Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. Cold spraying results in an increased thickness of the finished workpiece in a target region, which can provide structural reinforcement, and which can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or another material.

Methods of forming a desired geometry at a location on a superalloy part are disclosed. The method may include directing particles of a powder mixture including a low melt temperature superalloy powder and a high melt temperature superalloy powder to the location on the superalloy part at a velocity sufficient to cause the superalloy powders to deform and to form a mechanical bond but not a metallurgical bond to the superalloy part. The directing of particles continues until the desired geometry is formed. Heat is applied to the powder mixture on the repair location. The heat causes the low melt temperature superalloy powder to melt, creating the metallurgical bonding at the location. Another method uses the same directing to form a preform for repairing the location on the part. The low melt temperature superalloy powder melts at less than 1287° C., and the high melt temperature superalloy powder melts at greater than 1287° C.

The invention relates to a brake disk (3), which has at least one thermal conduction layer (4, 6) with a thermal conductivity and specific thermal resistivity that can be graduated, the thermal conduction layer consisting of at least two different materials or of a varying layer thickness, thereby graduating the thermal conductivity or the thermal resistivity within the thermal conduction layer.

In a method for producing a brake disc, a friction surface layer is sprayed onto the base body or onto an intermediate layer applied on the base body by cold gas spraying a particle mixture which consists 25 to 75% by weight of a metal matrix material and 75 to 25% by weight of a carbide material. The metal matrix material consists of an iron-based alloy, nickel-based alloy, titanium or titanium alloy. The carbide material consists of tungsten carbide, titanium carbide, iron carbide, silicon carbide, chromium carbide or niobium carbide.

A bearing component such as a bearing ring includes a metallic base body and at least one alloy steel coating on the base body, the coating being applied to the base body by deposition welding. The base body is preferably non-alloy steel or cast iron, and the alloy includes at least one carbide-forming transition metal such as niobium, tantalum, zirconium, titanium, hafnium, tungsten, molybdenum, vanadium, or manganese. The coating can form a raceway of the bearing component or a structural element such as a flange. Also a method of forming such a bearing component is provided.

Disclosed is an additive manufacturing process for making shingles and roof tiles. The entire shingle, including the substrate, can be manufactured on location, or a substrate can be manufactured at a manufacturing plant and then colored and textured on location to provide a wide variety of shapes and colors of shingles and roof tiles. Costs for inventory and shipping are reduced and a greater variety of shapes and colors can be provided for the shingles and roof tiles. The additive manufacturing equipment can be mounted on a truck so that the additive manufacturing techniques can be a mobile application of the additive manufacturing technology.

The invention relates to a laser metal deposition system, which comprises a feed nozzle (301), the tubular wall (306) of which has external fins (305) designed to allow heat dissipation by heat exchange with the immediate surroundings of the feed nozzle (301).

Apparatus and methods for making metal-connected particle articles. A metal containing fluid is selectively applied to a layer of particles. The metal in the fluid is used to form metal connections between particles. The metal connections are formed at temperatures below the sintering temperature of the particles in the layer of particles.

A tool coating processing method, comprising a molten pool forming step: converging a bonding phase (1) to a plasma arc heat source by means of a coaxial powder feeding channel, the bonding phase (1) being deposited on a tool base material after melting, so as to form a molten pool; and a reinforcing phase (2) adding step: feeding a reinforcing phase (2) by means of a side powder feeding channel into the molten pool after a plasma beam is removed, cladding the bonding phase (1) and the reinforcing phase (2) under the condition of ultrasonic vibration, and forming a coating on the surface of a tool. The processing method solves the feeding problem, the burning problem and the problem of uneven distribution in a coating of hard phase particles in a processing process of a tool coating, improves the hardness, corrosion resistance and wear resistance of the tool coating, and finally improves the service life of the tool.

Disclosed herein are embodiments of a powder feedstock, such as for bulk welding, which can produce welds. The powder feedstock can include high levels of boron, and may be improved over previously used cored wires. Coatings can be formed from the powder feedstock which may have high hardness in certain embodiments, and low mass loss under ASTM standards.