Techniques of additive deposition for producing articles of manufacture are disclosed herein. In one embodiment, an article of manufacture can include a substrate having a surface and composed of a metal or metal alloy and multiple layers of composite materials deposited on the surface of the substrate. The composite materials is composed of the metal or metal alloy and a ceramic material. The individual composite materials at each of the multiple layers has a composition with a corresponding ratio between the metal or metal alloy material and the ceramic material. The ratios between the metal or metal alloy material and the ceramic material change along at least one dimension of the article of manufacture.

Techniques of additive deposition for producing articles of manufacture are disclosed herein. In one embodiment, an article of manufacture can include a substrate having a surface and composed of a metal or metal alloy and multiple layers of composite materials deposited on the surface of the substrate. The composite materials is composed of the metal or metal alloy and a ceramic material. The individual composite materials at each of the multiple layers has a composition with a corresponding ratio between the metal or metal alloy material and the ceramic material. The ratios between the metal or metal alloy material and the ceramic material change along at least one dimension of the article of manufacture.

In one aspect, composite articles are described herein employing cobalt-based alloy claddings exhibiting high hardness and wear resistance while maintaining desirable integrity and adhesion to surfaces of metallic substrates. A composite article, in some embodiments, comprises a metallic substrate and a composite cladding metallurgically bonded to one or more surfaces of the metallic substrate, the composite cladding including cobalt-based alloy having a chromium gradient, wherein chromium content increases in a direction from the composite cladding surface to an interface of the composite cladding with the metallic substrate.

A powder-deposition apparatus for an additive manufacturing system includes a recoater, a mixer, and a powder feeder. The recoater is configured to discharge powder such that a powder layer is formed from the powder. The mixer is configured to mix a plurality of powder constituents to produce the powder and to dispense the powder to the recoater. The powder feeder is configured to selectively dispense a mass of each one of the plurality of powder constituents to the mixer such that a composition of the powder is selectively controlled.

A powder-deposition apparatus for an additive manufacturing system includes a recoater, a mixer, and a powder feeder. The recoater is configured to discharge powder such that a powder layer is formed from the powder. The mixer is configured to mix a plurality of powder constituents to produce the powder and to dispense the powder to the recoater. The powder feeder is configured to selectively dispense a mass of each one of the plurality of powder constituents to the mixer such that a composition of the powder is selectively controlled.

The present disclosure provides an additive manufacturing method for manufacturing an object. The method comprises depositing successive layers of a granular metal construction material. The method comprises selectively binding a first region of each layer to form a bound shell of the construction material defining an exterior of the object by depositing a binder into the first region surrounding a second region that remains unbound. The method comprises separating the shell and the enclosed unbound construction material from the construction material remaining outside the shell. The present disclosure also provides apparatuses implementing the manufacturing method, and objects manufactured by the manufacturing method.

The present disclosure provides an additive manufacturing method for manufacturing an object. The method comprises depositing successive layers of a granular metal construction material. The method comprises selectively binding a first region of each layer to form a bound shell of the construction material defining an exterior of the object by depositing a binder into the first region surrounding a second region that remains unbound. The method comprises separating the shell and the enclosed unbound construction material from the construction material remaining outside the shell. The present disclosure also provides apparatuses implementing the manufacturing method, and objects manufactured by the manufacturing method.

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 spark plug electrode with an electrode tip formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique. The spark plug electrode includes an electrode base, an electrode tip that is formed on the electrode base and includes a precious metal-based material, and a thermally resilient joint that is located between the electrode base and the electrode tip, wherein the electrode tip and the thermally resilient joint together include a number of laser deposition layers.

A spark plug electrode with an electrode tip formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique. The spark plug electrode includes an electrode base, an electrode tip that is formed on the electrode base and includes a precious metal-based material, and a thermally resilient joint that is located between the electrode base and the electrode tip, wherein the electrode tip and the thermally resilient joint together include a number of laser deposition layers.