Systems and methods for the manufacture of a solid wire using additive manufacturing techniques are disclosed. In one embodiment, a fine powdery material is sintered or melted or soldered or metallurgically bonded onto a metal strip substrate in a compacted solid form or a near-net shape (e.g., a near-net solid wire shape) before being turned into a final product through forming or drawing dies.

A method for producing a component structure of two components includes subjecting the components to beam energy for melting in a contact region. A variation of beam current is set to melt the components in the contact region over a defined component depth less than the perpendicular distance between sides of the contact region. A defined beam current pulse is periodically imparted to the variation of the beam current, to melt the components at least approximately over the entire perpendicular distance between the sides of the contact region and to produce in the region of the second side weld regions of a weld root of the weld connecting the components projecting from the contact region and form a pattern which representative of a weld quality. Between the weld regions there is no melting of the components in the region between the defined component depth and the second side.

This disclosure provides systems, methods and apparatus systems and methods described herein provide, among other things, a system for additive manufacturing of metal objects. The system includes two electron beams. In one optional implementation, one beam is high powered and acts as a deposition beam that melts a metal feed stock material which is delivered to a deposition zone and onto a work surface and the second electron beam is a low power electron source. The second electron beam acts as an interrogating source that generates an electron beam which interacts with the deposited material. The second electron beam may be active after material is deposited and provides post-deposition in-situ metrology. Various signals generated by this second beam/material interaction are collected and used to provide information about the melted and deposited material.

A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.

An additive manufacturing device manufactures an additively manufactured article by preheating a powder material by irradiating the powder material with a charged particle beam and then melting the powder material by irradiating the powder material with the charged particle beam. The additive manufacturing device includes a beam emitting unit emitting the charged particle beam and irradiating the powder material with the charged particle beam, and a position detection unit detecting a position of scattering of the powder material when the powder material scatters by being irradiated with the charged particle beam. When the powder material scatters by being irradiated with the charged particle beam, the beam emitting unit emits the charged particle beam such that a thermal dose of the preheating is increased at the position of scattering.

There is provided a tool blade comprising a backing strip, binding material forming a binder layer, with discrete regions of binder layer formed as teeth along an edge of the backing strip, and abrasive particles bound to the backing strip by the binder layer, wherein each tooth is formed with a ductile region bonded to the backing strip, a crown and an intermediate region of thermal material disposed between the ductile region and the crown so as to absorb thermal expansion and contraction. The binding material powder is heated by laser beam to form a binder layer which binds the abrasive particles to the backing strip. The laser beam is used to form discrete regions of binder layer as teeth. The binding material is typically braze material.

In one aspect, a method of making a sintered article comprises providing a composite article comprising a porous exterior printed from a powder composition via one or more additive manufacturing techniques, the porous exterior defining an interior volume and providing a loose powder component in the interior volume. The porous exterior and loose powder component are simultaneously sintered to provide the sintered article comprising a sintered interior and sintered exterior.

A component includes an additively manufactured component with an internal passage and an additively manufactured elongated member within the internal passage. A method of additively manufacturing a component including additively manufacturing a component with an internal passage; and additively manufacturing an elongated member within the internal passage concurrent with additively manufacturing the component.

In manufacturing method of shunt resistor according to the present invention, at least one of first and second conductors that is thicker than a resistance alloy plate member includes a joining surface abutted to the resistance alloy plate member with their edges on one side in a plate-thickness direction being aligned with each other, a first inclined surface that is gradually located on one side in the plate-thickness direction from the joining surface toward the side opposite to the resistance alloy plate member in the plate-surface direction, and a first plate surface extending to the side opposite to the resistance alloy plate member in the plate-surface direction from the first inclined surface. Electron beams or laser is emitted to the joining surfaces of the conductor having the larger thickness and the resistance alloy plate member from one side in the plate-thickness direction to weld the joining surfaces.

In manufacturing method of shunt resistor according to the present invention, at least one of first and second conductors that is thicker than a resistance alloy plate member includes a joining surface abutted to the resistance alloy plate member with their edges on one side in a plate-thickness direction being aligned with each other, a first inclined surface that is gradually located on one side in the plate-thickness direction from the joining surface toward the side opposite to the resistance alloy plate member in the plate-surface direction, and a first plate surface extending to the side opposite to the resistance alloy plate member in the plate-surface direction from the first inclined surface. Electron beams or laser is emitted to the joining surfaces of the conductor having the larger thickness and the resistance alloy plate member from one side in the plate-thickness direction to weld the joining surfaces.