The present invention involves a method for manufacturing a blade (1) for a propeller, which blade (1) has a leading edge (2) and a trailing edge, the method comprising the steps of: forming a conduit in the blade (1), making a plurality of holes (7) through which the conduit (6) communicates with the exterior of the blade (1), and providing a blade blank having an edge part receiving surface (4) extending along at least a major part of the leading edge (2) of the blade (1) to be manufactured, wherein forming a conduit (6) comprises building up an edge part (3) onto the edge part receiving surface (4) by a wire-based additive manufacturing process, wherein the additive manufacturing process is adapted to form the conduit (6) at least partly delimited by the edge part (3) and extending along the leading edge (2) of the blade (1) to be manufactured.

An iron-based alloy composition including: boron (B): 1.6-2.4 wt. %; carbon (C): 2.2-3.0 wt. %; chromium (Cr): 3.5-5.0 wt. %; manganese (Mn): below 0.8 wt. %; molybdenum (Mo): 16.0-19.5 wt. %; nickel (Ni): 1.0-2.0 wt. %; silicon (Si): 0.2-2.0 wt. %; vanadium (V): 10.8-13.2 wt. %; and balanced with iron (Fe). Further, an item including a substrate portion and a hardfacing coating bonded to the substrate portion, wherein the hardfacing coating is made by an overlay welding process using the iron-based alloy composition.

An iron-based alloy composition including: boron (B): 1.6-2.4 wt. %; carbon (C): 2.2-3.0 wt. %; chromium (Cr): 3.5-5.0 wt. %; manganese (Mn): below 0.8 wt. %; molybdenum (Mo): 16.0-19.5 wt. %; nickel (Ni): 1.0-2.0 wt. %; silicon (Si): 0.2-2.0 wt. %; vanadium (V): 10.8-13.2 wt. %; and balanced with iron (Fe). Further, an item including a substrate portion and a hardfacing coating bonded to the substrate portion, wherein the hardfacing coating is made by an overlay welding process using the iron-based alloy composition.

A directed energy deposition nozzle assembly including (1) a nozzle configured to dispense material for directed energy deposition, wherein the material comprises one or more of metallic powder, ceramic powder, and glass powder, and wherein (a) the nozzle has an orifice through which the material exits the nozzle, wherein the nozzle comprises an inner body and an outer body that is peripherally disposed around the inner body, and wherein the orifice is defined by a gap between the inner body and the outer body, or (b) the nozzle comprises a plurality of orifices through which the material exits the nozzle, and (2) a vibrator configured to apply a vibration to the nozzle.

A directed energy deposition nozzle assembly including (1) a nozzle configured to dispense material for directed energy deposition, wherein the material comprises one or more of metallic powder, ceramic powder, and glass powder, and wherein (a) the nozzle has an orifice through which the material exits the nozzle, wherein the nozzle comprises an inner body and an outer body that is peripherally disposed around the inner body, and wherein the orifice is defined by a gap between the inner body and the outer body, or (b) the nozzle comprises a plurality of orifices through which the material exits the nozzle, and (2) a vibrator configured to apply a vibration to the nozzle.

A method of reprocessing a metal product includes a welding step for welding a dummy member to the metal product, a reprocessing step for reprocessing the metal product in a state where the metal product is supported by a first support unit and the dummy member is supported by a second support unit, and a removal step for removing the dummy member from the metal product after the reprocessing step. The reprocessing of the metal product while the metal product is fixed is thus enabled without restriction from the shape of the metal product.

A method of reprocessing a metal product includes a welding step for welding a dummy member to the metal product, a reprocessing step for reprocessing the metal product in a state where the metal product is supported by a first support unit and the dummy member is supported by a second support unit, and a removal step for removing the dummy member from the metal product after the reprocessing step. The reprocessing of the metal product while the metal product is fixed is thus enabled without restriction from the shape of the metal product.

An additive manufacturing system may include an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component; a powder delivery device configured to direct a powder stream toward the melt pool; a plurality of mass sensors, each mass sensor associated with a portion of the additive manufacturing system; a plurality of heat sensors; and one or more computing devices. The computing device(s) are configured to receive data from the plurality of mass sensors; determine an overall mass flux based on the data from the mass sensors; control the powder delivery device based on the overall mass flux; receive data from the plurality of heat sensors; determine an overall heat flux based on the data from the heat sensors; and control the energy delivery device based on the overall heat flux.

An additive manufacturing system may include an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component; a powder delivery device configured to direct a powder stream toward the melt pool; a plurality of mass sensors, each mass sensor associated with a portion of the additive manufacturing system; a plurality of heat sensors; and one or more computing devices. The computing device(s) are configured to receive data from the plurality of mass sensors; determine an overall mass flux based on the data from the mass sensors; control the powder delivery device based on the overall mass flux; receive data from the plurality of heat sensors; determine an overall heat flux based on the data from the heat sensors; and control the energy delivery device based on the overall heat flux.

The present invention relates generally to laser welding in the manufacture of sheet metal components, such as for example automobile components. More particularly, the present invention relates to a process and a system for forming a localized anti-corrosion surface layer along a laser welded joint (weld bead), subsequent to the laser welding together of sheet metal plates having an anti-corrosion surface layer pre-coat.