A method of forming an airfoil includes the steps of depositing material to form an airfoil in a first layer, and then depositing material in a second layer on the first layer. The first and second layers have distinct densities. An airfoil is also disclosed. The method provides powerful design advantages.

A method of forming an airfoil includes the steps of depositing material to form an airfoil in a first layer, and then depositing material in a second layer on the first layer. The first and second layers have distinct densities. An airfoil is also disclosed. The method provides powerful design advantages.

A gas turbine engine component may include a coating adapted to protect the component during use. The coating may be applied by sintering metallic particles to form a metallic matrix fused to the component.

A micro-nano composite powder dedicated for laser repair of tiny crack on stainless steel surface, includes 3 wt %-7 wt % of nano-WC, 0.5 wt %-2 wt % of nano-Al.sub.2O.sub.3, 0.2 wt %-0.8 wt % of micro-V powder and the balance of micro stainless steel powder. The stainless steel powder includes 0.08 wt % of C, 0.5 wt % of Si, 1.46 wt % of Mn, 0.03 wt % of P, 0.005 wt % of S, 19 wt % of Cr, 9.5 wt % of Ni, 0.5 wt % of Mo and the balance of Fe. The micro and nano powders are mixed through ball milling and mixed with anhydrous ethanol. The composite powder is suitable for laser repair of tiny crack on the surface of stainless steel part with high toughness requirement. After laser repair, the composite powder can be fused with the substrate, the repaired layer and the substrate are metallurgically bonded at the interface, the repaired layer contains fine grains, and therefore the compatibility and fracture property of the repaired layer are improved.

A cutting tool has a substrate of cemented carbide including WC and a binder phase. The cutting tool has a gradient surface zone with a thickness of between 50-400 μm having a binder phase gradient with the lowest binder phase content in the outermost part of the gradient surface zone and wherein the cutting tool also includes free graphite. The present disclosure also relates to a method of making a cutting tool according to the above. The cemented carbide body shows improved resistance towards chemical wear when used for machining non-ferrous alloys such as Ti-alloys and Ni-based alloys.

An article includes a substrate and a structure including direct metal laser melted material of predetermined thickness attached to the substrate, the structure formed by providing and depositing a metal alloy powder to form an initial layer having a preselected thickness and shape including at least one aperture, melting the metal alloy powder with a focused energy source, transforming the powder layer to a sheet of metal alloy, sequentially depositing an additional layer of the metal alloy powder over the sheet of metal alloy, the additional preselected shape including an aperture corresponding to the aperture in the initial layer, and melting each additional layer of the metal alloy powder with the focused energy source, increasing the thickness of the sheet and forming at least one aperture having a predetermined profile, the article further including a passageway through the structure including the aperture and a corresponding metering hole.

A method for manufacturing a planet gear or a sun gear of a gearbox of a wind turbine includes forming a base of the planet gear via at least one of casting or forging. The base of the planet gear includes an inner circumferential surface and an outer circumferential surface. Therefore, at least one of the inner circumferential surface or the outer circumferential surface of the planet gear includes a plurality of net or near-net gear teeth. The method also includes applying a coating material to at least a portion of the base of the gear and at least a portion of the plurality of gear teeth of the gear via an additive manufacturing process so as to increase a hardness of the portions of the base and the plurality of gear teeth that includes the coating material.

Provided are a refractory article, an anti-redox coating composition, and a method of manufacturing the refractory article. The refractory article includes: a platinum (Pt)-based substrate; and a coating layer for preventing a redox reaction on a surface of the Pt-based substrate, wherein the coating layer for preventing a redox reaction includes on an oxide basis SiO.sub.2 in an amount of about 40 wt % to about 70 wt %, Al.sub.2O.sub.3 in an amount of about 20 wt % to about 52 wt %, B.sub.2O.sub.3 in an amount of about 3 wt % to about 6 wt %; and CaO in an amount of about 2.4 wt % to about 4.8 wt %.

An atomizing spray device includes a housing having inlets that receive a first fluid and a slurry of ceramic particles and a second fluid. The inlets are fluidly coupled with outlets by an interior chamber that mixes the first fluid with the slurry to form a primary mixture of the first fluid and first atomized droplets of the slurry. A first outlet on a first side of the housing and a second outlet on the first side of the housing are shaped to change the primary mixture to form a secondary mixture of the first fluid and second atomized droplets of the slurry. The first outlet sprays the secondary mixture onto a first surface as a first layer of coating and the second outlet sprays the secondary mixture onto the first surface as a second layer of coating while the housing moves in a direction along the first surface.

An atomizing spray device includes a housing having inlets that receive a first fluid and a slurry of ceramic particles and a second fluid. The inlets are fluidly coupled with outlets by an interior chamber that mixes the first fluid with the slurry to form a primary mixture of the first fluid and first atomized droplets of the slurry. A first outlet on a first side of the housing and a second outlet on the first side of the housing are shaped to change the primary mixture to form a secondary mixture of the first fluid and second atomized droplets of the slurry. The first outlet sprays the secondary mixture onto a first surface as a first layer of coating and the second outlet sprays the secondary mixture onto the first surface as a second layer of coating while the housing moves in a direction along the first surface.