to conventional tool bits, and therefore better grips engagement surfaces of a mating recess of the fastener during use. The reduction of camout provides greater durability to the tool bit and resists erosion and wear of the engagement surfaces of the fastener. 1. A tool comprising:a shank portion; anda tip portion adapted to engage a fastener and including a surface layer disposed on a substrate layer using electro spark deposition,wherein the surface layer is harder than the substrate layer.2. The tool of claim 1 , wherein the shank portion is adapted to engage a bit driver.3. The tool of claim 2 , wherein the bit driver is a ratchet wrench claim 2 , a drill claim 2 , or a screw driver.4. The tool of claim 1 , wherein the shank portion is an integrated part with a hand tool.5. The tool of claim 4 , wherein the hand tool is a screwdriver.6. The tool of claim 1 , wherein the tip portion is adapted to engage a cross-cut mating recess of the fastener.7. The tool of claim 1 , wherein the tip portion includes flutes claim 1 , engagement surfaces claim 1 , lands between the flutes claim 1 , and an end.8. The tool of claim 7 , wherein the surface layer is disposed on one or more of the lands claim 7 , the engagement surfaces claim 7 , the flutes claim 7 , and the end.9. The tool of claim 7 , wherein the flutes taper towards the end.10. The tool of claim 7 , wherein the engagement surfaces slant at an angle towards the end.11. (canceled)12. The tool of claim 1 , wherein the surface layer has a hardness between about 50 HRC to about 100 HRC.13. The tool of claim 1 , wherein the surface layer has a thickness between about 0.0001 inches to about 0.002 inches.14. The tool of claim 1 , wherein the surface layer has ...

PRECIPITATION-STRENGTHENED CAST PRODUCT WELDING REPAIR METHOD

A precipitation-strengthened cast product welding repair method repairs a damaged portion of a precipitation-strengthened cast product. The method includes welding the damaged portion by micro tungsten inert gas (TIG) welding using a welding material containing a solid-solution-strengthened alloy and having higher toughness than the precipitation-strengthened cast product.

METHOD AND APPARATUS FOR FABRICATION OF ARTICLES BY MOLTEN AND SEMI-MOLTEN DEPOSITION

A method and apparatus for depositing metals and metal-like substances in two and three dimensional form without a substrate in a safe, rapid and economical fashion using gas shielded arc welding equipment and programmable robotic motion. The method and apparatus includes the use and application of robotic controls, temperature and position feedback, single and multiple material feeds, and semi liquid deposition thereby creating near net shape parts particularly well suited to rapid prototyping and lower volume production. 1. An apparatus configured to fabricate a metal or metal-like object , the apparatus comprising:a deposition head configured to deposit a metal or a metal-like material;a multi-axis robotic system configured to support the deposition head, the multi-axis robotic positioning system further configured for movement in a first plane;a build table disposed beneath the deposition head the build table defining a support surface parallel to a first plane, wherein the build table is configured for independent movement in a first axis substantially perpendicular to the first plane.2. The apparatus of wherein the build table includes a support frame and a plurality of platens.3. The apparatus of further comprising a tank configured to hold a quenchant claim 1 , wherein the build table is configured to be adjustably located in the tank such that the build table is submergible in the quenchant during fabrication of the object.4. The apparatus of wherein the build table is configured to be adjustably located in the tank such that the build table is submerged in the quenchant during fabrication of the object and a portion of the object being formed is not submerged in the quenchant.5. The apparatus of further comprising an actuator rod coupled to the deposition head and the multi-axis robotic positioning system claim 4 , the actuator rod configured to adjust the location of the deposition head substantially in the first axis.6. The apparatus of wherein the ...

SYSTEMS AND METHODS PROVIDING LOCATION FEEDBACK FOR ADDITIVE MANUFACTURING

A system and method to correct for height error during a robotic welding additive manufacturing process. One or both of a welding output current and a wire feed speed are sampled during a robotic welding additive manufacturing process when creating a current weld layer. A plurality of instantaneous contact tip-to-work distances (CTWD's) are determined based on at least one or both of the welding output current and the wire feed speed. An average CTWD is determined based on the plurality of instantaneous CTWD's. A correction factor is generated, based on at least the average CTWD, which is used to compensate for any error in height of the current weld layer. 1. A welding system , comprising a welding power source , wherein the welding power source is configured to:sample, in real time, instantaneous parameter pairs of welding output current and wire feed speed during a robotic welding additive manufacturing process for creating a current weld layer of a 3D workpiece part;determine an instantaneous contact tip-to-work distance for, and based on at least, each parameter pair of the instantaneous parameter pairs sampled during creation of the current weld layer;determine an average contact tip-to-work distance based on each instantaneous contact tip-to-work distance determined for the current weld layer; andgenerate a correction factor to be used when creating a next weld layer of the 3D workpiece part based on at least the average contact tip-to-work distance.2. The welding system of claim 1 , wherein each instantaneous contact tip-to-work distance is determined in real time claim 1 , and wherein the welding power source is further configured to:determine, in real time, a running average of contact tip-to-work distance as each instantaneous contact tip-to-work distance is determined during creation of the current weld layer; andadjust, in real time, one or more of a weld duration or a wire feed speed during creation of the current weld layer in response to the running ...

ADDITIVE MANUFACTURING USING ALUMINUM-CONTAINING WIRE

The disclosed technology generally relates to consumable electrode wires and more particularly to consumable electrode wires having a core-shell structure, where the core comprises aluminum. In one aspect, a welding wire comprises a sheath having a steel composition and a core surrounded by the sheath. The core comprises aluminum (Al) at a concentration between about 3 weight % and about 20 weight % on the basis of the total weight of the welding wire, where Al is in an elemental form or is alloyed with a different metal element. The disclosed technology also relates to welding methods and systems adapted for using the aluminum-comprising electrode wires. 1. A method of fabricating an article by additive manufacturing , the method comprising: a sheath having a steel composition, and', 'a core surrounded by the sheath, the core comprising aluminum (Al) at a concentration between about 3 weight % and about 20 weight % on the basis of the total weight of the wire,', 'wherein Al in an elemental form or is alloyed with a different metal element;, 'providing a wire configured to serve as a source of metal that forms at least part of the article, the wire comprisingapplying an energy sufficient to form molten droplets of the metal; anddepositing the molten droplets to form a layer of beads that forms the at least part of the article.2. The method of fabricating the article according to claim 1 , wherein depositing the molten droplets comprises forming a plurality of stacked layers of beads that form a substantial portion of the article.3. The method of fabricating the article according to claim 1 , wherein applying the energy comprises applying energy sufficient to generate a plasma arc between the wire and a workpiece to cause the formation of the molten droplets.4. The method of fabricating the article according to claim 1 , wherein applying the energy comprises resistively heating the wire while directing a laser beam over a workpiece to cause the formation of the ...

Method and device for manufacturing titanium objects

A method and reactor of manufacturing an object by solid freeform fabrication, especially an object made of titanium or titanium alloys. An objective is to provide a method for rapid layered manufacture of objects in titanium or titanium alloys. A further objective is to provide a deposition chamber which allows prosecution of the method according to the invention.

GAS TURBINE ENGINE BLADE CONTAINMENT SYSTEM

A gas turbine engine blade containment system is disclosed. The blade containment system may include a generally cylindrical casing being made of a first material, and a generally cylindrical ring being made of a second material coaxially surrounding the casing, at least some portion of the ring metallurgically bonded to the casing. 1. A gas turbine engine blade containment system , comprising:a generally cylindrical casing being made of a first material; anda generally cylindrical ring being made of a second material coaxially surrounding the casing, at least some portion of the ring metallurgically bonded to the casing.2. The gas turbine engine blade containment system of claim 1 , further including a generally cylindrical second ring comprising a third material axially spaced apart from the ring claim 1 , at least some portion of the second ring metallurgically bonded to the casing.3. The gas turbine engine blade containment system of claim 2 , wherein the second material and third material are the same.4. The gas turbine engine blade containment system of claim 2 , wherein the second material and third material are different.5. The gas turbine engine blade containment system of claim 1 , further including a gap positioned between the casing and the ring.6. The gas turbine engine blade containment system of claim 1 , further including a sheet metal core positioned between the casing and the ring.7. The gas turbine engine blade containment system of claim 5 , further including a rib connected to at least some portion of the sheet metal core and extending through the ring.8. The gas turbine engine blade containment system of claim 1 , further including metallic foam positioned between the casing and the ring.9. A gas turbine engine claim 1 , comprising:a fan section;a compressor section downstream of the fan section;a combustor section downstream of the compressor section; anda turbine section downstream of the combustor section, the turbine section including a ...

Systems and methods providing dynamic bead spacing and weave fill in additive manufacturing

Embodiments of systems and methods of additive manufacturing are disclosed. In one embodiment, a computer control apparatus accesses multiple planned build patterns corresponding to multiple build layers of a three-dimensional (3D) part to be additively manufactured. A metal deposition apparatus deposits metal material to form at least a portion of a build layer of the 3D part. The metal material is deposited as a beaded weave pattern, based on a planned path of a planned build pattern, under control of the computer control apparatus. A weave width, a weave frequency, and a weave dwell of the beaded weave pattern may be dynamically adjusted during deposition of the beaded weave pattern. The adjustments are under control of the computer control apparatus based on the planned build pattern, as a width of the build layer varies along a length dimension of the build layer.

METHOD AND ARRANGEMENT FOR BUILDING METALLIC OBJECTS BY SOLID FREEFORM FABRICATION

Provided are a systems and methods for manufacturing objects by solid freeform fabrication, especially titanium and titanium alloy objects, wherein the deposition rate is increased by using two separate heat sources, one heat source for heating the deposition area on the base material and one heat source for heating and melting a metallic material, such as a metal wire or a powdered metallic material. 121.-. (canceled)22. A system for building metallic objects by solid freeform fabrication , comprising:a first welding gun comprising a first power source, the first welding gun arranged to direct thermal energy toward a portion of a surface of a base material to pre-heat said portion of the surface of the based material onto which metallic material melted from a source of metal is to be deposited;a second welding gun comprising a second power source independent of the first power source, the second welding gun configured to pulsate thermal energy onto the portion of the surface of the base material after it is pre-heated by the first welding gun; anda control system comprising a computer processor, the control system configured to independently operate the first welding gun and the second welding gun.23. The system of claim 22 , wherein the second welding gun is further configured to melt the source of metal into droplets of the metallic material.24. The system of claim 22 , further comprising a deposition chamber closed to ambient atmosphere claim 22 , the deposition chamber sized to accommodate at least the first welding gun claim 22 , the second welding gun claim 22 , and the base material.25. The system of claim 22 , further comprising an actuator tray that moves the base material relative to at least the first welding gun.26. The system of claim 22 , further comprising an actuator arm that moves the first welding gun or the second welding gun.27. The system of claim 22 , further comprising:an actuator tray that moves the base material relative to at least the ...

Wire arc hybrid manufacturing

A processing head assembly is disclosed. In some examples, the processing head assembly comprises a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles. In some examples, the fabrication energy source includes the wire feedstock surrounded by the shield. A method of depositing material on a substrate using a processing head assembly for use with a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles is disclosed. In some examples, the method comprises projecting a fabrication energy beam from the fabrication energy source onto the substrate at a spot, projecting the wire feedstock surrounded by the shield onto the substrate at the spot and projecting the one or more filler feedstocks surrounded by the one or more nozzles onto the substrate close to the spot.

METHOD FOR MANUFACTURING T-SHAPED STRUCTURES

A method for manufacturing a T-shaped structure includes depositing one or more layers of weld beads over a portion of a surface of a first component such that the one or more layers of weld beads develop a metallurgical bond with the portion. Also, the method includes placing an end of a second component over the one or more layers of weld beads such that the end develops a metallurgical bond with the one or more layers of weld beads. The one or more layers of weld beads define a fully penetrated weld joint between the end and the portion to form the T-shaped structure. 1. A method for manufacturing a T-shaped structure , the method comprising:depositing one or more layers of weld beads over a portion of a surface of a first component such that the one or more layers of weld beads develop a metallurgical bond with the portion; and 'the one or more layers of weld beads define a fully penetrated weld joint between the end and the portion to form the T-shaped structure.', 'placing an end of a second component over the one or more layers of weld beads such that the end develops a metallurgical bond with the one or more layers of weld beads, wherein'}2. The method of claim 1 , wherein the one or more layers of weld beads are deposited by wire-arc additive manufacturing.3. The method of further comprising imparting claim 1 , by one or more ultrasonic peening tools claim 1 , compressive residual stress to the one or more layers of weld beads.4. The method of claim 3 , wherein to impart compressive residual stress to the one or more layers of weld beads claim 3 , the one or more ultrasonic peening tools operates at an impact angle of up to 45 degrees with respect to the surface of the first component.5. The method of claim 1 , wherein the end of the second component is placed at an offset from the surface of the first component.6. The method of claim 1 , wherein the second component includes a first side surface and a second side surface opposed to the first side surface ...

METHOD AND APPARATUS FOR FABRICATION OF ARTICLES BY MOLTEN AND SEMI-MOLTEN DEPOSITION

A method and apparatus for depositing metals and metal-like substances in two and three dimensional form without a substrate in a safe, rapid and economical fashion using gas shielded arc welding equipment and programmable robotic motion. The method and apparatus includes the use and application of robotic controls, temperature and position feedback, single and multiple material feeds, and semi liquid deposition thereby creating near net shape parts particularly well suited to rapid prototyping and lower volume production. 1. An additive manufacturing apparatus to fabricate objects by depositing metal or metal like materials in three dimensions comprising:a build table;a deposition head configured to deposit the metal objects on the build table;a multi-axis robotic system configured to support the deposition head;wherein said build table is configured to be adjustably located in a tank;wherein the quenchant fluid is added to the tank during the build.2. The additive manufacturing apparatus of further comprising one or more level sensors maintaining the level of said quenchant fluid.3. The apparatus of further comprising a weir_maintaining the level of said quenchant fluid.4. The apparatus of further comprising said quenchant fluid being circulated in the tank.5. The apparatus of further comprising said quenchant fluid being circulated at a rate sufficient for convective cooling.6. The apparatus of further comprising a forced flow heat exchanger to maintain said quenchant temperature.7. The apparatus of further comprising a forced flow heat exchanger in a circulating plumbing system.8. The apparatus of wherein only the bottom of said platen is submerged at the beginning or during the build.9. A method for fabricating an object from a metal and a metal like material on a build table while controlling the temperature of the object further comprises:measuring the temperature of the object; andspraying object with quenchant fluid.10. The method of wherein the spray of ...

METHOD AND APPARATUS FOR FABRICATION OF ARTICLES BY MOLTEN AND SEMI-MOLTEN DEPOSITION

A method and apparatus for depositing metals and metal-like substances in two and three dimensional form without a substrate in a safe, rapid and economical fashion using gas shielded arc welding equipment and programmable robotic motion. The method and apparatus includes the use and application of robotic controls, temperature and position feedback, single and multiple material feeds, and semi liquid deposition thereby creating near net shape parts particularly well suited to rapid prototyping and lower volume production. 1. An additive manufacturing apparatus for fabricating a three dimensional object comprising:a multi-axis robotic system configured to support and move a deposition head;the robotic system contained within a sealed enclosed space;an oxygen sensor within the enclosed space.2. The additive manufacturing apparatus as set forth in for fabricating a three dimensional object further comprising means for introducing a gas and monitoring the oxygen concentration within the enclosed space.3. The additive manufacturing apparatus as set forth in further comprising a means for reducing or discontinuing gas flow in response to said oxygen monitoring.4. The additive manufacturing apparatus as set forth in further comprising an air filtration system.5. An additive manufacturing apparatus to fabricate objects by depositing metal or metal like materials in three dimensions comprising:a build table;a deposition head configured to deposit the metal objects on the build table;a multi-axis robotic system configured to support the deposition head;wherein said build table is configured to be adjustably located in a tank, said tank having a quenching fluid therein;wherein material is deposited at a set distance from the level of the quenchant.6. The additive manufacturing apparatus as set forth in wherein said deposition head is capable of being fully submerged in said quenchant.7. The additive manufacturing apparatus of further comprising use of wire with internal inert ...

LAMINATION PLANNING METHOD FOR LAMINATE MOLDED OBJECT, AND LAMINATE MOLDED OBJECT MANUFACTURING METHOD AND MANUFACTURING DEVICE

A building time for building an additively-manufactured object is calculated on the basis of the inter-pass time and the welding pass time and is compared with a preset upper limit value, and welding conditions in a depositing plan are repeatedly modified until the building time is equal to or less than the upper limit value. Alternatively, corrections are repeatedly performed until the shape difference between a building shape of built-up object shape data relating to the additively-manufactured object created on the basis of the inter-pass time and the inter-pass temperature, and a building shape of three-dimensional shape data, is smaller than a near net value. 1. A depositing planning method for an additively-manufactured object , to build an additively-manufactured object using three-dimensional shape data of the additively-manufactured object by an additive manufacturing apparatus for depositing a weld bead on a base plate , whereina computer executes:a step of acquiring the three-dimensional shape data;a step of creating a depositing plan that defines a welding pass for forming each layer obtained by dividing a shape of the three-dimensional shape data into layers using the weld bead, and a welding condition for forming the weld bead;a step of setting an inter-pass time from an end of a welding pass to a start of a next welding pass for a plurality of the welding passes, and calculating an inter-pass temperature by performing heat transfer calculation in the inter-pass time;a step of determining whether the inter-pass temperature falls within a preset inter-pass temperature range, adjusting the inter-pass time until the inter-pass temperature falls within the inter-pass temperature range, and repeating the heat transfer calculation;a step of calculating a building time required for building the additively-manufactured object according to the inter-pass time when the inter-pass temperature falling within the inter-pass temperature range is calculated and a ...

METHOD FOR MANUFACTURING INDUCTION COIL ASSEMBLY

A method for manufacturing an induction coil assembly is disclosed. The method includes preparing a Computer Aided Design (CAD) model of an induction coil. The method further includes communicating the CAD model of the induction coil with a Three Dimensional (3D) printing machine The method further includes operating the 3D printing machine to deposit a plurality of layers of copper material one above other to manufacture the induction coil corresponding to the CAD model. The method further includes forming at least one hole in an annular member of the induction coil to receive a coolant and at least one hole in a first leg and a second leg to discharge the coolant. 1. A method for manufacturing an induction coil assembly , the method comprising:preparing a Computer Aided Design (CAD) model of an induction coil;communicating the CAD model of the induction coil with a Three Dimensional (3D) printing machine; an annular member having a first end and a second end;', 'a first leg extending from the first end, and adapted to couple with a positive terminal of an electric power source; and', 'a second leg extending from the second end, and adapted to couple with a negative terminal of the electric power source,', 'wherein each of the annular member, the first leg, and the second leg includes a fluid passage to receive coolant therein; and, 'operating the 3D printing machine to deposit a plurality of layers of copper material one above other to manufacture the induction coil corresponding to the CAD model, wherein the induction coil manufactured using the 3D printing machine includesforming at least one hole in the annular member of the induction coil to receive the coolant and at least one hole in the first leg and the second leg to discharge the coolant.2. The method of claim 1 , further comprising inserting an insulator between the first leg and the second leg of the induction coil claim 1 , and electrically isolating the first leg from the second leg using the ...

METHOD FOR MODIFYING AN APERTURE AND SYSTEM FOR MODIFYING FLOW THROUGH A COMPONENT

A method for modifying an aperture in a component, a system for modifying flow through a component, and a turbine component are disclosed. The method includes providing a substrate having at least one aperture having an electrically-conductive surface, providing a deposition device including an ESD torch, the ESD torch including an aperture penetrating electrode including a conductive material, inserting the aperture penetrating electrode at least partially into the aperture, and generating an arc between the aperture penetrating electrode and the electrically-conductive surface to deposit electrode material within the aperture. The system includes the ESD torch removably supported in an electrode holder. The turbine component includes at least one aperture having an electrospark deposited material along an electrically-conductive surface, the electrospark deposited material providing modified fluid flow through the turbine component. 1. A method for modifying an aperture in a component comprising:providing a substrate having at least one aperture having an electrically-conductive surface;providing a deposition device including an electrospark deposition torch, the electrospark deposition torch including an aperture penetrating electrode including a conductive material;inserting the aperture penetrating electrode at least partially into the aperture; andgenerating an arc between the aperture penetrating electrode and the electrically-conductive surface to deposit an electrode material within the aperture.2. The method of claim 1 , wherein the at least one aperture is a cooling hole or fluid metering passage.3. The method of claim 2 , further comprising measuring a fluid flow of the component.4. The method of claim 3 , further comprising selecting at least one of the cooling holes in the component for modifying claim 3 , the at least one cooling hole at a location corresponding to the temperature to which the location is exposed.5. The method of claim 1 , where the ...

METAL LAMINATING AND MOLDING METHOD

A metal laminating and molding method molds a 3-dimensional molded object formed by sequentially laminating a plurality of metal layers. The metal laminating and molding method is accomplished by repeatedly performing a unit process including a metal layer laminating process of laminating the metal layer constituted by welding beads formed through arc welding and a removal process of removing impurities from a surface of the metal layer laminated in the metal layer laminating process. When the unit process is repeated, the metal layer laminating process is performed again such that a new metal layer is laminated on the surface of the metal layer from which impurities have been removed in the removal process. 1. A metal laminating and molding method of molding a 3-dimensional molded object formed by sequentially laminating a plurality of metal layers , the metal laminating and molding method comprising: a metal layer laminating process of laminating the metal layer constituted by welding beads formed through arc welding; and', 'a removal process of removing impurities on a surface of the metal layer laminated through the metal layer laminating process, wherein, 'a unit process including'}the unit process is repeatedly performed, andwhen the unit process is repeated, the metal layer laminating process is performed again such that a new metal layer is laminated on the surface of the metal layer from which impurities have been removed in the removal process.2. The metal laminating and molding method according to claim 1 , comprising a temperature measuring process of measuring a temperature on the surface of the metal layer as the uppermost layer laminated in the metal layer laminating process claim 1 ,wherein, when the unit process is repeated, in the case in which the temperature on the surface of the metal layer measured in the temperature measuring process is lower than a predetermined reference temperature, the metal layer laminating process is performed again such ...

Method for controlling deformation and precision of parts in parallel during additive manufacturing process

A method for controlling deformation and precision of a part in parallel during an additive manufacturing process includes steps of: performing additive forming and isomaterial shaping or plastic forming, and simultaneously, performing one or more members selected from a group consisting of isomaterial orthopedic process, subtractive process and finishing process in parallel at a same station, so as to achieve a one-step ultra-short process, high-precision and high-performance additive manufacturing, wherein: performing in parallel at the same station refers to simultaneously implement different processes in a same pass or different passes of different processing layers or a same processing layer when a clamping position of the part to be processed is unchanged. The method can realize the one-step high-precision and high-performance additive manufacturing which has the ultra-short process, has high processing precision, and the parts can be directly applied, so that the method has strong practical application value.

CONTACT ARRANGEMENT FOR USE IN AN APPARATUS FOR PRODUCING THREE-DIMENSIONAL WORK PIECES

A contact arrangement () for use in an apparatus () for producing three-dimensional work pieces by irradiating layers of a raw material powder with electromagnetic or particle radiation, the contact arrangement () comprises a replaceable building chamber () adapted to receive a work piece generated in the apparatus () by an additive layering process and a building chamber support element () adapted to support the replaceable building chamber (). A first contact element () is fastened to the replaceable building chamber () and comprises at least one first electrical conductor element (), the first electrical conductor element () being provided with a first planar conductor surface (). A second contact element () is fastened to the building chamber support element () and comprises at least one second electrical conductor element (), the second electrical conductor element () being provided with a second planar conductor surface (). The first planar conductor surface () provided on the first electrical conductor element () of the first contact element () and the second planar conductor surface () provided on the second electrical conductor element () of the second contact element () are adapted to interact with each other so as to establish an electrical contact between the replaceable building chamber () and the building chamber support element () when the replaceable building chamber () is supported on the building chamber support element (). 1. A contact arrangement for use in an apparatus for producing three-dimensional work pieces by irradiating layers of a raw material powder with electromagnetic or particle radiation , the contact arrangement comprising:a replaceable building chamber adapted to receive a work piece generated in the apparatus by an additive layering process,a building chamber support element adapted to support the replaceable building chamber,a first contact element fastened to the replaceable building chamber and comprising at least one first ...

3D METAL PRINTING DEVICE AND PROCESS

A 3D metal printing machine or apparatus includes a welder that deposits one or more layers of metal, and a powered cutting tool that may be utilized to remove a portion of the metal deposited by the welder after the metal has solidified. Numerous layers of metal can be deposited and machined to form complex 3D metal parts. During fabrication, a part may be formed on a support whereby the part can be fabricated by welding and machining operations without removing the part from the support. A 3D CAD model of a part may be utilized to generate code that controls the 3D metal printing apparatus. A measuring device such as a probe or laser scanner may be utilized to measure the shape/size of parts in the 3D metal printing machine. 1. An apparatus for fabricating 3D metal components , the apparatus comprising:a support table configured to retain a partially formed metal component as the metal component is being fabricated;a head assembly including a welding head and a machining head, the machining head including a tool that is configured to remove metal deposited by the welding head during fabrication of metal components; anda control system configured to cause the welding head to move relative to the support and deposit molten metal in successive layers, and wherein the control system is configured to cause the tool to remove metal from at least one layer of metal deposited by the welding head after the molten metal has solidified.2. The apparatus of claim 1 , wherein:the head assembly includes a powered weld actuator that is configured to extend and retract the welding head relative to the machining head.3. The apparatus of claim 2 , wherein:the apparatus includes a base;the head assembly includes a support structure and a powered vertical actuator that shifts the support structure vertically relative to the base when the powered vertical actuator is actuated by the controller.4. The apparatus of claim 3 , wherein:the machining head is mounted on the support structure; ...

METAL WIRE FEEDING SYSTEM

Provided are a systems and methods for continuously providing a metal wire to a welding torch for manufacturing objects by solid freeform fabrication to provide continuous deposition of metal to the freeform object, especially objects made with titanium or titanium alloy wire. 1. A metal wire feeding system , comprising:a positionally adjustable wire supply spool;a cabinet comprising an entry wire position detector containing an aperture;a wire feeding device comprising a first motorized grooved roller, a first passive grooved roller, and a first motor attached to the first motorized grooved roller, wherein the first motorized grooved roller and the first passive grooved roller form a channel therebetween;a combination of at least three slack wire guides, wherein a first slack wire guide is positioned after the wire feeding device an in line therewith, a second slack wire guide positioned to the right of and below the first slack wire guide, and a third slack wire guide positioned to the left of and below the first slack wire guide;a slack wire pulling device comprising a second motorized grooved roller, a second passive grooved roller, and a second motor attached to the second motorized grooved roller, wherein the second motorized grooved roller and the second passive grooved roller form a channel therebetween; anda cabinet exit guide.2. The metal wire feeding system of claim 1 , where: a first dual grooved roller having a first and second groove, the roller being attached to a first arm pivotally connected to a back plate of the cabinet; and', 'a second dual grooved roller having a first and second groove, where the first groove of the first grooved roller and the first groove of the second grooved roller form a channel therebetween, and the first groove of the first dual grooved roller is biased by a spring on the first arm connected to a first support connected to the back plate of the cabinet;, 'the first slack wire guide comprises a third passive grooved ...

WIRE ARC HYBRID MANUFACTURING

A processing head assembly is disclosed. In some examples, the processing head assembly comprises a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles. In some examples, the fabrication energy source includes the wire feedstock surrounded by the shield. A method of depositing material on a substrate using a processing head assembly for use with a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles is disclosed. In some examples, the method comprises projecting a fabrication energy beam from the fabrication energy source onto the substrate at a spot, projecting the wire feedstock surrounded by the shield onto the substrate at the spot and projecting the one or more filler feedstocks surrounded by the one or more nozzles onto the substrate close to the spot. 1. A method of depositing material on a substrate using a processing head assembly for use with a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles , the method comprising:projecting a fabrication energy beam from the fabrication energy source onto the substrate at a spot;projecting the wire feedstock surrounded by the shield onto the substrate at the spot; andprojecting the one or more filler feedstocks surrounded by the one or more nozzles onto the substrate close to the spot.2. The method of claim 1 , further comprising claim 1 , melting the wire feedstock and the one or more filler feedstocks using the fabrication energy beam from the fabrication energy source.3. The method of claim 1 , wherein the fabrication energy source includes the wire feedstock surrounded by the shield.4. The method of claim 1 , wherein the one or more filler feedstocks surrounded by the one or more nozzles include at least one of one or more filler wire feedstocks and one or more filler ...

ADDITIVE MANUFACTURING OF METALLIC STRUCTURES

In various embodiments, a three-dimensional metallic structure is fabricated in layer-by-layer fashion via deposition of discrete metal particles resulting from the passing of an electric current between a metal wire and an electrically conductive base or a previously deposited layer of particles. 1. A method of layer-by-layer fabrication of a three-dimensional metallic structure upon an electrically conductive base , the method comprising:forming a first layer of the structure by depositing a plurality of metal particles onto the base, each metal particle being deposited by (i) disposing a metal wire in contact with the base, and (ii) passing an electrical current through the metal wire and the base, whereby a portion of the metal wire melts to form the metal particle on the base; andforming one or more subsequent layers of the structure by depositing pluralities of metal particles over the first layer of the structure, each metal particle being deposited by (i) disposing the metal wire in contact with a previously deposited metal particle, and (ii) passing an electrical current through the metal wire, the previously deposited metal particle, and the base, whereby a portion of the metal wire melts to form the metal particle on the previously deposited metal particle.2. The method of claim 1 , further comprising flowing a gas over a tip of the wire during deposition of the metal particles claim 1 , the gas (i) reducing or substantially preventing oxidation of the metal particles during deposition and/or (ii) increasing a cooling rate of the metal particles during deposition.3. The method of claim 1 , further comprising claim 1 , after deposition of each metal particle claim 1 , changing a relative position of the metal wire and the base with one or more mechanical actuators.4. The method of claim 1 , wherein the metal wire comprises at least one of stainless steel claim 1 , copper claim 1 , or aluminum.5. The method of claim 1 , further comprising controlling a ...

Hammer Mill Hammer with Grooves for Receiving Hard Facing Material and Method of Making Same

An improved hammer mill hammer constructed by forming a groove in an edge of the grinding end of a hammer for receiving hard facing material and placing hard facing in the groove. 1. A hammer comprising:a rod hole end having a rod hole disposed therein and wherein said rod hole is configured to engage said hammer with a hammer mill rod;{'b': '13', 'a grinding end () is spaced from said rod hole end along a length of said hammer, the grinding end having a length, a width, and a thickness defined between a first face and a second face with an edge disposed between the first face and the second face;'}a neck connecting said rod hole end and said grinding end;the grinding end being disposed in a plane, the plane being between the first face and the second face of the grinding end, and the plane intersecting the edge of the grinding end;a groove in the edge for receiving hard facing material; andhard facing disposed in the groove.2. The hammer of wherein the grinding end is connected to the neck at one end place of the length of the grinding end claim 1 , the one end place being a connected to the neck end and the other end place being a free end spaced from the neck.3. The hammer of wherein the edge of the grinding end extends at least partially along the length of the grinding end claim 2 , on at least one side of the grinding end and the groove being disposed in the edge of the grinding end that extends at least partially along the length of the grinding end.4. The hammer of wherein the edge of the grinding end extends at least partially along the width of the grinding end claim 2 , at the other end place claim 2 , which is the free end spaced from the neck claim 2 , and the groove being disposed in the edge of the grinding end that extends at least partially along the width of the grinding end.5. The hammer of wherein the edge of the grinding end extends completely across and along the width of the grinding end and the groove extends entirely across the entire width ...

Systems and methods for making blade sheaths

A method of making a sheath for an airfoil may include the steps of forming an upper sleeve and a lower sleeve, and forming a central portion bonded to the upper sleeve and the lower sleeve. The central portion may be formed by depositing a material on the upper sleeve and the lower sleeve. A portion of the material may be removed from at least one of the central portion, the upper sleeve, or the lower sleeve. The sheath may include a first flank, a central portion bonded to the first flank, and a second flank bonded to the central portion. The central portion may have a substantially uniform microstructure resulting from additive manufacturing.

SYSTEMS AND METHODS OF ADDITIVE STRUCTURAL BUILD TECHNIQUES

Embodiments of systems and methods of additive manufacturing are disclosed. In one embodiment, a metal deposition device (MDD) is configured to deposit a metal material during an additive manufacturing process. A controller is operatively coupled to the MDD and is configured to command the MDD to deposit the metal material on a base to form a contour of a part. The controller is configured to command the MDD to deposit the metal material on the base to form an infill pattern within a region outlined by the contour. The infill pattern is a wave shape having a wavelength. The controller is configured to command the metal deposition device to fuse the infill pattern to the metal contour at crossover points, where the infill pattern meets the contour, by applying energy at the crossover points and reducing a deposition rate of the metal material at the crossover points to prevent distorting the contour. 1. An additive manufacturing system , the system comprising:a metal deposition device configured to deposit a metal material during an additive manufacturing process to form a part; and command the metal deposition device to deposit the metal material on a base during a contour deposition phase of the additive manufacturing process to form a contour of the part,', 'command the metal deposition device to deposit the metal material on the base during an infill pattern deposition phase of the additive manufacturing process to form an infill pattern within a region outlined by the contour of the part,', 'wherein the infill pattern is a wave shape having a wavelength, and', 'wherein, during the infill pattern deposition phase, the controller is configured to command the metal deposition device to fuse the metal material of the infill pattern to the metal material of the contour at crossover points, where the infill pattern meets the contour, by applying energy at the crossover points and reducing a deposition rate of the metal material at the crossover points to prevent ...

HIGH-DENSITY, CRACK-FREE METALLIC PARTS

In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material. 114.-. (canceled)15. A three-dimensional metallic part manufactured by additive manufacturing using a metallic feedstock material , the part (i) comprising a plurality of layers of one or more of molybdenum , niobium , rhenium , or tungsten , (ii) being free of gaps between successive layers , and (iii) being free of cracks , wherein a density of the part is no less than 97% of a theoretical density , and wherein a concentration within the part of at least one of sodium , silicon , calcium , antimony , magnesium , phosphorous , sulfur , or potassium is less than 20 ppm by weight and at least 0.001 ppm by weight.16. The part of claim 15 , wherein the concentration within the part of each of sodium claim 15 , silicon claim 15 , calcium claim 15 , antimony claim 15 , magnesium claim 15 , phosphorous claim 15 , sulfur claim 15 , and potassium is less than 20 ppm by weight and at least 0.001 ppm by weight.17. The part of claim 15 , wherein the concentration within the part of each of sodium claim 15 , silicon claim 15 , calcium claim 15 , antimony claim 15 , magnesium claim 15 , phosphorous claim 15 , sulfur claim 15 , and potassium is less than 10 ppm by weight and at least 0.001 ppm by weight.18. The part of claim 15 , wherein the concentration within the part of each of sodium claim 15 , silicon claim 15 , calcium claim 15 , antimony claim 15 , magnesium claim 15 , phosphorous claim 15 , sulfur claim 15 , and potassium is less than 5 ppm by weight and at least 0.001 ppm by weight.19. The part of claim 15 , wherein the concentration within the part of at least one of sodium claim 15 , silicon claim 15 , calcium claim 15 , antimony claim 15 , magnesium claim 15 , phosphorous claim 15 , sulfur claim 15 , or potassium is less than ...

Systems and methods providing location feedback for additive manufacturing

A system and method to correct for height error during a robotic additive manufacturing process. One or both of an output current, output voltage, output power, output circuit impedance and a wire feed speed are sampled during an additive manufacturing process when creating a current layer. A plurality of instantaneous contact tip-to-work distances (CTWD's) are determined based on at least one or both of the output current, output voltage, output power, output circuit impedance and the wire feed speed. An average CTWD is determined based on the plurality of instantaneous CTWD's. A correction factor is generated, based on at least the average CTWD, which is used to compensate for any error in height of the current layer.

EARTH AND SAND ABRASION RESISTANT COMPONENT AND METHOD FOR PRODUCING THE SAME

A tooth as the earth and sand abrasion resistant component includes a base, a first overlay layer disposed in contact with the base so as to cover a distal end face which is a part of a surface of the base, and a second overlay layer disposed on the first overlay layer. The first overlay layer and the second overlay layer each include a matrix made of iron or steel, and cermet particles made of cermet and dispersed in the matrix. 1. An earth and sand abrasion resistant component , comprising:a base;a first overlay layer disposed in contact with the base so as to cover a covered region being a part of a surface of the base; anda second overlay layer disposed on the first overlay layer; a matrix made of iron or steel, and', 'hard particles made of cermet and dispersed in the matrix., 'the first overlay layer and the second overlay layer each including'}2. The earth and sand abrasion resistant component according to claim 1 , wherein in a region including an interface between the first overlay layer and the second overlay layer claim 1 , the matrix has a Vickers hardness that is not more than a half of a Vickers hardness of the hard particles.3. The earth and sand abrasion resistant component according to claim 1 , whereinthe earth and sand abrasion resistant component is a tooth, andthe covered region is located in a region in the base corresponding to a distal end portion of the tooth.4. A method for producing an earth and sand abrasion resistant component claim 1 , comprising the steps of:preparing a base;forming a first overlay layer to cover a covered region being a part of a surface of the base; andforming a second overlay layer on the first overlay layer;the step of forming the first overlay layer and the step of forming the second overlay layer including forming, by overlaying welding, the first overlay layer and the second overlay layer each including a matrix made of iron or steel and hard particles made of cermet and dispersed in the matrix.5. The earth and ...

VALVE APPARATUS, METHOD OF MANUFACTURING VALVE APPARATUS, AND METHOD OF REPAIRING VALVE APPARATUS

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. 1. A valve apparatus comprising: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; anda 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,wherein 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.2. The valve apparatus according to claim 1 , wherein the movable member comprises a valve body or a valve rod claim 1 , and the stationary member comprises a seal ring in sliding contact with the valve body or a bushing in sliding contact with the valve rod.3. The valve apparatus according to claim 1 , wherein the movable member comprises a valve body claim 1 , and the stationary member comprises a valve seat in abutting contact with the valve body.4. The valve apparatus according to claim 1 , wherein the cladding portion comprises a penetrant diffusion layer ...

METHODS FOR MANUFACTURING A ROTOR ASSEMBLY FOR AN ELECTRICAL MACHINE

A method for manufacturing a rotor assembly for an electrical machine includes printing a first part of a rotor shaft. The method also includes printing a rotor core onto the first part of the rotor shaft. In addition, the method includes printing a second part of the rotor shaft onto the rotor core; printing a first part of the rotor winding. The method also includes coupling the first part of the rotor winding to the rotor core. After coupling the first part of the rotor winding to the rotor core, the method includes printing a second part of the rotor winding onto the first part of the rotor winding to form the rotor assembly. 1. A method for manufacturing a rotor assembly for an electrical machine , the method comprising:printing a first part of a rotor shaft;printing a rotor core onto the first part of the rotor shaft;printing a second part of the rotor shaft onto the rotor core;printing a first part of a rotor winding;coupling the first part of the rotor winding to the rotor core; andafter coupling the first part of the rotor winding to the rotor core, printing a second part of the rotor winding onto the first part of the rotor winding to form the rotor assembly.2. The method of claim 1 , wherein printing the first part of the rotor shaft comprises printing the first part of the rotor shaft using a first material claim 1 , and wherein printing the rotor core comprises printing the rotor core using a second material that is different than the first material.3. The method of claim 1 , wherein printing the rotor core comprises:printing a first lamination sheet;printing at least one spacer after printing the first lamination sheet; andprinting a second lamination sheet after printing the at least one spacer,wherein the at least one spacer is positioned between the first lamination sheet and the second lamination sheet.4. The method of claim 3 , wherein the at least one spacer is formed from a first material having a high resistivity relative to a second material ...

METHODS FOR PRODUCING FORGED PRODUCTS AND OTHER WORKED PRODUCTS

Generally, the present disclosure is directed various embodiments to additively manufacture AM preforms to reduce, prevent, and/or eliminate defects that occur in post processing operations (e.g. forging, shot peening, machining, or other post processing operations). 1. A method comprising:(a) additively manufacturing a metal shaped-preform from an additive manufacturing feedstock;(b) concomitant with (a), using a bead deposition strategy to modify a bead path, whereby the combination of (a) and (b) provide the metal shaped preform configured with a smoothed external surface having non-stepped walls as compared to the metal shaped preform without such bead deposition strategy; and(c) performing at least one post processing operation on the metal shaped preform to form a final formed product, whereby, due to (b), the final formed product has reduced post processing operation defects as compared to without (b).2. The method of claim 1 , wherein the bead deposition strategy comprises path planning of the bead path.3. The method of claim 2 , wherein path planning is selected from the group consisting of:a. a non-linear build path around the interior of a part build;b. a non-linear build path around the perimeter of a part build;c. an overlapping bead deposition in the build direction, when comparing a first AM deposition layer to a subsequent AM deposition layer, wherein each deposition layer is configured from a plurality of beads, such that between the first AM deposition layer and the subsequent AM deposition layer, a subsequent layer bead does not completely overlap with a first layer bead, andd. combinations thereof.4. The method of claim 1 , wherein the bead deposition strategy comprises path planning claim 1 , wherein a first bead in a first AM build layer overlaps at least a portion but not entirely with a subsequent bead in a subsequent AM build layer claim 1 , wherein the subsequent bead is in contact with the first bead.5. The method of claim 1 , wherein the ...

SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING USING ALUMINUM METAL-CORED WIRE

A method of forming an additively manufactured aluminum part includes establishing an arc between a metal-cored aluminum wire and the additively manufactured aluminum part, wherein the metal-cored aluminum wire includes a metallic sheath and a granular core disposed within the metallic sheath. The granular core comprises aluminum metal matrix nano-composites (Al-MMNCs) that comprise an aluminum metal matrix and ceramic nanoparticles. The method includes melting a portion of the metal-cored aluminum wire using the heat of the arc to form molten droplets. The method includes transferring the molten droplets to the additively manufactured aluminum part under an inert gas flow, and solidifying the molten droplets under the inert gas flow to form deposits of the additively manufactured aluminum part. 1. A method of forming an additively manufactured aluminum part , comprising:establishing an arc between a metal-cored aluminum wire and the additively manufactured aluminum part, wherein the metal-cored aluminum wire comprises a metallic sheath and a granular core disposed within the metallic sheath;melting a portion of the metal-cored aluminum wire using the heat of the arc to form molten droplets;transferring the molten droplets to the additively manufactured aluminum part under an inert gas flow; andsolidifying the molten droplets under the inert gas flow to form deposits of the additively manufactured aluminum part;wherein the granular core comprises aluminum metal matrix nano-composites (Al-MMNCs) that comprise an aluminum metal matrix and ceramic nanoparticles, and wherein the ceramic nanoparticles have an average particle size of between 10 and 250 nm.2. The method of claim 1 , comprising providing claim 1 , via a controller of an additive manufacturing system claim 1 , a control signal to a robotic system of the additive manufacturing system to position a torch of the additive manufacturing system relative to the additively manufactured aluminum part claim 1 , ...

Systems and methods providing dynamic bead spacing and weave fill in additive manufacturing

Embodiments of systems and methods of additive manufacturing are disclosed. In one embodiment, a computer control apparatus accesses multiple planned build patterns corresponding to multiple build layers of a three-dimensional (3D) part to be additively manufactured. A metal deposition apparatus deposits metal material to form at least a portion of a build layer of the 3D part. The metal material is deposited as a beaded weave pattern, based on a planned path of a planned build pattern, under control of the computer control apparatus. A weave width, a weave frequency, and a weave dwell of the beaded weave pattern are dynamically adjusted during deposition of the beaded weave pattern. The adjustments are under control of the computer control apparatus based on the planned build pattern, as a width of the build layer varies along a length dimension of the build layer.

ONE-PIECE PISTON FEATURING ADDITIVE MACHINING PRODUCED COMBUSTION BOWL RIM AND COOLING GALLERY

A piston capable of withstanding high temperatures and extreme conditions of a combustion chamber of an internal combustion engine and manufactured with reduced costs is provided. The method of manufacturing the piston includes casting or forging the bulk of the piston as a single-piece with an open cooling gallery from an economical first material, such as steel, cast iron, or aluminum. The method further includes forming a portion of a combustion bowl surface, which is a small area of the piston directly exposed to the combustion chamber, from a second material by additive machining. The second material has a higher thermal conductivity and higher resistance to oxidation, erosion, and oil coking, compared to the first material. The additive machining process is efficient and creates little waste, which further reduces production costs. 1. A method for manufacturing a piston for use in an internal combustion engine , comprises the steps of:forming a crown portion and a skirt portion from a first material; andforming at least a portion of a combustion surface along the crown portion from a second material by an additive machining process.2. The method of claim 1 , wherein the additive machining process includes applying the second material to the first material by a plasma transfer arc.3. The method of claim 1 , wherein the additive machining process includes applying the second material to the first material by a high velocity oxygen fuel spray.4. The method of claim 1 , wherein the additive machining process includes applying the second material to the first material by laser cladding or selective laser sintering.5. The method of claim 1 , wherein the additive machining process includes applying the second material to the first material by arc welding or additive welding.6. The method of including melting the first material along an area of the crown portion after forming the crown portion; and wherein the additive machining process includes melting the second ...

METHODS OF WELDING AND WELDED ARTICLES

In some embodiments, a method of welding includes welding at least one fill bead to fill at least one gap on a substrate with arc scanning by an arc welder. The gap is defined by at least one weld bead on the substrate. The weld beads are non-overlapping. A welded article includes a substrate including a crack-prone superalloy and at least one weld bead and at least one fill bead welded on the substrate. The fill bead, the weld bead, and a heat-affected zone of the substrate are micro-crack-free and macro-crack-free. In some embodiments, a method of welding includes welding weld beads on a substrate and welding fill beads on the substrate with an arc welder while arc scanning. The fill beads fill the gaps between neighboring pairs of weld beads. The fill beads are welded in a non-sequential order. 1. A method of welding comprising:welding at least one fill bead to fill at least one gap on a substrate with arc scanning by an arc welder, wherein the gap is defined by at least one weld bead on the substrate and the at least one weld bead is non-overlapping.2. The method of claim 1 , wherein the arc scanning comprises oscillating the arc welder back and forth between surface contour lines of the at least one weld bead and the substrate defining the at least one gap.3. The method of claim 1 , wherein the substrate comprises a crack-prone superalloy.4. The method of claim 3 , wherein the crack-prone alloy is selected from the group consisting of a first composition claim 3 , by weight claim 3 , of between about 9% and about 10% cobalt (Co) claim 3 , between about 9.3% and about 9.7% tungsten (W) claim 3 , between about 8.0% and about 8.7% chromium (Cr) claim 3 , between about 5.25% and about 5.75% aluminum (Al) claim 3 , between about 2.8% and about 3.3% tantalum (Ta) claim 3 , between about 1.3% and about 1.7% hafnium (Hf) claim 3 , up to about 0.9% titanium (Ti) claim 3 , up to about 0.6% molybdenum (Mo) claim 3 , up to about 0.2% iron (Fe) claim 3 , up to about 0.12% ...

PROGRAM CREATION DEVICE, WELDING SYSTEM, AND PROGRAM CREATION METHOD

A welding program is created for performing spot welding by a program creation device. The program creation device includes a display unit configured to display an image, and an image generation unit configured to generate image data of a product model before being subjected to spot welding in accordance with shape data on a product and display the product model on the display unit, a display control unit configured to make a workpiece having a selected surface in the product model to be semitransparent, a welding portion setting unit configured to set welding portions to be allotted for the selected surface in the product model, and a program creation unit configured to create the welding program including related data for a welding robot with regard to the set welding portions. 1. A program creation device for creating a welding program used for a welding system to control a welding robot for performing spot welding on a plurality of stacked sheet-like workpieces so as to manufacture a product , the device comprising:a display unit configured to display an image;an image generation unit configured to generate image data of a product model and display the product model on the display unit;a detection unit configured to determine whether there are any overlapping workpieces on a back side of the workpiece having the selected surface in the product model;a display control unit configured to make a workpiece having a selected surface in the product model to be semitransparent;a welding portion setting unit configured to set a welding portion to be allotted for the selected surface while the workpiece having the selected surface is made to be semitransparent; anda program creation unit configured to create the welding program including related data for the welding robot with regard to the set welding portion.2. The program creation device according to claim 1 ,wherein the display control unit makes the workpiece having the selected surface in the product model to be ...

FABRICATION OF METALLIC PARTS BY ADDITIVE MANUFACTURING

In various embodiments, wire composed at least partially of arc-melted refractory metal material is utilized to fabricate three-dimensional parts by additive manufacturing. 1. A method of fabricating a three-dimensional part comprising molybdenum , the method comprising:(a) compacting powder to form a feed electrode, the powder comprising molybdenum;(b) arc-melting the feed electrode in a processing ambient comprising a vacuum or one or more inert gases, thereby forming a billet;(c) mechanically deforming the billet into wire having a diameter less than a diameter of the billet;(d) translating a tip of the wire relative to a platform;(e) while the tip of the wire is being translated, melting the tip of the wire with an energy source to form a molten bead, whereby the bead cools to form at least a portion of a layer of a three-dimensional part; and(f) repeating steps (d) and (e) one or more times to produce the three-dimensional part,wherein the three-dimensional part comprises molybdenum.2. The method of claim 1 , wherein a concentration within the wire of at least one of sodium claim 1 , calcium claim 1 , antimony claim 1 , magnesium claim 1 , phosphorous claim 1 , or potassium is less than 5 ppm by weight.3. The method of claim 1 , wherein a concentration of oxygen within the wire is less than 20 ppm by weight.4. The method of claim 1 , wherein a density of the three-dimensional part is greater than 97% of a theoretical density of molybdenum.5. The method of claim 1 , wherein a density of the three-dimensional part is greater than 99% of a theoretical density of molybdenum.6. The method of claim 1 , wherein step (c) comprises at least one of drawing claim 1 , rolling claim 1 , swaging claim 1 , extruding claim 1 , or pilgering.7. The method of claim 1 , wherein step (a) comprises sintering the compacted powder at a temperature greater than 900° C.8. The method of claim 1 , wherein in step (e) the energy source comprises an electron beam and/or a laser beam.9. The ...

SYSTEMS AND METHODS PROVIDING LOCATION FEEDBACK FOR ADDITIVE MANUFACTURING

A system and method to correct for height error during a robotic welding additive manufacturing process. One or both of a welding output current and a wire feed speed are sampled during a robotic welding additive manufacturing process when creating a current weld layer. A plurality of instantaneous contact tip-to-work distances (CTWD's) are determined based on at least one or both of the welding output current and the wire feed speed. An average CTWD is determined based on the plurality of instantaneous CTWD's. A correction factor is generated, based on at least the average CTWD, which is used to compensate for any error in height of the current weld layer. 1. A welding system , comprising a welding power source , wherein the welding power source is configured to:sample, in real time, instantaneous parameter pairs, where each instantaneous parameter pair of the instantaneous parameter pairs includes a welding output current and a wire feed speed, during a robotic welding additive manufacturing process while creating a current weld layer of a 3D workpiece part;determine an instantaneous contact tip-to-work distance in real time for, and based on at least, each parameter pair of the instantaneous parameter pairs as each parameter pair is sampled during creation of the current weld layer;determine, in real time, a running average contact tip-to-work distance based on each instantaneous contact tip-to-work distance as each instantaneous contact tip-to-work distance is determined during creation of the current weld layer; andgenerate a correction factor, based on at least the running average contact tip-to-work distance, to be used in real time while creating the current weld layer of the 3D workpiece part to compensate for deviations in a deposit level from a desired deposit level for the current weld layer.2. The welding system of claim 1 , wherein the instantaneous contact tip-to-work distance is further based on one or more of a welding output voltage claim 1 , a ...

ADDITIVE MANUFACTURING WITH METALLIC COMPOSITES

A class of metallic composites is described with advantageous bulk properties for additive fabrication. In particular, the composites described herein can be used in fused filament fabrication or any other extrusion or deposition-based three-dimensional printing process. 1. An apparatus comprising:a build material including a composite formed of a metallic base that melts at a first temperature and a high temperature inert second phase in particle form that remains inert up to at least a second temperature greater than the first temperature;a build plate within a working volume, the build plate including a surface that is rigid and substantially planar;a liquefaction system configured to heat the composite to a working temperature within a range between the first temperature and the second temperature;a nozzle that dispenses the build material at the working temperature; anda robotic system configured to three-dimensionally position the nozzle within the working volume; anda controller electrically coupled to the liquefaction system and the robotic system and operable to control the robotic system and the liquefaction system to fabricate an object in three-dimensions within the working volume from the build material.2. The apparatus of wherein the metallic base includes a pure metal.3. The apparatus of wherein the metallic base includes aluminum.4. The apparatus of wherein the metallic base includes an alloy.5. The apparatus of wherein the metallic base includes a eutectic alloy.6. The apparatus of wherein the metallic base includes a brazing filler metal.7. The apparatus of wherein a sufficient volume of the high temperature inert second phase is added to the composite to increase a viscosity of the composite at the working temperature by at least an order of magnitude.8. The apparatus of wherein the high temperature inert second phase consists of particles having a size not greater than five microns.9. The apparatus of wherein the high temperature inert second ...

Reinforced faces of club heads and related methods

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.

Systems and methods for hybrid laser and arc welding additive manufacturing

Disclosed is a hybrid additive manufacturing system that includes a laser system and an additive manufacturing tool, such as an arc welding type torch. The tool is configured to receive a metallic electrode wire, which is heated by a power supply to create droplets for deposition to create the part by building up successive layers of metal. The additive manufacturing system operates through coordination of the laser system to generate a laser beam, which is applied to a weld bead, and an arc welding process, which provides material for the part. A threshold value of laser intensity and/or power can be applied to the weld puddle to stabilize the arc. Through the laser beam, an arc cone position can be manipulated such that the energy into the molten pool can be redistributed.

MACHINE FOR THE DEPOSITION OF MATERIAL FOR THE PRODUCTION OF PIECES

A machine for the deposition of material for the production of pieces, with a structural housing including an inner chamber in which an arc torch operates in order to melt a strand of material with which pieces are formed on a supporting table; the arc torch is mounted on a frame positioned horizontally in the upper part of the chamber, on which the arc torch is mounted with a movement system driven by several actuation devices located on the outside of the structural housing. The supporting table is positioned below the frame in an assembly that can move towards or away from the frame, with a side sub-chamber located facing the supporting table and equipped with a cover that opens outwards, and towards which the supporting table can pivot for the removal of the pieces. 1. A machine for the deposition of material for the production of pieces , comprising a structural housing which forms an inner chamber in which an arc torch operates in order to melt a strand of material with which pieces are formed on a supporting table , wherein the arc torch is mounted on a frame positioned horizontally in the upper part of the chamber , on which said arc torch is mounted with a movement system driven by several actuation means located on the outside of the structural housing. The supporting table is positioned below the frame in an assembly that can move towards or away from the frame , with a side sub-chamber located facing the supporting table and equipped with a moveable cover that opens outwards , and towards which the supporting table can pivot for the removal of the pieces.2. The machine for the deposition of material for the production of pieces claim 1 , according to claim 1 , wherein the system of movement of the arc torch comprises two perpendicular cross-pieces claim 1 , each of which is mounted on two opposing crossbars of the frame claim 1 , positioned for movement along the length of the crossbars by means of several linear actuators claim 1 , which are driven by ...

HYBRID ARTICLE, METHOD FOR FORMING HYBRID ARTICLE AND METHOD FOR WELDING

A hybrid article is disclosed including a sintered coating disposed on and circumscribing the lateral surface of a core having a core material and a greater density than the sintered coating. The sintered coating includes more than about 95% up to about 99.5% of a first metallic particulate material including a first melting point, and from about 0.5% up to about 5% of a second metallic particulate material having a second melting point lower than the first melting point. A method for forming the hybrid article is disclosed including disposing the core in a die, introducing a slurry having the metallic particulate materials into a gap between the lateral surface and the die, and sintering the slurry. A method for welding a workpiece is disclosed including the hybrid article serving as a weld filler. 1. A hybrid article , comprising:a core including a lateral surface and a core material, and a first metallic particulate material including a first melting point and constituting, by weight, more than about 95% up to about 99.5% of the sintered coating; and', 'a second metallic particulate material including a second melting point and constituting, by weight, from about 0.5% up to about 5% of the sintered coating,, 'a sintered coating disposed on and circumscribing the lateral surface, the sintered coating includingwherein the second melting point is lower than the first melting point and the sintered coating includes a coating density less than the core.2. The hybrid article of claim 1 , wherein the hybrid article is a weld filler for a fusion welding process.3. The hybrid article of claim 1 , wherein the sintered coating includes a melting point depressant claim 1 , and the melting point depressant constitutes claim 1 , by weight claim 1 , between about 0.5% to about 5% of the hybrid article.4. The hybrid article of claim 1 , further including carbon claim 1 , wherein the carbon constitutes claim 1 , by weight claim 1 , between about 0.01% to about 0.08% of the hybrid ...

Welding method and steam generator channel head

A welding method for making cladding or buttering on an inner surface of a base material, an inner surface of an opening portion formed in the base material, and the cut surface formed in such a manner that the cut surface is continuous from the inner surface of the base material to the inner surface of the opening portion, wherein the welding method includes a step of forming a protruding portion on the base material in advance, the protruding portion including a temporary welding surface extending toward the center of the opening portion in such a manner that the temporary welding surface is uniformly continuous to the inner surface of the base material and including the cut surface buried therein.

Single-Pass, Single-Radial Layer, Circumferential-Progression Fill-Welding System, Apparatus and Method for Refurbishing Railway and other Transit Rails

A method and related system and apparatus for refurbishing worn rail transit rails to a desired refurbished rail surface profile substantially similar to the surface profile of a newly-manufactured rail, comprising: depositing a first line of fill material along a lower-inside section to be refurbished; in N−1 successive iterations thereafter, progressing circumferentially from the lower-inside section to be refurbished to an upper-outside section to be refurbished, depositing an n+1line of fill material adjacent an nline of fill material wherein the nline of fill material substantially provides a flow barrier against the n+1line of fill material flowing past the nline of fill material. 1. A method for refurbishing worn rail transit rails to a desired refurbished rail surface profile substantially similar to the surface profile of a newly-manufactured rail , comprising , for a rail in need of refurbishment between a lower-inside section thereof to be refurbished and an upper-outside section thereof to be refurbished , expanding a surface profile of said rail in need of refurbishment to a filled rail surface profile beyond a surface profile of the desired refurbished rail , by:depositing a first line of fill material along said lower-inside section to be refurbished;{'sup': th', 'th', 'th', 'th', 'th, 'in N−1 successive iterations thereafter, progressing circumferentially from said lower-inside section to be refurbished to said upper-outside section to be refurbished, depositing an n+1line of fill material adjacent an nline of fill material wherein said nline of fill material substantially provides a flow barrier against said n+1line of fill material flowing past said nline of fill material; whereinsaid n=1, 2, 3 . . . N is an integer designating an iteration number, and where N≥2 is an integer designating a total number of lines of fill material deposited and a total number of iterations.2. The method of claim 1 , further comprising claim 1 , during each of said N−1 ...

METHOD FOR DESIGNING LAMINATE MOLDED ARTICLE, PRODUCTION METHOD, PRODUCTION DEVICE, AND PROGRAM

A method for designing an additively-manufactured object includes: a slicing step of slicing a shape of the additively-manufactured object into weld bead layers each having a height corresponding to one bead layer using data of the shape of the additively-manufactured object, thereby generating a plurality of virtual bead layers; a reference direction setting step of setting, as a reference direction, a direction in which the sliced layer of the additively-manufactured object is continuously provided and extended in an intermediate layer disposed at a deposition-direction center of the plurality of virtual bead layers; and a bead adjusting step of adjusting a bead size of the weld bead to be formed in the plurality of virtual bead layers depending on a bead shape in a section perpendicular to the reference direction. 1. A method for designing an additively-manufactured object to be built by depositing a plurality of weld bead layers formed of a weld bead formed by melting and solidifying a filler metal , the method comprising:a slicing step of slicing a shape of the additively-manufactured object into weld bead layers each having a height corresponding to one bead layer using data of the shape of the additively-manufactured object, thereby generating a plurality of virtual bead layers;a reference direction setting step of setting, as a reference direction, a direction in which the sliced layer of the additively-manufactured object is continuously provided and extended in an intermediate layer disposed at a deposition-direction center of the plurality of virtual bead layers; anda bead adjusting step of adjusting a bead size of the weld bead to be formed in the plurality of virtual bead layers depending on a bead shape in a section perpendicular to the reference direction.2. The method for designing an additively-manufactured object according to claim 1 , wherein in the bead adjusting step claim 1 , the bead shape is adjusted by changing at least one of a continuous ...

METHOD OF MANUFACTURING HIGH-CONDUCTIVITY WEAR RESISTANT SURFACE ON A SOFT SUBSTRATE

A method of forming a valve seat of an engine head formed from a first composition includes forming a groove at a predetermined valve seat location of a bore defined by the engine head. A source of directed heat energy preheats at least the valve seat location to about a temperature of the melting point of the first composition with the source of directed heat energy. The source of directed heat energy is infused with a material having a second composition generating a melt pool upon the groove by direct metal deposition with the melt pool including the second composition. The second composition includes a heat conductivity generally equal to a heat conductivity of the first composition for providing efficient transfer of heat energy from the first composition to the second composition. 1. A method of forming a valve seat of an engine head formed from a first composition includes the steps of:forming a groove at a predetermined valve seat location of a bore defined by said engine head;providing a source of directed heat energy;preheating at least said valve seat location to about a temperature of the melting point of the first composition with the source of directed heat energy;infusing the source of directed heat energy with a material having a second composition and generating a melt pool upon the groove by direct metal deposition, with the melt pool including the second composition; andsaid second composition including a heat conductivity generally equal to or greater than a heat conductivity of the first composition for providing efficient transfer of heat energy from the first composition to the second composition.2. The method set forth in claim 1 , wherein said step of infusing the source of directed heat energy with a material having a second composition is further defined by providing a second composition comprising:copper in the amount of 40-50 percent by weight;cobalt in the amount of 15-25 percent by weight;carbon in the amount of less than 0.1 percent ...

Method for repairing an upstream rail of a turbine engine turbine casing

A method for repairing an upstream rail of a turbine engine turbine casing, the casing including a casing body extending along a longitudinal axis, the upstream rail including: a base including a radial surface, extending substantially radially from the casing body; a plate including an upper surface, extending substantially along the longitudinal axis; and a connection portion between the base and the plate, including a concave surface connecting the radial surface and the upper surface, the concave surface and the radial surface extending on either side of an edge, the method including: covering a surface with a solder, the surface including the upper surface and the concave surface, such that the solder extends substantially until the edge; and a step of machining the covered surface, in a single action, in the direction of the radial surface, and at least until the edge, so as to reshape the surface.

LOW HEAT INPUT WELD REPAIR OF CAST IRON

A method of repairing a cast iron component is disclosed. The method may include removing a damaged or defective portion of the cast iron component, and pre-heating the cast iron component to a temperature in a range from 200-800 degrees F. After pre-heating, the method may include welding a removed area of the cast iron component using a Cold Metal Transfer (CMT) process with a consumable wire electrode made from one of a carbon steel alloy, a nickel alloy, or a nickel-iron alloy material having a Coefficient of Thermal Expansion (CTE) that is within ±10% of a CTE of the cast iron material of the cast iron component to fill the area where the damaged or defective portion was removed. After welding, the cast iron component may be cooled and the welded portion of the cast iron component may be final machined. 1. A method of weld repairing a cast iron component , comprising:removing a damaged or defective portion of the cast iron component;pre-heating the cast iron component to a temperature in a range from 200-800 degrees F.;welding a removed area of the cast iron component using a Cold Metal Transfer (CMT) process with a consumable wire electrode made from one of a carbon steel alloy, a nickel alloy, or a nickel-iron alloy material having a Coefficient of Thermal Expansion (CTE) that is within ±10% of a CTE of the cast iron material of the cast iron component to fill the area where the damaged or defective portion was removed;cooling the welded cast iron component; andfinal machining the welded portion of the cast iron component.2. The method of claim 1 , wherein the cast iron component is pre-heated to a temperature in a range from 300-400 degrees F.3. The method of claim 1 , wherein the CMT process is a Short-Circuit Gas Metal Arc Welding (GMAW-S) process.4. The method of claim 3 , wherein the CMT process comprises pulsing at least one of a welding current and a welding voltage supplied to the consumable wire electrode.5. The method of claim 3 , wherein the CMT ...

Systems and methods for non-continuous deposition of a component

A method of manufacturing using an additive manufacturing process includes providing a deposition system, the deposition system configured to provide a plurality of cells to form a blank of a part, depositing a first layer of the blank, the first layer comprising a first deposited cell, a second deposited cell spaced apart from the first deposited cell, and a third deposited cell spaced apart from the first deposited cell and the second deposited cell, and depositing a second layer of the part on the first layer, the second layer comprising a fourth deposited cell, a fifth deposited cell spaced apart from the fourth deposited cell, and a sixth deposited cell spaced apart from the fourth deposited cell and the fifth deposited cell. Each of the first layer and the second layer are formed using non-continuous deposition to form the blank.

DED ARC THREE-DIMENSIONAL ALLOY METAL POWDER PRINTING METHOD AND APPARATUS USING ARC AND ALLOY METAL POWDER CORED WIRE

A DED arc 3D alloy metal powder cored printing method, according to an embodiment of the present invention, comprises the steps of: (a) connecting a 3D printing part to a first electrode via a ground line, contacting a second electrode, in which an electrode contact tip is tapped on a peripheral surface of an alloy metal powder cored wire, and then generating an arc by a potential difference between the first electrode and the second electrode to melt the tip of the alloy metal powder cored wire and the surface of the printing part at the same time; (b) forming a monolayer by mixing and solidifying the melt of the alloy metal powder cored wire and the melt of the surface of the printing part; and (c) stacking the monolayer by continuously performing a monolayer overlay, layer-upon-layer. 1. A directed energy deposition (DED) arc 3D printing method using an arc and an alloy metal powder cored wire , the method comprising the steps of:(a) connecting a 3D printing part to a first electrode through a ground line, bringing a second electrode on which an electrode contact tip is tapped on a circumferential surface of an alloy metal powder cored wire into contact with a portion of a surface of the printing part, and generating an arc by a potential difference between the first electrode and the second electrode to simultaneously melting a tip of the alloy metal powder cored wire and the surface of the printing part;(b) forming a monolayer by mixing and solidifying melts of the alloy metal powder cored wire and the surface of the printing part; and(c) continuously performing a monolayer overlay to stack the monolayers, layer-upon-layer andwherein the steps (a) to (c) are performed in an inert gas atmosphere,after information including a printing program, a voltage regulation, a current regulation, a wire feeding speed regulation, and a protective gas regulation is input to a direct-current (DC) constant voltage characteristic power supply device, an arc length and a wire ...

METHOD FOR MODIFYING AN APERTURE AND SYSTEM FOR MODIFYING FLOW THROUGH A COMPONENT

A method for modifying an aperture in a component, a system for modifying flow through a component, and a turbine component are disclosed. The method includes providing a substrate having at least one aperture having an electrically-conductive surface, providing a deposition device including an ESD torch, the ESD torch including an aperture penetrating electrode including a conductive material, inserting the aperture penetrating electrode at least partially into the aperture, and generating an arc between the aperture penetrating electrode and the electrically-conductive surface to deposit electrode material within the aperture. The system includes the ESD torch removably supported in an electrode holder. The turbine component includes at least one aperture having an electrospark deposited material along an electrically-conductive surface, the electrospark deposited material providing modified fluid flow through the turbine component. 1. A system for modifying flow through a component , comprising:an electrospark deposition torch removably supported in an electrode holder, the electrospark deposition torch including an aperture-penetrating electrode;wherein the aperture-penetrating electrode is configured to extend past a non-electrically-conductive layer of the component to apply an electrode material to an electrically-conductive surface in an aperture of the component to modify flow through the aperture of the component.2. The system of claim 1 , wherein the aperture-penetrating electrode includes a feature for modifying the aperture.3. The system of claim 2 , wherein the feature is selected from the group consisting of a bend claim 2 , a curve claim 2 , a projection claim 2 , a variation in thickness along a length of the aperture-penetrating electrode claim 2 , a variation on geometry along a length of the aperture-penetrating electrode claim 2 , and a combination thereof.4. The system of claim 1 , wherein the aperture-penetrating electrode comprises a nickel- ...

METHOD AND APPARATUS FOR MANUFACTURING LAYERED MODEL

A method for producing an additively manufactured object includes melting and solidifying a filler metal to form weld beads and depositing the weld beads adjoining each other, thereby forming a weld-bead layer, and repeatedly depositing a next weld-bead layer on the formed weld-bead layer to conduct additive manufacturing. The method includes a bead formation step of forming a new weld bead so as to fill a recess formed by at least three of the already formed weld beads, in a cross-section perpendicular to a longitudinal direction of the weld beads. 1. A method for producing an additively manufactured object , comprising melting and solidifying a filler metal to form weld beads and depositing the weld beads adjoining each other , thereby forming a weld-bead layer , and repeatedly depositing a next weld-bead layer on the formed weld-bead layer to conduct additive manufacturing ,the method comprising a bead formation step of forming a new weld bead so as to fill a recess formed by at least three of the already formed weld beads, in a cross-section perpendicular to a longitudinal direction of the weld beads.2. The method for producing an additively manufactured object according to claim 1 , wherein in the bead formation step claim 1 , a bead size of the new weld bead is changed such that the recess is filled up.3. The method for producing an additively manufactured object according to claim 1 , wherein in the bead formation step claim 1 , any of boundaries between the at least three already formed weld beads is used as a target position for forming the new weld bead.4. The method for producing an additively manufactured object according to claim 2 , wherein in the bead formation step claim 2 , any of boundaries between the at least three already formed weld beads is used as a target position for forming the new weld bead.5. The method for producing an additively manufactured object according to claim 3 , wherein in the bead formation step claim 3 , a torch axis ...

METAL LAMINATING AND MODELING METHOD

In a metal laminating and modeling method, a three-dimensional modeled object having a main surface and an outer circumferential surface is modeled by sequentially laminating a plurality of metal layers . The metal laminating and modeling method has a metal layer formation step of forming the metal layers by forming a plurality of weld beads so as to be arranged in a horizontal direction on a table , and a first end portion weld bead formation step of inclining the table such that a target surface faces in a first inclination direction and forming first end portion weld beads so as to overlap, among a plurality of center weld beads , the center weld beads located at an uppermost end in a vertical direction Dv. 1. A metal laminating and modeling method for modeling a three-dimensional modeled object having a main surface and a side surface extending in a direction intersecting with the main surface from an end portion of the main surface by sequentially laminating metal layers , the method comprising:a metal layer formation step of forming one of the metal layers by forming a plurality of weld beads formed by arc welding so as to be arranged in a horizontal direction on a table having a target surface on which the metal layers are to be formed,wherein the metal layer formation step hasa center portion weld bead formation step of setting the table in a horizontal state such that the target surface faces upward in a vertical direction and forming the plurality of weld beads so as to be overlapped in a direction in which the target surface extends anda first end portion weld bead formation step of inclining the table such that the target surface faces in a first inclination direction intersecting with the vertical direction and forming at least one first end portion weld bead so as to overlap, among the plurality of weld beads formed in the center portion weld bead formation step, weld beads located at an uppermost end in the vertical direction.2. The metal laminating ...

AUTOMATED WELDING OF MOULDS AND STAMPING TOOLS

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. 1. A method of welding a tool comprising the steps of:determining weld path and weld parameters to provide a desired weld shape;heating a tool having an initial tool shape;adjusting the desired weld path based upon initial tool shape variations, the adjusting step including detecting a position of a heated mould surface indicative of the thermal growth of the tool;adjusting a position of a robot having a welding head relative to the tool using a gantry system; andautomating welding of the tool according to the weld path and weld parameters to provide the desired weld shape to achieve the desired tool shape.2. The method as recited in claim 1 , wherein the gantry system includes at least one longitudinal support and a cross-wise support extending substantially perpendicular to the at least one longitudinal support.3. The method as recited in claim 2 , wherein the step of adjusting the position of the robot includes:adjusting the position of the robot in a first direction using the gantry system; andadjusting the position of the robot in a second direction substantially perpendicular to the first direction using the gantry system.4. The method as recited in claim 1 , wherein the gantry system includes at least one longitudinal support and a cross-wise support extending ...

AUTOMATED WELDING APPARATUS AND COMPUTER -IMPLEMENTED METHOD FOR FILING A VOLUME

An automated welding apparatus and computer-implemented method are described which generally perform the steps of: scanning a joint interface of a workpiece using a three-dimensional scanner (S); determining a volume to be filled by a welding process (S); determining a specification for the welding process based on the volume to be filled using an algorithm (S, S); and controlling a welding device so as to execute the specification by moving the welding device relative to the workpiece (S). 1. An automated welding apparatus comprising:a welding device configured to move relative to a workpiece in order to perform a welding process;a three-dimensional scanner configured to scan a joint interface of the workpiece and to determine a volume to be filled by the welding process; anda controller connected to the three-dimensional scanner and the welding device, the controller having an algorithm configured to determine a specification for the welding process based on the volume determined by the three-dimensional scanner and being configured to control the welding device so as to execute the specification by moving the welding device relative to the workpiece.2. An automated welding apparatus as claimed in claim 1 , wherein the algorithm determines the number of weld passes required to fill the volume.3. An automated welding apparatus as claimed in claim 2 , wherein the algorithm determines the position and order of the weld passes.4. An automated welding apparatus as claimed in claim 3 , wherein the position and order of the weld passes is optimised based on a defined characteristic.5. An automated welding apparatus as claimed in claim 2 , wherein the three-dimensional scanner is configured to rescan the joint interface of the workpiece following the or each weld pass and to determine a remaining volume to be filled by the welding process.6. An automated welding apparatus as claimed in claim 5 , wherein the controller is configured to adjust the specification for the ...

AGENT-BASED SLICING

An agent engine allocates a collection of agents to scan the surface of an object model. Each agent operates autonomously and implements particular behaviors based on the actions of nearby agents. Accordingly, the collection of agents exhibits swarm-like behavior. Over a sequence of time steps, the agents traverse the surface of the object model. Each agent acts to avoid other agents, thereby maintaining a relatively consistent distribution of agents across the surface of the object model over all time steps. At a given time step, the agent engine generates a slice through the object model that intersects each agent in a group of agents. The slice associated with a given time step represents a set of locations where material should be deposited to fabricate a 3D object. Based on a set of such slices, a robot engine causes a robot to fabricate the 3D object. 1. A computer-implemented method for slicing object models , the method comprising:deploying a group of agents onto a surface of an object model;causing the group of agents to traverse the surface of the object model towards a first region, wherein the group of agents surrounds a first portion of the object model, the first portion being located proximate to or at the first region; andgenerating a first slice that intersects the group of agents and the first portion of the object model.2. The computer-implemented method of claim 1 , wherein causing the group of agents to traverse the surface of the object model comprises:determining a set of heading vectors associated with a set of agents residing proximate to a first agent;combining the set of heading vectors to generate an influence vector;determining a first heading vector for the first agent based on the influence vector and a previous heading vector associated with the first agent; andmoving the first agent to a first position based on the first heading vector.3. The computer-implemented method of claim 1 , further comprising:determining a number of agents ...

AERODYNAMIC NOISE REDUCING THIN-SKIN LANDING GEAR STRUCTURES AND MANUFACTURING TECHNIQUES

A thin-skin support member is provided. The thin-skin support member may include a semi-circular edge and a flat edge that define a hollow cavity. A cylindrical cavity may be adjacent the hollow cavity and at least partially defined by the semi-circular edge. The cylindrical cavity may be configured to retain a strut assembly. A mounting interface may be coupled to the semi-circular edge and the flat edge. A torsion interface may be disposed adjacent the cylindrical cavity and configured to receive a torsion link. The thin-skin support member may be made using additive manufacturing and thus may have a grain structure grown in the direction of material being added. 1. A thin-skin support member , comprising:a semi-circular edge and a flat edge that define a hollow cavity;a cylindrical cavity adjacent the hollow cavity and at least partially defined by the semi-circular edge, wherein the cylindrical cavity is configured to retain a strut assembly;a mounting interface coupled to the semi-circular edge and the flat edge; anda torsion interface disposed adjacent the cylindrical cavity and configured to receive a torsion link, wherein the thin-skin support member has a grain structure grown in the direction of material being added.2. The thin-skin support member of claim 1 , wherein the thin-skin support member is made using wire arc additive manufacturing.3. The thin-skin support member of claim 2 , further comprising at least one of aluminum or titanium.4. The thin-skin support member of claim 3 , wherein a deposit width of the wire arc additive manufacturing is 3.5 mm or less.5. The thin-skin support member of claim 1 , further comprising a mid-body support claim 1 , wherein the cylindrical cavity extends from the mid-body support.6. The thin-skin support member of claim 1 , wherein the flat edge has a yield strength ranging from approximately 105 MPa to 121 MPa.7. The thin-skin support member of claim 6 , wherein the flat edge has an ultimate tensile strength ranging ...

AUTOMATED FABRICATION SYSTEM IMPLEMENTING 3-D VOID MODELING

A fabrication system is disclosed for use in joining two components of a work piece. The fabrication system may have a mount configured to hold the work piece with a void to be filled with material. The fabrication system may also have a scanner configured to capture at least one image of the void, a robotic fabrication device movable relative to the mount, and a controller in communication with the scanner and the robotic fabrication device. The controller may be configured to generate a model of the void based on the at least one image, and to slice the model into at least one layer. The controller may also be configured to develop a tool path for each of the at least one layer, and to cause the robotic fabrication device to deposit material within the void based on the tool path. 1. A fabrication system , comprising:a mount configured to hold a work piece having a void to be filled with material;a scanner configured to capture at least one image of the void;a robotic fabrication device movable relative to the mount; and generate a model of the void based on the at least one image;', 'slice the model into at least one layer;', 'develop a tool path for each of the at least one layer; and', 'cause the robotic fabrication device to deposit material within the void based on the tool path., 'a controller in communication with the scanner and the robotic fabrication device and configured to2. The fabrication system of claim 1 , wherein the model is a 3-D model.3. The fabrication system of claim 2 , wherein the at least one layer includes a plurality of layers.4. The fabrication system of claim 3 , wherein:the robotic fabrication device is a welder configured to deposit the material in a bead formation; andeach of the plurality of layers has a thickness about equal to a diameter of the bead formation.5. The fabrication system of claim 1 , wherein the controller is configured to develop the tool path based at least in part on a shape of the void claim 1 , a volume of the ...

METHOD FOR MANUFACTURING OR FOR REPAIRING A COMPONENT OF A ROTARY MACHINE AS WELL AS A COMPONENT MANUFACTURED OR REPAIRED USING SUCH A METHOD

A method for manufacturing a component of a rotary machine, the component extends in an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end in a center of the component to a second end at a radial limiting surface of the component and which is partially closed. A blank includes the center of the component and is limited by an outer surface in the radial direction. The maximum dimension of the outer surface in the radial direction is smaller than the dimension of the limiting surface in the radial direction, A first subtractive process step is performed such that a part of the channel is manufactured by a machining process, with the part extending from the first end of the channel to the outer surface of the blank. Afterwards the channel is finished by a build-up process on the blank. 1. A method for manufacturing a component of a rotary machine , the component extending in an axial direction and a radial direction vertical thereto , and having at least one inner channel extending from a first end in a center of the component to a second end at a radial limiting surface of the component and which is at least partially closed , that the method comprising:providing a blank comprising the center of the component, and the blank being limited by an outer surface in the radial direction, the maximum dimension of the outer surface in the radial direction being smaller than a dimension of the limiting surface in the radial direction;performing a first subtractive process step in which a part of the channel is manufactured by a machining process, with the part extending from the first end of the channel to the outer surface of the blank; andafterwards finishing the channel by a build-up process on the blank by application of at least part of a shapeless or a neutrally shaped material.2. The method according to claim 1 , wherein the at least one inner channel includes a plurality of inner channels claim 1 , each of the ...

METHOD FOR MANUFACTURING OR FOR REPAIRING A COMPONENT OF A ROTARY MACHINE AS WELL AS A COMPONENT MANUFACTURED OR REPAIRED USING SUCH A METHOD

A method for manufacturing a component of a rotary machine, the component extending to an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end of a core of a center of the component and to a second end at a radial limiting surface of the component and which is at least partially closed. A blank includes the core of the component and is limited by an outer surface in the radial direction. The blank is subtractively processed in a first subtractive process step, such that an outer contour is elaborated in the area of the outer surface, which extends in the radial direction, and a part of the channel is manufactured, which radially extends in the blank to the first end. The channel is finished by a build-up process on the blank. 1. A method for manufacturing a component of a rotary machine , the component extending in an axial direction and in a radial direction vertical thereto , and having at least one inner channel extending from a first end of a core of a center of the component , and to a second end at a radial limiting surface of the component and which is at least partially closed , the method comprising:providing a blank comprising the core of the component, the blank being limited by an outer surface in the radial direction;subtractively processing the blank in a first subtractive process step in such a manner, that an outer contour in an area of the outer surface is elaborated, the outer contour extending at least in the radial direction, and a part of the channel is manufactured, the part at least partially extends radially in the blank to the first end; andthen finishing the channel by a build-up process on the blank.2. The method according to claim 1 , wherein the outer contour comprises parts of a cover plate of the component or parts of a shroud of the component.3. The method according to claim 1 , wherein the build-up process is performed layer by layer claim 1 , at least in a direction vertical ...

SYSTEMS AND METHODS FOR MAKING BLADE SHEATHS

A method of making a sheath for an airfoil may include the steps of forming an upper sleeve and a lower sleeve, and forming a central portion bonded to the upper sleeve and the lower sleeve. The central portion may be formed by depositing a material on the upper sleeve and the lower sleeve. A portion of the material may be removed from at least one of the central portion, the upper sleeve, or the lower sleeve. The sheath may include a first flank, a central portion bonded to the first flank, and a second flank bonded to the central portion. The central portion may have a substantially uniform microstructure resulting from additive manufacturing. 1. A sheath for an airfoil comprising:a first flank having a contour matching a suction side of the airfoil;a central portion bonded to the first flank, wherein the central portion is deposited using additive manufacturing; anda second flank bonded to the central portion and having a contour matching a pressure side of the airfoil.2. The sheath of claim 1 , wherein the central portion comprises a substantially uniform microstructure.3. The sheath of claim 2 , wherein the first flank is formed from a sheet of a metal.4. The sheath of claim 3 , wherein the metal comprises at least one of titanium claim 3 , aluminum claim 3 , nickel claim 3 , or steel.5. The sheath of claim 1 , wherein the central portion comprises a titanium alloy.6. The sheath of claim 1 , further comprising an inner surface having a curved surface to join the first flank and the second flank.7. The sheath of claim 6 , wherein the inner surface is substantially smooth with a substantially uniform microstructure.8. A fan comprising:a blade having a leading edge, a pressure side, a suction side, and a trailing edge; anda sheath bonded to the blade by an adhesive, wherein the sheath comprises a first flank on the pressure side, a second flank on the suction side, and a central portion joining the first flank and the second flank, wherein the central portion ...

SYSTEMS AND METHODS FOR AUTOMATED WELDING

An automated welding system includes a mounting platform, a welding tool, an imaging device configured to acquire data associated with an object, and a controller. The controller is configured to receive the acquired data, determine an area to be welded in the acquired data, retrieve stored master model data associated with the object, and compare the acquired data to the stored master model data to identify a master model area in the acquired data. The controller is also configured to mask the master model area in the acquired data, such that the master model area is excluded from the area to be welded, and generate control instructions for controlling at least one of the mounting platform and the welding tool to weld the area to be welded. 1. An automated welding system comprising:a mounting platform;a welding tool;an imaging device configured to acquire data associated with an object; and receive the acquired data;', 'determine an area to be welded in the acquired data;', 'retrieve stored master model data associated with the object;', 'compare the acquired data to the stored master model data to identify a master model area in the acquired data;', 'mask the master model area in the acquired data, such that the master model area is excluded from the area to be welded; and', 'generate control instructions for controlling at least one of said mounting platform and said welding tool to weld the area to be welded., 'a controller configured to2. The automated welding system of claim 1 , wherein said controller is further configured to generate control instructions for controlling at least one of a position and an orientation of at least one of said mounting platform and said welding tool.3. The automated welding system of claim 1 , wherein said controller is further configured to analyze at least one image pixel in the acquired data to determine the area to be welded.4. The automated welding system of claim 1 , wherein said controller is further configured to ...

FABRICATION OF METALLIC PARTS BY ADDITIVE MANUFACTURING

In various embodiments, wire composed at least partially of arc-melted refractory metal material is utilized to fabricate three-dimensional parts by additive manufacturing. 128.-. (canceled)29. A method of fabricating a three-dimensional part comprising a metallic material , the method comprising:(a) compacting powder to form a feed electrode, the powder comprising the metallic material;(b) arc-melting the feed electrode in a processing ambient comprising a vacuum or one or more inert gases, thereby forming a billet;(c) mechanically deforming the billet into wire having a diameter less than a diameter of the billet;(d) translating a tip of the wire relative to a platform;(e) while the tip of the wire is being translated, melting the tip of the wire with an energy source to form a molten bead, whereby the bead cools to form at least a portion of a layer of a three-dimensional part; and(f) repeating steps (d) and (e) one or more times to produce the three-dimensional part,wherein the three-dimensional part comprises the metallic material.30. The method of claim 29 , wherein the metallic material comprises at least one of niobium claim 29 , tantalum claim 29 , rhenium claim 29 , tungsten claim 29 , or molybdenum.31. The method of claim 29 , wherein a concentration within the wire of at least one of sodium claim 29 , calcium claim 29 , antimony claim 29 , magnesium claim 29 , phosphorous claim 29 , or potassium is less than 5 ppm by weight.32. The method of claim 29 , wherein a concentration of oxygen within the wire is less than 20 ppm by weight.33. The method of claim 29 , wherein a density of the three-dimensional part is greater than 97% of a theoretical density of the metallic material.34. The method of claim 29 , wherein step (c) comprises at least one of drawing claim 29 , rolling claim 29 , swaging claim 29 , extruding claim 29 , or pilgering.35. The method of claim 29 , wherein step (a) comprises sintering the compacted powder at a temperature greater than 900° ...

AERODYNAMIC NOISE REDUCING THIN-SKIN LANDING GEAR STRUCTURES AND MANUFACTURING TECHNIQUES

A thin-skin support member is provided. The thin-skin support member may include a semi-circular edge and a flat edge that define a hollow cavity. A cylindrical cavity may be adjacent the hollow cavity and at least partially defined by the semi-circular edge. The cylindrical cavity may be configured to retain a strut assembly. A mounting interface may be coupled to the semi-circular edge and the flat edge. A torsion interface may be disposed adjacent the cylindrical cavity and configured to receive a torsion link. The thin-skin support member may be made using additive manufacturing and thus may have a grain structure grown in the direction of material being added. 1. A method of making a thin-skin support member , comprising:selecting a metal; andforming the thin-skin support member from the metal, wherein the thin-skin support member defines a hollow cavity and a cylindrical cavity proximate the hollow cavity and wherein the thin-skin support member comprises a cutaway section configured to reduce a weight of the thin-skin support member.2. The method of claim 1 , wherein the forming the thin-skin support member further comprises using wire arc additive manufacturing to form the thin-skin support member.3. The method of claim 2 , wherein the forming the thin-skin support member comprises:depositing a first layer of the metal; andremoving an excess material from the first layer of the metal; anddepositing a second layer of the metal over the first layer of the metal.4. The method of claim 2 , wherein the forming the thin-skin support member comprises:depositing a first layer of the metal; anddepositing a second layer of the metal over the first layer of the metal; andremoving an excess material from the first layer of the metal and the second layer of the metal.5. The method of claim 1 , wherein the forming the thin-skin support member comprises machining the thin-skin support member from a block of the metal claim 1 , wherein the metal is aluminum. This ...

MANUFACTURING METHOD, MANUFACTURING SYSTEM, AND MANUFACTURING PROGRAM FOR ADDITIVE MANUFACTURED OBJECT

A welding robot () forms a laminate-molded object () by forming and laminating a melt bead () of each layer (L to Lk) so that a height (h) of the melt bead () of each layer (L to Lk) is within a range of a tolerance (ϵ) with respect to a planned height (h). When the height (h) of the melt bead () is lower than a value obtained by subtracting the tolerance (ϵ) from the planned height (h), the welding robot () forms another melt bead () over the melt bead (). When the height (h) of the melt bead () is higher than a value obtained by adding the tolerance (ϵ) to the planned height (h), the melt bead () is removed by a cutting robot (). 1. A method for manufacturing a laminate-molded object , comprising:acquiring shape data representing the shape of a shaped object;dividing the shaped object into a plurality of parallel layers based on the shape data and generating layer shape data representing the shape of each layer; andforming a melt bead of each layer and laminating the melt bead until the shape of the shaped object is formed, wherein forming the melt bead by a laminating device based on the layer shape data of each layer;', 'measuring the height of the formed melt bead;', 'comparing whether the measured height of the melt bead is within a range of a tolerance with respect to a planned height;', 'forming another melt bead over the melt bead when the height of the melt bead is lower than a value obtained by subtracting the tolerance with respect to the planned height; and', 'removing the melt bead when the height of the melt bead is higher than a value obtained by adding the tolerance to the planned height., 'the formation of the melt bead of each layer includes2. The method for manufacturing a laminate-molded object according to claim 1 , whereinthe measuring and the comparing are performed again after the another melt bead forming or the melt bead removing is performed.3. A system for manufacturing a laminate-molded object claim 1 , comprising:a laminating device ...

METHOD AND DEVICE FOR MANUFACTURING SHAPED OBJECTS

A method for producing a built-up object, includes: producing maps beforehand, the maps indicating bead heights BH and bead widths BW corresponding to a base-surface inclination angle θ and a track inclination angle φ, in which the base-surface inclination angle is an angle between a base surface on which the weld beads are to be formed and a vertical direction, and the track inclination angle is an angle between a track direction of the torch and a vertical direction on the base surface; selecting a bead height BHand a bead width BWfrom the maps correspondingly to the base-surface inclination angle θ and the track inclination angle φ in forming a weld bead on the base surface; and forming the weld bead based on the selected bead height BHand bead width BW. 1. A method for producing a built-up object by melting and solidifying a filler metal , thereby forming weld beads with a torch , the method comprising:producing maps beforehand, the maps indicating bead heights BH and bead widths BW corresponding to a base-surface inclination angle θ and a track inclination angle φ, wherein the base-surface inclination angle is an angle between a base surface on which the weld beads are to be formed and a vertical direction, and the track inclination angle is an angle between a track direction of the torch and a vertical direction on the base surface;{'sub': 0', '0, 'selecting a bead height BHand a bead width BWfrom the maps correspondingly to the base-surface inclination angle θ and the track inclination angle φ in forming a weld bead on the base surface; and'}{'sub': 0', '0, 'forming the weld bead based on the selected bead height BHand bead width BW.'}2. The method for producing a built-up object according to claim 1 , the method comprising:{'sub': m', 'm', 'm', 'm', '0', '0, 'measuring a surface profile of an already deposited weld bead before the formation of the weld bead, thereby determining an actual value θof the base-surface inclination angle and an actual value φof ...

SYSTEMS AND METHODS FOR HEIGHT CONTROL IN LASER METAL DEPOSITION

Disclosed is a welding system configured to perform additive manufacturing, particularly a welding system to achieve a stable a laser metal deposition with hot wire process by controlling the contact point between the welding wire and the workpiece. For example, the resistance of the stick-out wire is measured and the measured resistance is converted to a distance signal, which can then be used for comparison to a desired distance. The distance between the contact tip and the workpiece can then be adjusted based on the comparison. The present disclosure also relates to using a constant enthalpy system to determine and control the contact tip to workpiece distance. 1. An additive manufacturing system , comprising:an additive manufacturing tool configured to advance an electrode wire to a weld puddle on a surface of a workpiece;a heater configured to preheat the electrode wire at a location in an electrode wire feed path that is prior to the surface;a laser generator to provide a laser beam to create and heat the weld puddle to at least a melting temperature of the electrode wire; and monitor a current or a voltage associated with the electrode wire;', 'determine a resistance of the electrode wire based in part on the current or the voltage;', 'determine a distance between the tool and the surface based in part on the resistance; and', 'control a position of the tool to adjust the distance between the tool and the surface based on the resistance., 'a control circuitry configured to2. The system of claim 1 , the control circuitry further configured to:compare the distance against one or more threshold distances; andcontrol the position of the tool based the comparison.3. The system of claim 2 , wherein the one or more threshold distances are based on a predetermined range of angles measured between the electrode wire and the surface of the workpiece.4. The system of claim 3 , wherein the predetermined range of angles includes a 45-degree angle.5. The system of claim 3 ...

Agent-based slicing

An agent engine allocates a collection of agents to scan the surface of an object model. Each agent operates autonomously and implements particular behaviors based on the actions of nearby agents. Accordingly, the collection of agents exhibits swarm-like behavior. Over a sequence of time steps, the agents traverse the surface of the object model. Each agent acts to avoid other agents, thereby maintaining a relatively consistent distribution of agents across the surface of the object model over all time steps. At a given time step, the agent engine generates a slice through the object model that intersects each agent in a group of agents. The slice associated with a given time step represents a set of locations where material should be deposited to fabricate a 3D object. Based on a set of such slices, a robot engine causes a robot to fabricate the 3D object.

Method of manufacturing an article

A gas turbine engine ( 10 ) fan outlet guide vane ( 34 ) is manufactured by diffusion bonding titanium alloy sheet metal workpieces ( 52,54 ) together to form an in integral structure ( 66 ). A titanium alloy is weld deposited at predetermined positions ( 70,72 ) and in a predetermined shape to build up bosses ( 42,44 ) at the radially outer end ( 40 ) of the hollow integral structure ( 68 ). The integral structure ( 66 ) is inflated at high temperature to form a hollow integral structure ( 68 ) of predetermined aerofoil shape. Apertures ( 46,48 ) are drilled through the bosses ( 42,44 ) to enable the radially outer end ( 40 ) of the fan outlet guide vane ( 34 ) to be attached to a fan casing ( 32 ) of the gas turbine engine ( 10 ).

造型物的制造方法、制造装置以及造型物

提供能够在没有下垂、凹凸不平等不良状况的情况下效率良好地形成熔敷焊道从而造型造型物的造型物的制造方法、制造装置以及造型物。在该造型物的制造方法中，使焊料熔融以及凝固而在沿着焊炬的轨道的基面上形成熔敷焊道，并利用该熔敷焊道形成造型物。此时，造型物具有重力影响为最大的焊道形成部位，在该焊道形成部位形成熔敷焊道的形成时的粘度比其他熔敷焊道高的支承焊道。并且，与支承焊道重叠地形成其他熔敷焊道。

层叠造形物的制造方法以及制造装置

提供能够一边防止在熔敷焊道的层叠过程中的焊炬的干扰，一边确保为了不会在相邻的熔敷梁彼此之间的狭窄部形成未熔敷部而所需足够的熔深量，来得到高品质的层叠造形物的层叠造形物的制造方法以及制造装置。层叠造形物的制造方法将使焊接填充材料熔融以及凝固而得的熔敷焊道相互相邻来形成熔敷焊道层，在形成的熔敷焊道层重复层叠下一层的熔敷焊道层来进行造形。在与熔敷焊道的长边方向正交的剖面，形成新的熔敷焊道，以便填埋通过已经形成的至少三个熔敷焊道而形成的一个凹部。