Abstract:
An additive manufacturing system includes a particulate delivery system including at least one dispenser configured to dispense a plurality of first particulates and a plurality of second particulates onto a surface. The particulate delivery system includes a first particulate supply and a second particulate supply coupled to the at least one dispenser. The at least one dispenser is configured to deposit the plurality of first particulates and the plurality of second particulates adjacent each other. At least a portion of at least one of the plurality of first particulates and the plurality of second particulates is fused.
Abstract:
A surface of an article is modified by first disposing a nickel-enriched region at the surface of a substrate, then enriching the nickel-enriched region with aluminum to form an aluminized region, and finally removing at least a portion of the aluminized region to form a processed surface of the substrate. Upon removal of this material, the roughness of the surface is reduced from a comparatively high initial roughness value to a comparatively low processed roughness value. In some embodiments, the processed roughness is less than about 95% of the initial roughness. Moreover, the sequence of steps described herein may be iterated one or more times to achieve further reduction in substrate surface roughness.
Abstract:
A method of manufacturing soft magnetic thin laminates includes producing a bulk component comprising a soft magnetic material, wherein the bulk component extends in an axial direction, and slicing the bulk component in a radial direction, perpendicular to the axial direction, to produce a plurality of soft magnetic thin laminates.
Abstract:
An apparatus and method for rapid screening of material properties in a plurality of additively manufactured test specimens. The apparatus includes a build plate having the plurality of additively manufactured test specimens disposed on a first substantially planar surface. The plurality of additively manufactured test specimens are coupled to at least one actuator to one of individually or simultaneously translationally displace each of the test specimens along an axis “z”, and perpendicular to the build plane of the build plate to test material properties of each of the plurality of additively manufactured test specimens. A sensor is coupled to each of the plurality of additively manufactured test specimens. Load vs. displacement data may be used to monitor the progression of monotonic and/or cyclic tests of the plurality of additively manufactured test specimens.
Abstract:
An article, for example a turbomachinery article is presented. The article includes a weldable first component having a base portion and a flange portion. The flange portion is outwardly projecting normal to a surface of the base portion; and is joined with the base portion by a solid state joint. The base portion comprises a nanostructured ferritic alloy; and the flange portion comprises a steel substantially free of oxide nanofeatures. The first component is joined to a second component through the flange portion of the first component by a weld joint.
Abstract:
Additive manufacturing methods, and articles made using additive manufacturing methods, are described herein. One embodiment is an article that comprises a hafnium-bearing superalloy. The superalloy includes at least about 50 weight percent nickel, from about 0.015 weight percent to about 0.06 weight percent carbon, and up to about 0.8 weight percent hafnium. The article further includes a plurality of primary carbide phase particulates disposed within the superalloy; the plurality has a median size less than about 1 micrometer. A method includes melting and solidifying particulates of a metal powder feedstock to build an intermediate article comprising a series of layers of solidified material. The feedstock includes the above-described superalloy composition. The method further includes heating the intermediate article to a temperature of at least about 950 degrees Celsius to form a processed article. The processed article further includes a plurality of primary carbide phase particulates disposed within the solidified material, the plurality of particulates having a median size less than about 1 micrometer.
Abstract:
Additive manufacturing methods, and articles made using additive manufacturing methods, are described herein. One embodiment is an article that comprises a hafnium-bearing superalloy. The superalloy includes at least about 50 weight percent nickel, from about 0.015 weight percent to about 0.06 weight percent carbon, and up to about 0.8 weight percent hafnium. The article further includes a plurality of primary carbide phase particulates disposed within the superalloy; the plurality has a median size less than about 1 micrometer. A method includes melting and solidifying particulates of a metal powder feedstock to build an intermediate article comprising a series of layers of solidified material. The feedstock includes the above-described superalloy composition. The method further includes heating the intermediate article to a temperature of at least about 950 degrees Celsius to form a processed article. The processed article further includes a plurality of primary carbide phase particulates disposed within the solidified material, the plurality of particulates having a median size less than about 1 micrometer.
Abstract:
An alloy and method of forming the alloy are provided. The alloy includes a matrix phase, and a population of particulate phases dispersed within the matrix. The matrix includes iron and chromium; and the population includes a first subpopulation of particulate phases and a second subpopulation of particulate phases. The first subpopulation of particulate phases include a complex oxide, having a median size less than about 20 mu, and present in the alloy in a concentration from about 0. 1 volume percent to about 5 volume percent. The second subpopulation of particulate phases have a median size in a range from about 30 nm to about 10 microns, and present in the alloy in a concentration from about 1 volume percent to about 15 volume percent.
Abstract:
An article, for example a turbomachinery article is presented. The article includes a weldable first component having a base portion and a flange portion. The flange portion is outwardly projecting normal to a surface of the base portion; and is joined with the base portion by a solid state joint. The base portion comprises a nanostructured ferritic alloy; and the flange portion comprises a steel substantially free of oxide nanofeatures. The first component is joined to a second component through the flange portion of the first component by a weld joint.
Abstract:
A system for mechanical milling and a method of mechanical milling are disclosed. The system includes a container, a feedstock, and milling media. The container encloses a processing volume. The feedstock and the milling media are disposed in the processing volume of the container. The feedstock includes metal or alloy powder and a ceramic compound. The feedstock is mechanically milled in the processing volume using metallic milling media that includes a surface portion that has a carbon content less than about 0.4 weight percent.