A computing device for controlling the operation of an additive manufacturing machine comprises a memory element and a processing element. The memory element is configured to store a three-dimensional model of a part to be manufactured, wherein the three-dimensional model defines a plurality of cross sections of the part. The processing element is in communication with the memory element. The processing element is configured to receive the three-dimensional model, determine a plurality of paths, each path including a plurality of parallel lines, determine a radiation beam power for each line, such that the radiation beam power varies non-linearly according to a length of the line, and determine a radiation beam scan speed for each line, such that the radiation beam scan speed is a function of a temperature of a material used to manufacture the part, the length of the line, and the radiation beam power for the line.

A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, the method comprising the steps of: providing a model of the at least one three dimensional article; applying a first powder layer on a first build platform and on a second build platform; directing a deflectable laser beam from a laser beam source arranged in a first position to cause the first powder layer to fuse in a first selected locations on the first build platform according to the model; at least one of rotating or tilting the laser beam source a predetermined angle to a second position; and directing the deflectable laser beam from the laser beam source in the second position to cause the first powder layer to fuse in a second selected locations on the second build platform according to the model.

A powder feeding device includes: a hopper including a discharge port for discharging powder; and a conveyance device configured to move a conveyance surface disposed below the discharge port in a first direction and invert the conveyance surface in a front end portion. The hopper includes a front wall portion positioned on a downstream side of the discharge port in the first direction. A predetermined gap is formed between a lower end of the front wall portion and the conveyance surface. In the powder feeding device, powder deposited on the conveyance surface is conveyed in the first direction by the conveyance device with a thickness corresponding to the gap and dropped from the front end portion.

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

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.

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved optical systems supporting beam combining, beam steering, and both patterned and unpatterned beam recycling and re-use are described.

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.

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

An aluminum alloy precursor composition and method for fusion processing is provided which reduces hot cracking, improves compositional control, reduces porosity, and/or enhances the mechanical properties of the fusion processed article. The precursor material and fusion process using the same may be utilized for forming an article that meets compositional specifications for aluminum 6061 alloy, while minimizing defects and meeting desired strength and ductility requirements. The fusion process may include a leading energy beam for liquefying the precursor material to form a melt pool, and a trailing energy beam directed toward a trailing region of the melt pool. The trailing energy beam may be configured to enhance agitation and/or redistribution of liquid in the melt pool to prevent hot cracking, reduce porosity, or improve other characteristics of the solidified part. The method also may improve processing parameters, such as adjusting vacuum level to prevent volatilization of alloying elements.

The present disclosure is directed at alloys and method for layer-by-layer deposition of metallic alloys on a substrate to produce a metallic part. Applications for the metallic parts include pumps, pump parts, valves, molds, bearings, cutting tools, filters or screens.