The present invention relates to a method and a tool for removing a partial region of a coating from a substrate, in which the partial region to be removed is removed by a machining process in such a way that an undercutting of the partial region of the coating that is to be removed takes place. For the undercutting of the partial region of the coating that is to be removed, at least one machining tool that is rotating relative to the substrate about an axis of rotation is moved relative to the substrate along a direction of advancement that runs parallel to a surface having the coating, wherein a layer of the substrate that is directly adjacent to the coating is also removed together with the coating. Considered in the direction of advancement, the tool thereby penetrates deeper into the substrate than into the coating to be removed.

Various embodiments include a gas turbine seal and methods of forming such seal. The method of forming the seal includes forming a freestanding ceramic seal for sealing in a gas turbine by applying a ceramic material on a substrate to form a ceramic layer, removing the substrate from the ceramic layer and finishing the ceramic layer to define the freestanding ceramic seal. The method includes depositing particles of the ceramic material in one of a molten or vapor state on a surface of the substrate and quenching the ceramic material to form the ceramic layer. The ceramic material comprises yttria-stabilized zirconia having a t tetragonal structure. A gas turbine including the freestanding ceramic seal is additionally disclosed.

Disclosed is a multiple-feature compact direct-metal deposition additive manufacturing (AM) print head. The head configures off-axis, solid-state diode or diode-pumped lasers into an array to perform precision controlled, direct metal deposition printing through a single print nozzle. Dual-mode printing capability using metal wire and powder feedstock sources in the same print nozzle is provided with in-line control, precision wire feed driver/controller, adjustable shield gas diffuser, and nozzles tailored to wire feedstock diameter.

Apparatus and methods are described for performing additive manufacturing. The apparatus includes a vacuum chamber for fabricating a workpiece composed of deposited metal, a table positioned within the vacuum chamber, and configured to support fabrication of the workpiece on a substrate, and one or more multiple droplet emitters coupled to the vacuum chamber, and arranged to irradiate the workpiece with a stream of molten metal droplets during fabrication.

A method of fabricating a component having active cooling with film holes and other exposed holes is provided. The method includes the step of providing a component including at least one aperture disposed on a surface of the component and fluidly connected to at least one fluid flow passage, the at least one aperture comprising a floor extending from the at least one fluid flow passage to the surface of the component, and a ceiling facing the floor. The method further includes the step of applying a thermal barrier coating over at least a portion of a substrate. The method further includes the step of removing a portion of the thermal barrier coating covering the at least one aperture. The method further includes the step of forming with an additive manufacturing method one or both of a sharp-edged hood of the at least one aperture and at least one feature disposed on the floor.

Systems, apparatus, and method for manufacturing are disclosed. In an aspect, the apparatus may be a cold-spray nozzle. The cold-spray nozzle may include a variable diameter convergent part. The cold-spray nozzle may also include a variable diameter divergent part. The variable diameter divergent part may form a diffuser. Additionally, The cold-spray nozzle may include a ring portion. The ring portion may couple the variable diameter convergent part and the variable diameter divergent part. Additionally, the ring portion may control the opening to the diffuser.

An yttrium-base sprayed coating is obtained by thermally spraying yttrium oxide, yttrium fluoride or yttrium oxyfluoride onto a substrate to form a coating of 10-500 m thick, and chemically cleaning the coating with a cleaning liquid of organic acid, inorganic acid or a mixture thereof until the population of particles with a size of up to 300 nm becomes no more than 5 particles/mm.sup.2 of the coating surface. The yttrium-base sprayed coating exhibits high corrosion resistance even in a halogen gas plasma atmosphere and prevents yttrium-base particles from spalling off during etching treatment.

The invention relates to a method for producing a composite material component, comprising the following steps: providing a negative mold, fine machining of the negative mold, applying at least one functional layer by means of thermal spraying to the negative mold, applying at least one fiber-reinforced plastic layer with a curable matrix material, curing the matrix material, and detaching the composite material component from the negative mold.

A method and an apparatus for manufacturing a metallic article involve providing a non-metallic feedstock, for example in the form of an oxide of a desired metal or a mixture of oxides of the components of a desired metal alloy. A manufacturing apparatus has a reduction apparatus for electrochemically reducing the feedstock to a metallic product and a processor for converting the metallic product to a metallic powder. The powder is fed into an additive-manufacturing apparatus for fabricating the metallic article from the metallic powder. At least the reduction apparatus and the processor, and preferably also the additive-manufacturing apparatus, are collocated, or located in the same container, or in the same building, or on the same site.

A method for forming a metallic structure having a non-linear aperture includes providing a main tool having a formation surface corresponding to a desired structure shape of the metallic structure. The method also includes attaching a removable tool having a shape corresponding to a desired aperture shape of the non-linear aperture to the main tool. The method also includes depositing a layer of material on the formation surface using a cold-spray technique. The method also includes removing the removable tool from the layer of material such that the layer of material defines the non-linear aperture.