An airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member including an upper skin; a lower skin; and a support network having a plurality of interconnected support members in a lattice arrangement and/or a reticulated arrangement, the support network being configured to provide tailored characteristics of the airfoil member. Also provided are methods and systems for repairing an airfoil member.

A magnetic domain refining treatment is performed by dividing a surface of a steel sheet into a plurality of regions in a widthwise direction, disposing a laser irradiation apparatus or an electron beam irradiation apparatus in each of the regions, and forming beam-irradiated regions through beam irradiation, wherein beams are irradiated so that a nature of a juncture between beam-irradiated regions satisfies 00.3a and 1.2a+0.02w0.56.50.13a200(1/w)+5.4 when TD spacing at the juncture between the beam-irradiated regions is 3 to 0 mm, whereby a grain oriented electrical steel sheet having an excellent iron loss property is produced in a good productivity.

A heat exchanger includes a core comprising a single piece continuous boundary having a first surface defining a first labyrinth, and an opposing second surface defining a second labyrinth; a first inlet manifold connected to the first labyrinth and configured to supply a first fluid to the first labyrinth; and a second inlet manifold connected to the second labyrinth and configured to supply a second fluid to the second labyrinth; wherein the core comprises a plurality of identical three dimensional unit cell structures replicated in three orthogonal spatial dimensions.

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.

Method and system for manufacturing of three dimensional objects comprising of base substrate (18) placed on the supporting plate (30), electron beam gun (2), feed means (17) for feeding of feedstock material to melting zone, positioning system (31, 36) for positioning of said supporting plate (30) with base substrate (18), vacuum tight operating chamber (29), wherein an energy source for generating of molten pool on the substrate and for melting of feedstock material in said system is gas-discharge electron beam gun (2) with cold circular cathode (8) placed between two circular anodic electrodes placed coaxially to said cathode (8) which generates electron beam (9) in the shape of hollow inverted cone, and feedstock guide (17) is placed along the axis of said of said electron beam gun (2), and said gas-discharge electron beam gun (2) and said feedstock guide (17) are combined in one functional assembly.

An additive manufacturing system includes an ultrasonic inspection system integrated in such a way as to minimize time needed for an inspection process. The inspection system may have an ultrasonic phased array integrated into a build table for detecting defects in each successive slice of a workpiece and such that each slice may be re-melted if and when defects are detected.

Aspects of the present disclosure relate generally to preparing models of three-dimensional structures. In particular, a model of a three-dimensional structure constructed of porous geometries is prepared. A component file including a porous CAD volume having a boundary is prepared. A space including the porous CAD volume is populated with unit cells. The unit cells are populated with porous geometries having a plurality of struts having nodes on each end. The space is populated with at least one elongated fixation element extending beyond the boundary to produce an interlocking feature enabling assembly or engagement with a mating structure.

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 component includes a body, and an interface in the body defining a first and second portion of the body made by different melting beam sources of a multiple melting beam source additive manufacturing system during a single build. The component also includes a channel extending through the body. The channel includes an interface-distant area on opposing sides of the interface, each interface-distant area having a first width. The channel also includes an enlarged width area fluidly communicative with the interface-distant areas and spanning the interface, the enlarged width area having a second width larger than the first width. Any misalignment of the melting beams at the interface is addressed by the enlarged width area, eliminating the problem of reduced cooling fluid flow in the channel.

A method and system are provided for mapping a melt pattern of material created during directed energy fabrication. An infrared camera and a video camera are provided to record images of the pattern of melted material. Each frame of the infrared camera's images is processed to generate a first map of pixels identifying pixels indicative of a highest temperature greater than or equal to a liquidus temperature of the meltable material. Each frame of the video camera's images is processed to generate a second map of pixels identifying pixels indicative of a highest temperature greater than or equal to the liquidus temperature of the meltable material. The first map of pixels and said second map of pixels are overlaid on each other wherein a third map of pixels is generated and is indicative of a hybrid image of the pattern of melted material.