This invention quickly supplies a predetermined amount of powder from a hopper to a recoater. A powder supply apparatus includes, as its feature, a hopper, a powder spreader, a powder replenisher, and a pivoting unit. The hopper of the powder supply apparatus stores a powder. The powder spreader spreads the powder on a shaping surface. The powder replenisher of the powder supply apparatus is provided between the hopper and the powder spreader, and replenishes the powder spreader with a predetermined amount of powder. The pivoting unit of the powder supply apparatus causes the powder replenisher to pivot.

A method for additively manufacturing an article includes providing or obtaining a build material, directing a first energy beam at the build material to raise the temperature of the build material above a melting point of the build material, and thereafter withdrawing the first energy beam to allow the build material to solidify into a first layer. The method further includes directing a second energy beam at the first layer, wherein the second energy beam differs from the first energy beam in that the second energy beam is of insufficient energy to cause melting of the first layer of build material and after directing the second energy beam at the first layer, providing additional build material over the first layer. The second energy beam will have an effect of reducing or eliminating residual stresses of each build layer. The energy of the second energy beam can be controlled using a thermal or optical feedback loop. Still further, the method includes directing a third energy beam at the additional build material to form a second layer that is metallurgically fused with the first layer. The process is repeated until an entire 3D shape of desired geometry is completed resulting in a part with reduced of free of residual stress or the potential of cracks within the 3D shape.

A method for manufacturing a three-dimensional part. The method includes: performing partial densification processing on loose machining powder, to form a densified and sealed enclosure, where there is still loose machining powder accommodated inside the enclosure; and performing overall densification processing on the enclosure and the machining powder inside the enclosure, so as to implement metallurgical bonding between the machining powder inside the enclosure and the enclosure during the densification, thereby forming a target three-dimensional part.

An AM continuous welding system (AMCWS) is provided. The AMCWS includes a feedstock dispenser that configured to emit feedstock at a designated location, and a heat source configured to heat the feedstock. The AMCWS also includes a first eddy current sensor array that is configured to generate a first plurality of sensor signals while in current-sensing proximity of a re-solidified feedstock segment. A controller is coupled to the first eddy current sensor array and is configured to determine, based on the first plurality of sensor signals, a first characteristic of the re-solidified feedstock segment. The controller determines that the first characteristic is a first undesirable characteristic, and initiates an action based on the first undesirable characteristic.

This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensing system that monitors two discrete wavelengths associated with a blackbody radiation curve of the layer of powder; determining temperature variations for an area of the build plane traversed by the scans based upon a ratio of sensor readings taken at the two discrete wavelengths; determining that the temperature variations are outside a threshold range of values; and thereafter, adjusting subsequent scans of the energy source across or proximate the area of the build plane.

A method of additively manufacturing an article includes forming a first portion of the article by three-dimensional printing of a plurality of first layers from a first powder material cut having a first average particle size corresponding to a first feature resolution. The first layers have a first average layer thickness. The method also includes forming a second portion of the article by three-dimensional printing of a plurality of second layers from a second powder material cut having a second average particle size corresponding to a second feature resolution less than the first feature resolution. The second portion includes at least one feature. The second layers have a second average layer thickness less than the first average layer thickness. A three-dimensional printing system and an article formed from a powder material by three-dimensional printing are also disclosed.

An electricity storage device includes an electricity storage element that is constituted by an electrode body in a positive side and an electrode body in a negative side that face each other while holding a separator; a sealing member that seals a case member accommodating the electricity storage element; at least one electrode protrusion that is either of the electrode bodies, which protrudes from an element end-face of the electricity storage element, at least one current collector plate that is connected to the electrode protrusion; and a terminal member that is installed in the sealing member, a lateral face of the terminal member being connected to a lateral face of the current collector plate.

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 airfoiled component comprises: a root section, an airfoil section, a damper pocket enclosed within a portion of the airfoil section, and a damper. The airfoil section includes a suction sidewall and a pressure sidewall each extending chordwise between a leading edge and a trailing edge, and extending spanwise between the root section and an airfoil tip. The damper includes a fixed end unified with a damper mounting surface, and a free end extending into the damper pocket from the damper mounting surface.

The present invention relates to a methods, computer program products, program elements, and apparatuses for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article. The method comprising the steps of providing at least one electron beam source emitting an electron beam for at least one of heating or fusing the powder material, where the electron beam source comprises a cathode and an anode, and varying an accelerator voltage between the cathode and the anode between at least a first and second predetermined value during the forming of the three-dimensional article.