Embodiments of systems and methods of additive manufacturing are disclosed. In one embodiment, a computer control apparatus accesses multiple planned build patterns corresponding to multiple build layers of a three-dimensional (3D) part to be additively manufactured. A metal deposition apparatus deposits metal material to form at least a portion of a build layer of the 3D part. The metal material is deposited as a beaded weave pattern, based on a planned path of a planned build pattern, under control of the computer control apparatus. A weave width, a weave frequency, and a weave dwell of the beaded weave pattern are dynamically adjusted during deposition of the beaded weave pattern. The adjustments are under control of the computer control apparatus based on the planned build pattern, as a width of the build layer varies along a length dimension of the build layer.

A series of welding filler wires with innovative composition design for fusion welding precipitation-hardened lightweight austenitic Fe—Mn—Al—C alloys. The first class of the welding filler wires is composed of 23-34 wt. % Mn, 7.5-11.5 wt. % Al, 1.35-1.95 wt. % C, with the balance being essentially Fe. After fusion welding, there are high-density of nano-sized (˜3-5 nm) (Fe,Mn).sub.3AlC carbides (κ-carbides) uniformly distributed within the austenite dendrite cells in the fusion zone (FZ). The amount of nano-sized (˜6-10 nm) κ-carbides existing within the eutectic regions is significantly increased and the size of the austenite dendrite cells is substantially reduced. The second class of welding filler wires has the composition of 23-34 wt. % Mn, 7.5-11.5 wt. % Al, 1.40-1.95 wt. % C, 0.1-2.5 wt. % Ti, 0.1-3.0 wt. % Nb, 0.1-2.5 wt. % V, with the balance being essentially Fe. The microstructure of the FZ in the as-welded condition results in formation of substantial amount of nano-sized (˜6-10 nm) face-centered-cubic structured ductile Ti-rich Ti-carbides, Nb-rich Nb-carbides and V-rich V-carbides within the eutectic regions. These carbides are extremely hard (2000˜3500 Hv), enhancing hardness of the obtained FZ.

According to an embodiment, an object tracking device in a welding process tracks and outputs a predetermined object in a welding image. The object tracking device comprises a camera device capturing the welding image including a base material and a welding torch for welding the base material, a controller receiving a plurality of camera control parameter-varied images from the camera device, identifying the predetermined object in the received images, and generating an object tracking image, the plurality of camera control parameter-varied images having varied camera control parameters of the camera device, and an output device outputting the welding image captured by the camera device, the plurality of images received by the controller, or the object tracking image generated by the controller.

A dowel basket assembly apparatus includes a jig table rotationally supported on a bearing assembly, which supports a table top assembly having arms extending radially outwardly and supporting first, second and third jig table bases. The bases move through first, second and third stations by rotating the assembly. First jig table is positioned at first station, second jig table at second station, and third jig table at third station. Rods are located in receptacles on first jig table base at first station. Simultaneously, rods are welded to form a dowel basket on second jig table base at second station. Simultaneously, a welded dowel basket is unloaded from third jig table base at third station. After completion of the steps of locating, welding and retrieving, the apparatus is rotated to advance the jig tables to the next station.

A dowel basket assembly apparatus includes a jig table rotationally supported on a bearing assembly, which supports a table top assembly having arms extending radially outwardly and supporting first, second and third jig table bases. The bases move through first, second and third stations by rotating the assembly. First jig table is positioned at first station, second jig table at second station, and third jig table at third station. Rods are located in receptacles on first jig table base at first station. Simultaneously, rods are welded to form a dowel basket on second jig table base at second station. Simultaneously, a welded dowel basket is unloaded from third jig table base at third station. After completion of the steps of locating, welding and retrieving, the apparatus is rotated to advance the jig tables to the next station.

An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material of the plurality of metallic anchoring materials.

An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material of the plurality of metallic anchoring materials.

A welding torch includes a head (3) having a body (11) bearing an electrode (13); an electric power source (27); and a filler metal wire (17) and a wire guide (19) guiding the filler metal wire (17) to the electrode (13). The body (11) is obtained by additive manufacturing from an electrically conductive metal, and the electrode (13) is electrically connected to the electric power source (27) by the metal constituting the body (11). The wire guide (19) includes an insulating sheath (29) inside which the filler metal wire (17) moves, and the filler metal wire (17) is electrically insulated from the potential of the body (11) by the insulating sheath (29).

A welding system includes a welding torch, a power supply, one or more sensors, and a controller is provided. The welding torch advances an electrode toward a workpiece in a first direction. The power supply provides a flow of electricity to the electrode for generating a welding arc between the electrode and the workpiece. Generating the welding arc generates a weld puddle behind the welding arc as the electrode moves in the first direction. The sensor generates a voltage output signal based on the amount of light received from the weld puddle. The controller is communicatively coupled with the sensor to receive the voltage output signal, and the sensor controls a welding parameter of the welding system based the voltage output signal.

Alloy compositions, structures, and production methods for an appropriate slit cut surface shape improve productivity by increasing welding speed and stabilizing quality during high speed welding in Ti-containing Fe—Ni—Cr alloy production. The Ti-containing Fe—Ni—Cr alloy contains, hereinafter in weight %, C: 0.001 to 0.03%, Si: 0.05 to 1.25%, Mn: 0.10 to 2.00%, P: 0.001 to 0.030%, S: 0.0001 to 0.0030%, Ni: 15 to 50%, Cr: 17 to 25%, Al: 0.10 to 0.80%, Ti: 0.10 to 1.5%, N: 0.003 to 0.025%, 0: 0.0002 to 0.007%, Fe as a remainder, and inevitable impurities, and when the number and size of titanium nitrides contained in material are evaluated in a freely selected field of view of 5 mm2, the titanium nitrides having sizes of not more than 15 μm are not less than 99.3% of total of the titanium nitrides.