The present disclosure relates to new materials comprising Al, Co, Fe, and Ni. The new materials may realize a single phase field of a face-centered cubic (fcc) solid solution structure immediately below the solidus temperature of the material. The new materials may include at least one precipitate phase and have a solvus temperature of at least 1000° C. The new materials may include 4.4-11.4 wt. % Al, 4.9-42.2 wt. % Co, 4.6-28.9 wt. % Fe, and 44.1-86.1 wt. % Ni. In one embodiment, the precipitate is selected from the group consisting of the L1.sub.2 phase, the B2 phase, and combinations thereof. The new alloys may realize improved high temperature properties.

The present disclosure relates to new materials comprising Al, Ti, and Zr. The new materials may realize a single phase field of a hexagonal close-packed (hcp) solid solution structure immediately below the solidus temperature of the material. The new materials may include at least one precipitate phase and have a solvus temperature of at least 1240° C. The new materials may include 29.0-42.4 wt. % Al, 41.2-59.9 wt. % Ti, and 10.3-24.1 wt. % Zr. In one embodiment, the precipitate is selected from the group consisting of the L1.sub.0 phase, the Al.sub.2Zr phase, and combinations thereof. The new alloys may realize improved high temperature properties.

To provide a turbine rotor which enables mass production with a low-cost apparatus and which capable of suppressing leaning of the rotor shaft after welding to improve the yield, while a turbine blade rotor 12 and the rotor shaft 14 are fit to each other with concave and convex portions 12a and 14a and are permitted to be rotated, laser beam L from a laser beam generating device 30 is applied to a joint face 16 along the circumferential direction to weld the welding portion. Then, laser beam L is polarized to temper a region X on the rotor shaft side containing the welding portion with laser beam L. In contrast to residual stress R.sub.1 having a local angular distribution generated during the welding, residual stress R.sub.2 is permitted to be generated over the entire circumference by tempering. Leaning of the rotor shaft 14 after cooling is thereby be suppressed.

A material joining end effector generally includes a first arm, an optics assembly, a clamp, and a second arm. The first arm elongated along a longitudinal axis. The optics assembly is configured to focus an energy beam. The clamp is movably coupled to the first arm, the clamp being configured to move along a direction substantially parallel to the longitudinal axis. The second arm is rotationally coupled to the first arm, the second arm being configured to rotate relative to the first arm. The clamp is configured to removably couple the optics assembly to the first arm to allow the optics assembly to be decoupled from the first arm.

A method for processing a powder material includes cleaning surfaces of a powder material that has spherical metal particles, coating the cleaned surfaces with an organic bonding agent, mixing the coated particles with a dispersion that contains ceramic nanoparticles, drying the mixture to remove a carrier of the dispersion and deposit the ceramic nanoparticles with a spaced-apart distribution onto the organic bonding agent on the surfaces of the particles, and thermally removing the organic bonding agent to attach the ceramic nanoparticles to the surface of the particles.

A rotor for use in an aircraft engine, that has been repaired by (a) welding together a first portion of a damaged blade of the rotor and a second portion of metal to form a weld nugget, (b) compressively stressing the weld nugget throughout its volume, and (c) heat treating the compressively stressed weld nugget to recrystallize metal therein.

A method is provided for producing a three-dimensional object that includes an external skin, a 3D mesh enclosed in the skin and having a portion that penetrates at least a part of a thickness of the skin, and an unmelted portion enclosed in the skin. The object is formed from superposed layers each including an outer edge and an inner mesh, with the superposed outer edges forming the skin, and with the superposed inner meshes forming the 3D mesh. Each superposed layer is formed by scanning a powder layer using an energy beam to form micro-connections between grains of the powder without melting the metal powder. First and second melting and solidifying steps are performed using the energy beam to form the outer edge in one of the first and second steps and the inner mesh in the other of the first and second steps.

A method of controlling operation of an electron beam gun and wire feeder during deposition of pools of molten matter onto a substrate to form beads upon solidification of the molten matter. The method includes providing a substrate and a wire source. A molten pool of liquid phase metal is formed on the substrate by melting the wire utilizing an electron beam generated by an electron beam gun. The liquid metal solidifies into a solid phase. A controller utilizes data from a sensor to adjust a process perimeter based, at least in part, on data generated by the sensor.

A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes a build unit and a machining mechanism that are attached to a positioning mechanism, a rotating platform, and a rotary encoder attached to the rotating platform. The method involves rotating the build platform; determining the rotational speed; growing the object and the build wall through repetitive cycles of moving the build unit(s) over and substantially parallel to multiple build areas within the build platform to deposit a layer of powder at each build area, leveling the powder, and irradiating the powder to form a fused additive layer at each build area; machining the object being manufactured; and cutting and removing the build wall. The irradiation parameters are calibrated based on the determined rotational speed.

A method of forming a medical device lead connection element is described. The method includes positioning an end portion of a lead filar to overlap a lead end connection element such that the positioning creates mutual interference between the lead filar and the lead end connection element, and forming an interference configuration. Then melting the end portion of the lead filar to form a weld joint and allowint the end portion of the lead filar to move towards the end connection element.