The disclosure relates to a method for forming a metal article by additive manufacturing and related apparatus for performing the method. A metal particle suspension including a UV-curable polymeric resin liquid medium, and metal particles distributed throughout the liquid medium is deposited and cured by spatially selective exposure to UV radiation in a layer-by-layer process. Metal particle size can be selected in combination with the applied layer thickness to ensure complete cure throughout the applied layer while providing a high print speed and high spatial resolution. Intermittent or periodic partial curing of an applied layer can be used to maintain a homogeneous distribution of metal particles in the applied layer prior to full curing. The final product is achieved after sintering, which removes the cured binder in a debinding step and also provides the desired final article at close to the full density.

A turbine engine has: a compressor; a combustor; a turbine, a gas flowpath passing consecutively through the compressor, combustor, and turbine; and inlet member along the gas flowpath upstream of the compressor. The inlet member includes the unitarily-formed single piece combination of: a three dimensional (3D) lattice portion; and a nose cap body surrounding the lattice portion.

A capsule 2 for HIPing comprises a rigid, self-supporting additive manufactured (AM) component 3 which is welded to inner and outer cylindrical liners 4, 6 through which cooling channel tubes 8, 10 extend. A solid end plate 11 is welded to ends of the liners 4, 6 and tubes 8, 10 extend through the end plate 11 and open to the outside. A fill tube 12 communicates with an annular void 14 defined between liners 4, 6 which is filled with powder 16. In use, the capsule 2 is subjected to Hot Isostatic Pressing (HIP). Thereafter, the inner and outer liners 4, 6 are removed to define a valve seat assembly comprising the AM component 3, tubes 8, 10, HIPed powder 16 and end plate 11.

A method for forming a metallic structure having a secondary component includes positioning the secondary component on a main formation surface of a main tool, the main formation surface corresponding to a desired shape of a first layer of material. The method also includes depositing a layer of material on the secondary component and the main formation surface using a cold-spray technique such that the layer of material bonds to the secondary component. The method also includes removing the layer of material and the secondary component to form the metallic structure.

A rotor shroud for a rotary machine in a cabin air compressor includes a disk portion centered on a central axis of the rotor shroud, a frustoconical portion extending from the disk portion, a flared portion extending from the frustoconical portion, and a variable lattice structure in an interior of the rotor shroud. The variable lattice structure includes a first region of the rotor shroud having a first lattice structure and a second region of the rotor shroud having a second lattice structure. The second lattice structure of the second region is denser than the first lattice structure of the first region. The second region is a deflection region, a stress region, or an energy containment region of the rotor shroud.

A rotor for a rotary machine in includes a hub centered on a central axis and having a disk portion and a shaft portion, a blade extending outward from the hub, and a variable lattice structure in an interior of the rotor. The variable lattice structure includes a first region of the rotor having a first lattice structure and a second region of the rotor having a second lattice structure. The second lattice structure of the second region is denser than the first lattice structure of the first region. The second region is a deflection region or a stress region of the rotor.

Nickel-based superalloy suitable for additive manufacture, a method, and a product includes a special selection of the elements silicon, boron, zirconium, and hafnium. The nickel-based superalloy includes at least the following (in wt.%): carbon (C) 0.04%-0.08% chromium (Cr) 9.8%-10.2% cobalt (Co) 10.3%-10.7% molybdenum (Mo) 0.4%-0.6% tungsten (W) 9.3%-9.7% aluminum (Al) 5.2%-5.7% tantalum (Ta) 1.9%-2.1% boron (B) 0.0025%-0.01% zirconium (Zr) 0.0025%-0.01% hafnium (Hf) 0.1%-0.3%, and optionally yttrium (Y) and residual nickel (Ni).

A hybrid three-layer system is presented. The hybrid three-layer system includes a two-layer composite system and an additively manufactured third layer comprising a lattice structure. The composite layer system includes a metallic substrate, a structured surface, and a thermal protection system. The structured surface may be additively manufactured onto the metallic substrate and includes structured surface features formed to project above the metallic substrate. Each of the structured surface features are separated from adjacent structured surface features by grooves. The thermal protection coating may be thermally sprayed onto the structured surface and is bonded to each of the structured surface features. The lattice structure is in contact with a surface of the metallic substrate of the composite layer system.

A hybrid three-layer system is presented. The hybrid three-layer system includes a two-layer composite system and an additively manufactured third layer comprising a lattice structure. The composite layer system includes a metallic substrate, a structured surface, and a thermal protection system. The structured surface may be additively manufactured onto the metallic substrate and includes structured surface features formed to project above the metallic substrate. Each of the structured surface features are separated from adjacent structured surface features by grooves. The thermal protection coating may be thermally sprayed onto the structured surface and is bonded to each of the structured surface features. The lattice structure is in contact with a surface of the metallic substrate of the composite layer system.

A component includes an additively manufactured component with an internal passage; and an additively manufactured elongated member within the internal passage. A method of additively manufacturing a component including additively manufacturing a component with an internal passage; and additively manufacturing an elongated member within the internal passage concurrent with additively manufacturing the component.