Disclosed are a gear product having an enhance deposition surface and a deposition system for manufacturing the gear product. The gear product having a reinforced deposition surface according to the present disclosure includes: teeth in which valleys and crests are successively famed along an outer or inner circumference of a cylindrical body having a central rotation shaft; and a reinforced deposition layer, which is formed by radiating a laser beam in a coaxial nozzle system to be directed to the teeth and injecting powdered materials to be in contact with a radiation axis of the laser beam around the radiated laser beam such that the powdered materials are melted and integrated with a surface of the teeth. According to the present disclosure, a reinforced corrosion-resistant and wear-resistant deposition layer famed on a gear product is formed through a coaxial nozzle system in which powdered materials, which are injected so as to be in contact with the radiation axis of a laser beam radiated towards teeth around the radiated laser beam, is melted by the laser beam so as to be deposited on the surface of the teeth. Thus, it is possible to freely and finely control the laser beam power, the rotational speed of the gear, and the type and the injection amount of powdered materials according to the shape and size of the crests and valleys (teeth), and the physical properties of the raw material constituting the gear product, so that a deposition layer, optimized to the teeth having various shapes and physical properties, can be uniformly and precisely formed.

A method of manufacturing a mechanical part of the present invention includes a first process of forming, by performing a folding processing to an end portion of the material, a portion to be processed having a structure, in which a plurality of layers respectively having a thickness corresponding to a plate thickness of a material overlap each other, in the material such that a plate thickness direction of the layer is orthogonal to a plate thickness direction of the material; and a second process of changing, by performing a forging processing to the portion to be processed, a shape of the portion to be processed to a target shape while press-welding the layers of the portion to be processed to each other by plastic deformation.

A method and an apparatus for collecting powder samples in real-time in powder bed fusion additive manufacturing may involves an ingester system for in-process collection and characterizations of powder samples. The collection may be performed periodically and uses the results of characterizations for adjustments in the powder bed fusion process. The ingester system of the present disclosure is capable of packaging powder samples collected in real-time into storage containers serving a multitude purposes of audit, process adjustments or actions.

A method and an apparatus for collecting powder samples in real-time in powder bed fusion additive manufacturing may involves an ingester system for in-process collection and characterizations of powder samples. The collection may be performed periodically and uses the results of characterizations for adjustments in the powder bed fusion process. The ingester system of the present disclosure is capable of packaging powder samples collected in real-time into storage containers serving a multitude purposes of audit, process adjustments or actions.

A method according to one aspect of the present disclosure is a laser marking method for a powder compact containing metal powder, which includes: a first step of scanning with laser light of first power which is weaker over a predetermined area in a surface of the powder compact, to melt and smooth inside of the predetermined area; and a second step of scanning with laser light of second power which is greater, to form a dot formed of a recess of a predetermined depth at a predetermined location in the predetermined area.

A method of fusion welding two ferrous alloy component parts, at least one of which is considered unweldable, involves placing a low carbon steel band into a groove defined in part by each of the ferrous alloy component parts and then conveying a concentrated energy source along a welding line that overlaps the low carbon steel band to melt the steel band along with adjacent portions of the ferrous alloy component parts to form a blended alloy weld pool. The blended alloy weld pool solidifies behind the forward movement of the concentrated energy source into a weld joint that fusion welds the ferrous alloy component parts together. The ferrous alloy component parts may include a differential casing and a ring gear. In that regard, a differential casing and ring gear assembly that includes a weld joint is also disclosed.

It is an object of the present invention to effectively suppress the overflow of brazing material from each joint of a sinter-brazed component, such as a planetary carrier, obtained by brazing a plurality of members together. According to the present invention, there is provided a sinter-brazed component obtained by mating and joining a first member having a first bonding surface and a second member having a second bonding surface to each other. Brazing material is provided between the first bonding surface and the second bonding surface. The first bonding surface has a first recess, the first recess having an inner peripheral wall and a bottom surface. The inner peripheral wall extends along and on an inner side of a profile line of the first bonding surface.

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed.

A method and an apparatus for collecting powder samples in real-time in powder bed fusion additive manufacturing may involves an ingester system for in-process collection and characterizations of powder samples. The collection may be performed periodically and uses the results of characterizations for adjustments in the powder bed fusion process. The ingester system of the present disclosure is capable of packaging powder samples collected in real-time into storage containers serving a multitude purposes of audit, process adjustments or actions.

A composite metal flexplate is disclosed that includes an aluminum center plate and a steel ring gear joined to the aluminum center plate by a solid-state joint. The solid-state joint that joins together the aluminum center plate and the steel ring gear may be formed by friction welding. During the friction welding process, a surface of an annular body of the steel ring gear is preheated, followed by bringing the preheated surface of the annular body into contact with a surface of a periphery of a circular body of the aluminum center plate. The two contacting surfaces are then caused to experience relative rotational contacting movement, which generates frictional heat therebetween and softens adjacent regions of the steel ring gear and the aluminum center plate. Once this occurs, an applied force is administered to compress and forge the contacting surfaces together, thereby establishing the solid-state joint.