A method and system to manufacture workpieces employing a high intensity energy source to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets.

A processing method of formic acid soldering includes providing a solder, performing a formic acid providing step, performing a soldering step and performing a cooling step. The solder is disposed at a soldering object. In the formic acid providing step, a water-containing formic acid vapor extracted from a formic acid source is introduced to a soldering object so as to form a water-containing formic acid atmosphere surrounding the soldering object. In the soldering step, the solder and the soldering object are soldered in the water-containing formic acid atmosphere at a soldering temperature so as to form a soldered object with high temperature. In the cooling step, the soldered object with high temperature is cooled by a cooling method so as to form a soldered object. A range of a moisture content of the formic acid source is greater than or equal to 0.1 wt % and less than 15 wt %.

Some variations provide an aluminum alloy feedstock for additive manufacturing, the aluminum alloy feedstock comprising from 81.5 wt % to 88.8 wt % aluminum; from 1.1 wt % to 2.1 wt % copper; from 3.0 wt % to 4.6 wt % magnesium; and from 7.1 wt % to 9.0 wt % zinc. The aluminum alloy feedstock may be in the form of a free-flowing powder or a feedstock ingot, for example. In some variations, the aluminum alloy feedstock comprises from 84.9 wt % to 88.3 wt % aluminum; from 1.2 wt % to 2.0 wt % copper; from 3.2 wt % to 4.4 wt % magnesium; and from 7.3 wt % to 8.7 wt % zinc.

A method comprising the steps of: distributing a titanium alloy or pure titanium powder layer on a work table inside a vacuum chamber, directing at least one electron beam from at least one electron beam source over the work table causing the powder layer to fuse in selected locations, distributing a second powder layer on the work table of a titanium alloy or pure titanium inside the build chamber, directing the at least one electron beam over the work table causing the second powder layer to fuse in selected locations, and releasing a predefined concentration of the gas from the metal powder into the vacuum chamber when at least one of heating or fusing the metal powder layer, wherein at least one gas comprising hydrogen is absorbed into or chemically bonded to the titanium or titanium alloy powder to a concentration of 0.01-0.5% by weight of the hydrogen.

A method for forming a three-dimensional article through successive fusion of parts of a metal powder bed is provided, comprising the steps of: distributing a first metal powder layer on a work table inside a build chamber, directing at least one high energy beam from at least one high energy beam source over the work table causing the first metal powder layer to fuse in selected locations, distributing a second metal powder layer on the work table, directing at least one high energy beam over the work table causing the second metal powder layer to fuse in selected locations, introducing a first supplementary gas into the build chamber, which first supplementary gas comprising hydrogen, is capable of reacting chemically with or being absorbed by a finished three-dimensional article, and releasing a predefined concentration of the gas which had reacted chemically with or being absorbed by the finished three dimensional article.

An apparatus and method for protecting an inner radial surface of a radial member of a turbomachine from corrosion are provided. The method may include shaping the inner radial surface of the radial member and a corresponding outer radial surface of a corrosion-resistant liner. The method may also include heating the radial member to increase a diameter of the inner radial surface of the radial member, and inserting at least a portion of the corrosion-resistant liner into the radial member. The method may further include attaching the corrosion-resistant liner to the inner radial surface of the radial member to thereby protect the inner radial surface of the radial member of the turbomachine from corrosion.

Described is a design and method for producing a sputtering target assembly with low deflection made from target material solder bonded to composite backing plate with coefficient of thermal expansion (CTE) matching the target material. The composite backing plate is composite configuration composed of at least two different materials with different CTE. The composite backing plate, after plastic deformation, if necessary, has a CTE matching the target material and low and desirable deflection in the bonding process, and therefore, resulting in a low deflection and low stress target material bonded to composite backing plate assembly. The method includes manufacturing composite backing plate with a flat bond surface, heat treating of target blank and composite backing plate to achieve desirable shape of bond surfaces, solder bonding target to a backing plate, and slowly cooling the assembly to room temperature. Matching CTE in both target material and backing plate eliminates the problem of CTE mismatch and prevents the assembly from deflection and internal stress.

A flat plate heat exchanger module for use in aerospace applications, automotive applications, industrial applications or similar. The flat plate heat exchanger module comprises a stack of heat exchanger plates, where at least one of the heat exchanger plates further comprises at least one elongated aperture extending across the surface of the heat exchanger plate. This elongated aperture is in fluid isolation from the fluid flowing across the surface of the heat exchanger plate. The use of at least one elongated aperture throughout the stack of heat exchanger plates minimises the overall effect of the expansion and contraction of the metal due to exposure to high temperature gradients. A method of manufacturing such a heat exchanger module is also provided.

The method of metal-thermoplastic resin direct bonding is characterized by comprising a first step for irradiating a surface of the metal material with a pulse laser under an oxidizing atmosphere to form a surface modification region, a second step for causing the thermoplastic resin material to abut against the surface modification region to form a bonding interface, and a third step for heating up the bonding interface by laser irradiation to achieve bonding, the first step including forming metal oxide particle clusters obtained when metal oxide particles having a particle diameter of 5-500 nm to be continuously bonded at the surface modification region, so that the maximum height (Sz) of a surface of the metal oxide particle clusters is 50 nm-3 .Math.m.

A method for fabricating a turbomachine component including a metal alloy with a layering device is provided. The method for fabricating the turbomachine component may include combining two or more elemental powders to form a powdered material. The method for fabricating the turbomachine component may also include forming a first metal alloy layer of the turbomachine component on a substrate. Forming the first metal alloy layer on the substrate may include melting a first portion of the powdered material to a first molten material with a heat source, mixing the first molten material with the heat source, and cooling the first molten material. The method for fabricating the turbomachine component may further include forming a second metal alloy layer of the turbomachine component on the first metal alloy layer, and binding the first metal alloy layer with the second metal alloy layer.