Provided are a component and an additive manufacturing method for fabricating a component. The additive manufacturing method for fabricating a component includes providing a first wire segment and a second wire segment, the first and second wire segments each having a cross-sectional stackable geometry; positioning the first wire segment into an alignment with the second wire segment to form a workpiece stack, the alignment aligning adjacent surfaces in a line of sight direction; and directing an energy beam toward the first wire segment and the second wire segment along the alignment to weld the first wire segment to the second wire segment to form a welded stack. The component includes a workpiece stack comprising a plurality of wire segments welded together along aligned adjacent surfaces.

Provided are a component and an additive manufacturing method for fabricating a component. The additive manufacturing method for fabricating a component includes providing a first wire segment and a second wire segment, the first and second wire segments each having a cross-sectional stackable geometry; positioning the first wire segment into an alignment with the second wire segment to form a workpiece stack, the alignment aligning adjacent surfaces in a line of sight direction; and directing an energy beam toward the first wire segment and the second wire segment along the alignment to weld the first wire segment to the second wire segment to form a welded stack. The component includes a workpiece stack comprising a plurality of wire segments welded together along aligned adjacent surfaces.

A field of rotary blades, and more particularly to a method of fabricating a leading edge shield for protecting such a blade. The method includes at least steps of performing initial plastic deformation on at least one sheet from a pressure side sheet and a suction side sheet, using additive fabrication to add a reinforcement with a fiber insert on at least one of the pressure and suction side sheets, closing the pressure and suction side sheets around a core after the initial plastic deformation and after adding the reinforcement, performing subsequent plastic deformation by pressing the pressure and suction side sheets against an outside surface of the core after the sheets have been closed around the core, and extracting the core.

A field of rotary blades, and more particularly to a method of fabricating a leading edge shield for protecting such a blade. The method includes at least steps of performing initial plastic deformation on at least one sheet from a pressure side sheet and a suction side sheet, using additive fabrication to add a reinforcement with a fiber insert on at least one of the pressure and suction side sheets, closing the pressure and suction side sheets around a core after the initial plastic deformation and after adding the reinforcement, performing subsequent plastic deformation by pressing the pressure and suction side sheets against an outside surface of the core after the sheets have been closed around the core, and extracting the core.

A method and apparatus for direct writing of single crystal super alloys and metals. The method including heating a substrate to a predetermined temperature below its melting point; using a laser to form a melt pool on a surface of the substrate, wherein the substrate is positioned on a base plate, and wherein the laser and the base plate are movable relative to each other, the laser being used for direct metal deposition; introducing a superalloy powder to the melt pool; and controlling the temperature of the melt pool to maintain a predetermined thermal gradient on a solid and liquid interface of the melt pool so as to form a single crystal deposit on the substrate. The apparatus configured to generally achieve the aforementioned method.

The invention relates to a method for establishing a sectional or modular wind turbine blade. The method comprises the steps of transporting at least two blade sections of said wind turbine blade and a mobile factory for joining blade sections to a location at or in proximity of a wind turbine site, positioning said blade sections with two blade section ends facing each other and supported on a platform in said mobile factory, moving said platform in relation to the ground at the location for levelling said platform, aligning said blade section ends in relation to each other, and establishing said sectional or modular wind turbine blade by joining blade sections in an area of connection at said blade section ends. The invention also relates to a system for establishing a sectional or modular wind turbine blade and a mobile factory for joining sections of a wind turbine blade.

The invention relates to a method for establishing a sectional or modular wind turbine blade. The method comprises the steps of transporting at least two blade sections of said wind turbine blade and a mobile factory for joining blade sections to a location at or in proximity of a wind turbine site, positioning said blade sections with two blade section ends facing each other and supported on a platform in said mobile factory, moving said platform in relation to the ground at the location for levelling said platform, aligning said blade section ends in relation to each other, and establishing said sectional or modular wind turbine blade by joining blade sections in an area of connection at said blade section ends. The invention also relates to a system for establishing a sectional or modular wind turbine blade and a mobile factory for joining sections of a wind turbine blade.

A main rotor blade assembly is provided including a spar which comprises a main section. A main core is positioned adjacent a trailing side of the main section of the spar. A tip assembly includes a main tip core and a tip end pocket core. The tip assembly is positioned adjacent an outboard end of the main core and the spar such that the main tip core is substantially aligned with a longitudinal axis of the main core and the tip end pocket core is substantially aligned with a longitudinal axis of the spar. At least a portion of both the main tip core and the tip end pocket core comprises a high density core. An upper composite skin and a lower composite skin extend over the spar, the main core, the main tip core, and the tip end pocket core. A portion of the upper composite skin and the lower composite skin has a thickness sufficient to be load bearing.

A method for modifying an aperture in a component, a system for modifying flow through a component, and a turbine component are disclosed. The method includes providing a substrate having at least one aperture having an electrically-conductive surface, providing a deposition device including an ESD torch, the ESD torch including an aperture penetrating electrode including a conductive material, inserting the aperture penetrating electrode at least partially into the aperture, and generating an arc between the aperture penetrating electrode and the electrically-conductive surface to deposit electrode material within the aperture. The system includes the ESD torch removably supported in an electrode holder. The turbine component includes at least one aperture having an electrospark deposited material along an electrically-conductive surface, the electrospark deposited material providing modified fluid flow through the turbine component.

A method for modifying an aperture in a component, a system for modifying flow through a component, and a turbine component are disclosed. The method includes providing a substrate having at least one aperture having an electrically-conductive surface, providing a deposition device including an ESD torch, the ESD torch including an aperture penetrating electrode including a conductive material, inserting the aperture penetrating electrode at least partially into the aperture, and generating an arc between the aperture penetrating electrode and the electrically-conductive surface to deposit electrode material within the aperture. The system includes the ESD torch removably supported in an electrode holder. The turbine component includes at least one aperture having an electrospark deposited material along an electrically-conductive surface, the electrospark deposited material providing modified fluid flow through the turbine component.