A method of producing a freestanding ceramic tile. The method involves: grit-blasting a substrate using a grit size in the range from 36 to 220 mesh; depositing a release layer of carbon or graphite from 2 to 10 microns thick on the grit-blasted surface of the substrate; applying ceramic over the release layer until a desired thickness of ceramic is achieved to form a ceramic layer; heating the substrate, release layer, and ceramic layer to a temperature of from 800 to 1000 degrees Celsius; keeping the substrate, release layer, and ceramic layer at a temperature from 800 to 1000 degrees Celsius for a time from 10 to 20 minutes to remove the release layer; and cooling the substrate and ceramic layer at a rate of at least 200 degrees Celsius per minute, such that the ceramic layer separates from the substrate to produce a freestanding ceramic tile.

A method making a gun barrel liner includes depositing material on a mandrel that has ribs or ridges corresponding to the rifling grooves in the liner. The material may be deposited using plasma spraying, with sprayed splats of material re-melted after deposition for at least part of the deposition process to reduce or eliminate porosity in the deposited material. The mandrel may be made of metal, such as a high thermal conductivity metal such as copper. The mandrel may have a channel therein or therethrough. The channel may facilitate flow of liquid though the mandrel, one example of such a liquid being a coolant (such as water), used to remove heat produced during the material deposition. Another liquid passed through the channel may be an etchant (or other fluid) that is used to dissolve or otherwise remove the mandrel after the material of the gun barrel liner has been deposited.

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.

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.

The invention relates to a method for producing a thermally sprayed, thin-walled cylinder liner for insertion into a cylinder crankcase and to a cylinder liner produced with said method.

A method for forming a reinforced metallic structure includes providing a tool having a formation surface corresponding to a desired structure shape of the reinforced metallic structure. The method also includes positioning a plurality of fibers on the formation surface of the tool. The method also includes depositing a layer of material on the plurality of fibers using a cold-spray technique. The method also includes removing the layer of material with the plurality of fibers from the tool to create the reinforced metallic structure.

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.

Implementations of the present disclosure relate to a method of refurbishing a sinter or plasma sprayed electrostatic chuck. Initially, a portion of a used electrostatic chuck body is removed to expose a base surface. Then, a layer of new dielectric material is deposited onto the base surface using a suspension slurry plasma spray process. The suspension slurry plasma spray process atomizes a suspension slurry of a nano-sized dielectric material into a stream of droplets, and then the stream of droplets is injected into a plasma discharge to form partially melted drops. The partially melted drops is projected onto the base surface to form a layer of dielectric material thereon. Thereafter, material of the layer of the new dielectric material is selectively removed to form mesas. The refurbished electrostatic chuck is ready to return to service after cleaning.

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.

Systems and methods in accordance with embodiments of the invention fabricate objects including amorphous metals using techniques akin to additive manufacturing. In one embodiment, a method of fabricating an object that includes an amorphous metal includes: applying a first layer of molten metallic alloy to a surface; cooling the first layer of molten metallic alloy such that it solidifies and thereby forms a first layer including amorphous metal; subsequently applying at least one layer of molten metallic alloy onto a layer including amorphous metal; cooling each subsequently applied layer of molten metallic alloy such that it solidifies and thereby forms a layer including amorphous metal prior to the application of any adjacent layer of molten metallic alloy; where the aggregate of the solidified layers including amorphous metal forms a desired shape in the object to be fabricated; and removing at least the first layer including amorphous metal from the surface.