In some cases, an additive manufacturing (AM) system includes: a process chamber for additively manufacturing a component, the process chamber having: a build platform; at least one melting beam scanner configured to emit a melting beam for melting powder on the build platform; an applicator for applying layers of powder to the build platform; and a reservoir for storing powder; and a control system coupled with the set of melting beam scanners, the control system configured to: apply the melting beam to a layer of powder on the build platform along a primary melting path; and apply the melting beam to the layer of powder on the build platform along a re-melting path after applying the melting beam along the primary melting path, the re-melting path overlapping a portion of the primary melting path and applied only in an area proximate a perimeter of the component.

A variable vane having an airfoil, an inner trunnion shaft and an outer trunnion shaft, with the outer trunnion shaft having a threaded hole and a groove extending around a circumference of the outer trunnion shaft is repaired by removing a portion of the outer trunnion shaft leaving a shaft stub. A repair detail is prepared having an outer peripheral shaft portion with a nominal outer diameter. The repair detail further has a pilot portion extending forwardly and having a smaller outer diameter than an outer diameter of the nominal outer diameter. The shaft stub has a remaining bore portion, which is a portion of the threaded hole. The pilot portion is sized to be received within the remaining bore portion. The pilot is inserted into the remaining bore portion. The repair detail is welded to the shaft stub. A repaired variable vane is also disclosed.

Provided is a method of manufacturing an outer joint member of a constant velocity universal joint, which is constructed by welding a cup member and a shaft member, the method including: forming the cup member and the shaft member of medium carbon steel; preparing; preparing; bringing the joining end surface of the cup member and the joining end surface of the shaft member into abutment against each other; welding the cup member and the shaft member; and performing, after the welding, ultrasonic flaw detection-inspection from any one of a surface side of the cup member and a surface side of the shaft member, which has the another one of the joining end surface of the cup member and the joining end surface of the shaft member.

Provided is a method of manufacturing an outer joint member of a constant velocity universal joint, which is constructed by welding a cup member and a shaft member, the method including: forming the cup member and the shaft member of medium carbon steel; preparing; preparing; bringing the joining end surface of the cup member and the joining end surface of the shaft member into abutment against each other; welding the cup member and the shaft member; and performing, after the welding, ultrasonic flaw detection-inspection from any one of a surface side of the cup member and a surface side of the shaft member, which has the another one of the joining end surface of the cup member and the joining end surface of the shaft member.

A heat pipe and a sealing method thereof; the sealing method for a heat pipe includes the steps of: providing a metal pipe member, the metal pipe member including one end having a sealed end portion formed thereon and another end thereof having a narrowing neck section extended therefrom. The narrowing neck section includes a channel. A compression mold compresses the narrowing neck section and moves away from the metal pipe member in order to compress and elongate the narrowing neck section into a compression elongated column and to seal the channel. Finally, spot welding process is performed on the compression elongated column to form a sealed block thereon. The present invention is of the merits of improved work efficiency for heat pipe bending, compression and testing and increased length of the metal pipe member with enhanced thermal transfer performance of the heat pipe.

A method for improving the surface of an aluminum alloy article includes manufacturing the aluminum alloy article using an additive manufacturing technique, wherein the article as-manufactured includes one or more of cracks, roughness, or porosity at a surface of the article; coating the surface of the aluminum alloy article with a diffusion element, the diffusion element being capable of diffusing at least 0.2 mils into the article; heating the aluminum alloy article coated with the diffusion element to cause the diffusion element to diffuse the at least 0.2 mils into the article, thereby forming a diffusion layer of at least 0.2 mils in thickness comprising both aluminum alloy and diffusion element; and removing the diffusion layer from the aluminum alloy article, whereby upon the removing, a resulting improved surface of the article comprises fewer or smaller cracks, reduced roughness, or reduced porosity.

Methods and systems are provided for using optical interferometry in the context of material modification processes such as surgical laser, sintering, and welding applications. An imaging optical source that produces imaging light. A feedback controller controls at least one processing parameter of the material modification process based on an interferometry output generated using the imaging light. A method of processing interferograms is provided based on homodyne filtering. A method of generating a record of a material modification process using an interferometry output is provided.

A method for additively manufacturing a component is provided. The method may include forming a surface on the top layer of the component, scanning the surface of the top layer of the component to determine if a defect is present in the surface, and if detected, correcting the defect within the surface. Scanning the surface of the top layer of the component to determine if a defect is present in the surface may be performed by obtaining data indicative of the surface of the top layer of the component by interrogating the surface of the top layer of the component with a scanning device, and comparing the data with a reference database to determine if an irregularity is present.

Provided are a systems and methods for continuously providing a metal wire to a welding torch in the correct orientation with respect to the heat source of the welding torch for manufacturing objects by solid freeform fabrication to provide continuous deposition of metal to the freeform object, especially objects made with titanium or titanium alloy, or nickel or nickel alloy, wire.

In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material.