A hybrid manufacturing machine comprises a workpiece platform, a powder delivery system, and a scan head. The powder delivery system delivers powder from a powder storage system to the workpiece platform. A controller executes a program to perform a manufacturing operation on a part situated on the workpiece platform based upon a three-dimensional representation of the part. The scan head is controlled by the controller to emit a first energy beam that implements an additive process on the part, and a second energy beam that implements a material manipulation process on the part. The hybrid manufacturing machine can also include a measurement device, e.g., a laser profilometer, camera, microscope, etc. Under this configuration, the controller can control the scan head to emit the second energy beam to perform the material manipulation operation as a micro-machining operation to remove structure from the part based upon an output from the measurement device.

A hybrid manufacturing machine comprises a workpiece platform, a powder delivery system, and a scan head. The powder delivery system delivers powder from a powder storage system to the workpiece platform. A controller executes a program to perform a manufacturing operation on a part situated on the workpiece platform based upon a three-dimensional representation of the part. The scan head is controlled by the controller to emit a first energy beam that implements an additive process on the part, and a second energy beam that implements a material manipulation process on the part. The hybrid manufacturing machine can also include a measurement device, e.g., a laser profilometer, camera, microscope, etc. Under this configuration, the controller can control the scan head to emit the second energy beam to perform the material manipulation operation as a micro-machining operation to remove structure from the part based upon an output from the measurement device.

A manufacturing machine is capable of subtractive manufacturing and additive manufacturing for a workpiece. The manufacturing machine includes: a first headstock and a second headstock disposed in a machining area and configured to hold a workpiece; a tool spindle and a lower tool rest disposed in the machining area and configured to hold a tool to be used for subtractive manufacturing for the workpiece; an additive manufacturing head configured to discharge a material during additive manufacturing for the workpiece; a workpiece gripper configured to grip the workpiece during transportation of the workpiece into and out of the machining area; and a robot arm on which the additive manufacturing head and the workpiece gripper are mountable. Accordingly, the manufacturing machine improving the productivity in the simple and easy manner is provided.

A system for inspecting a part while said part is produced by additive manufacturing, includes an additive manufacturing apparatus having a build tray, the apparatus being configured to fabricate the part layer-by-layer on the tray; an automated tool holder carrying a tool configured to deposit, add or weld layer-upon-layer of material; the tool holder and tray are configured to move relative to one another along a defined path; and an inspection device attached to the tool holder and configured to scan a layer of material in situ. The tool holder alternately arranges the tool and inspection device in a working position so that the tool holder fixes the tool in the working position for depositing, adding, or welding the layer of material and thereafter the tool holder switches said tool with the inspection device into the working position for scanning and detecting defects in the layer of material.

Methods of producing three-dimensional alloy workpieces are described herein, which can comprise: producing a precursor workpiece on a layer-by-layer basis by depositing a layer of a mixed powder, the mixed powder comprising an elemental powder and a second powder; melting at least a portion of the elemental powder by directing an energy field onto a portion of the layer; and repeating the deposing and melting steps to form the precursor workpiece from a plurality of layers. The precursor workpiece can comprise a dispersed phase and a continuous phase, the dispersed phase being dispersed within the continuous phase, the dispersed phase comprising a plurality of discrete regions comprising the second powder, and the continuous phase comprising the melted elemental powder. The methods can further comprise heating the precursor workpiece to homogenize the continuous phase and the dispersed phase, thereby forming the three-dimensional alloy workpiece comprising a continuous alloy phase.

A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

The present disclosure relates to new materials comprising Al, Co, Ni and Ti. The new materials may realize a single phase field of a face-centered cubic (fcc) solid solution structure immediately below the solidus temperature of the material. The new materials may include at least one precipitate phase and have a solvus temperature of at least 1100° C. The new materials may include 2.1-8.4 wt. % Al, 4.7-60.6 wt. % Co, 29.6-89.3 wt. % Ni, and 3.9-9.4 wt. % Ti. In one embodiment, the precipitate is selected from the group consisting of the L1.sub.2 phase, the B2 phase, the Ni.sub.3Ti phase, and combinations thereof. The new alloys may realize improved high temperature properties.

The present disclosure relates to new materials comprising Al, Co, Cr, and Ni. The new materials may realize a single phase field of a face-centered cubic (fcc) solid solution structure immediately below the solidus temperature of the material. The new materials may include at least one precipitate phase and have a solvus temperature of at least 1000° C. The new materials may include 2.2-8.6 wt. % Al, 4.9-65.0 wt. % Co, 4.3-42.0 wt. % Cr, and 4.8-88.6 wt. % Ni. In one embodiment, the precipitate is selected from the group consisting of the L1.sub.2 phase, the B2 phase, the sigma phase, the bcc phase, and combinations thereof. The new alloys may realize improved high temperature properties.

A torque bar manufactured by an additive manufacturing process is provided. The torque bar may include a torque bar body made of more than one metallic material. The torque bar may also include a geometry that comprises one or more voids and one or more webs, as well as a varied geometry in the direction of a longitudinal axis. The torque bars can exhibit characteristics, such as vibration damping, tuned stiffness, and tuned bending resistance in order to enhance dynamic stability.