The present invention relates to a 3D-printed cobalt-based alloy product comprising carbon, tungsten and chromium with very good mechanical and thermal properties as well as a method of preparing the 3D-printed product and a powder alloy. The alloy has a high carbon content leading to high carbide content but small and evenly distributed carbides. A method facilitating 3D printing of high carbide content alloys such as the present alloy is also disclosed.

A method for additive manufacturing an object is disclosed. The method includes, for a first portion of the object to be built in a first overlapping field region of a plurality of melting beams of a metal powder AM system, sequentially forming each layer of the first portion by: forming only a border section of the first portion of the object using a first melting beam of the plurality of melting beams in the first overlapping field region; and forming an internal section of the first portion of the object within the border section using at least one second, different melting beam from the first melting beam in the first overlapping field region. An entirety of an internal edge of the border section of the first portion of the object is overlapped with an entirety of an external edge of the internal section of the first portion of the object.

The present invention provides a method of producing a modeled object by material extrusion using a 3D printer, the 3D printer including a modeling stage having a placement surface for placing the modeled object thereon, the method including: forming at least one first modeling layer on a surface of a modeling sheet disposed on the placement surface, using a molten product of a first modeling layer material; and forming at least one second modeling layer on the at least one first modeling layer, using a molten product of a second modeling layer material, wherein the first modeling layer material is different from the second modeling layer material.

A thin-skin side-stay beam may include an upper arm with thin skin and a mating flange extending longitudinally from the thin skin. A lower arm may also have a thin skin and a mating flange extending longitudinally from the lower arm. A joint may include a pin and/or a bushing extending through the mating flanges to pivotally couple the upper arm to the lower arm. The upper arm and/or the lower arm may include one or more internal walls defining one or more internal cavities.

This invention effectively suppresses the generation of scattered electrons such as secondary electrons and backscattered electrons. A three-dimensional laminating and shaping apparatus includes a linear funnel that recoats a material of a three-dimensional laminated and shaped object onto a shaping surface on which the three-dimensional laminated and shaped object is to be shaped. The three-dimensional laminating and shaping apparatus also includes an electron gun that generates an electron beam. The three-dimensional laminating and shaping apparatus further includes an anti-deposition cover made of a metal and formed between the shaping surface and the electron gun. In addition, the three-dimensional laminating and shaping apparatus includes a DC power supply that applies a positive voltage to the anti-deposition cover.

A method and an apparatus for collecting powder samples in real-time in powder bed fusion additive manufacturing may involves an ingester system for in-process collection and characterizations of powder samples. The collection may be performed periodically and uses the results of characterizations for adjustments in the powder bed fusion process. The ingester system of the present disclosure is capable of packaging powder samples collected in real-time into storage containers serving a multitude purposes of audit, process adjustments or actions.

A method of providing cooling structure for a component including forming a first cavity in the component and forming a first passageway in the first cavity in fluid communication with a second cavity positioned inside the component, the second cavity in fluid communication with a cooling air source. The method includes forming a unitary insert including a first surface, a second surface, the insert having an inlet formed in the first surface and an outlet formed in the second surface. A second passageway is in fluid communication with the inlet and the outlet. The method includes positioning the insert in the first cavity into fluid communication with the first passageway, the first surface facing the first cavity; and rigidly attaching the insert in the first cavity.

A method for forming a diffusion cooling hole in a substrate includes removing material from the substrate to form a metering section having an inlet on a first side of the substrate and removing material from the substrate to form a diffusing section that extends between the metering section and an outlet located on a second side of the substrate generally opposite the first side. The method also includes forming a feature on a substrate surface within one of the metering section and the diffusing section. Forming the feature includes depositing a material on the substrate surface and selectively heating the material to join the material with the substrate surface and form the feature.

System and method for welding a precipitation-hardened superalloy, e.g., Nickel-based superalloy, article to produce a weld joint, wherein one or more sections are defined longitudinally within the entire length of the weld joint to be produced, melting of superalloy material adjacent the weld joint to be produced in one of the one or more sections is subsequently performed, by directing a power beam towards the section and longitudinally oscillating the power beam within the section, an intensity of the power beam and a frequency of oscillation of the power beam are selected such that the superalloy material adjacent the weld joint to be produced are caused to become uniformly heated and melt thereby producing the weld joint from the consolidation of the superalloy material so melted, where the weld joint is thereafter solidified by gradually reducing the power beam intensity while oscillating longitudinally the power beam within the section.

This disclosure relates to a battery assembly for an electrified vehicle and a corresponding method. An exemplary battery assembly includes a battery cell including a terminal, a busbar, and at least one first weld bead securing the busbar to the terminal. The at least one first weld bead is substantially Z-shaped.