A system and process for fabricating motor laminations from sheet material. Various embodiments of the disclosure combine a separation process with one or both of a cutting and a scoring process that outlines the laminations prior to the separation process. In some embodiments, the separation process is a punching process and is integrated with the stacking of the motor laminations to form the stator core. In addition, a system and process where the cut and/or scored portion of the sheet material is subjected to flattening process prior to the separation process is disclosed. Performing the flattening process prior to the separation process has the effect of streamlining the process, in that the sheet material can be easily handled and conveyed from the scoring process, through the flattening process, and to the separation and stacking process, without need for separate handling of the laminations.

The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

System and method of manufacturing a laminated three-dimensional (3D) metallic object. The method includes: providing a plurality of foils of metal; marking portions of some of the foils in the plurality of foils with a marking agent that includes a material having electrochemical potential higher than the metal; bonding the plurality of marked foils into a block; and selectively etching parts of the block not in proximity to the marking agent.

A device for performing a method for producing a lamination pack, wherein in the method laminations are cut from an electric strip or sheet; the laminations are placed on top of each other to form a lamination stack; the laminations are connected by material fusion to each other by: locally plasticizing a material of the laminations in an edge region of the laminations by generating friction heat by a tool; mixing the locally plasticized material, at least of the laminations neighboring each other, with the tool; and allowing the plasticized material to cool and fuse the laminations in the edge region to form the lamination pack. The device has a punch press and/or a receptacle for one or a plurality of lamination stacks. The device further has a welding tool that is rotatably driven about an axis of the welding tool and moveable transverse to the axis of rotation.

Systems and methods are provided for fabricating a preform for a fuselage section of an aircraft. The method includes advancing a series of arcuate mandrel sections in a process direction through an assembly line, laying up fiber reinforced material onto the arcuate mandrel sections via layup stations, uniting the series of arcuate mandrel sections into a combined mandrel; and splicing the fiber reinforced material laid-up onto the arcuate mandrel sections.

An embodiment of a method includes fabricating a first single crystal boule having a uniform composition and grain orientation. The first uniform single crystal boule is divided into a first plurality of layered shapes. The shapes of the first plurality are stacked with at least a second plurality of layered shapes along a first axis. The second plurality of layered shapes have at least one physical aspect differing from at least one corresponding physical aspect of the first plurality of layered shapes. The first plurality of layered shapes and at least the second plurality of layered shapes are joined via a field assisted sintering technique (FAST) to form a bulk component.

A method of manufacturing a stator for a rotary electric machine includes: a step of preparing a stator core formed from a first metal material that is magnetic, the stator core having a space provided on a radially inner side and in which a rotor is to be disposed; a blocking step of covering at least a part of an end surface of the stator core in an axial direction and blocking the space using a blocking member; and a casting step of pouring a second metal material that is non-magnetic to a radially outer side of the stator core with at least a part of the end surface of the stator core covered and with the space blocked through the blocking step in a die.

An impact attenuation system comprises an aluminum honeycomb sheet having a top surface and a bottom surface. The aluminum honeycomb sheet defines a plurality of approximately hexagonally shaped cells. The bottom surface defines a single sheet of contiguous cells and the top surface defines two or more islands of contiguous cells separated by one or more slits. At least a portion of one or both of the top surface and bottom surface may be covered by a polymer skin. The polymer skin may comprise carbon fibers and/or fiberglass.

A device for performing a method for producing a lamination pack, wherein in the method laminations are cut from an electric strip or sheet; the laminations are placed on top of each other to form a lamination stack; the laminations are connected by material fusion to each other by: locally plasticizing a material of the laminations in an edge region of the laminations by generating friction heat by a tool; mixing the locally plasticized material, at least of the laminations neighboring each other, with the tool; and allowing the plasticized material to cool and fuse the laminations in the edge region to form the lamination pack. The device has a punch press and/or a receptacle for one or a plurality of lamination stacks. The device further has a welding tool that is rotatably driven about an axis of the welding tool and moveable transverse to the axis of rotation.

A method for producing a component is disclosed. In a first step, a planar component layer is produced on a base surface from a metal material which is above the melting temperature thereof. In a second step, shear stresses are introduced into the component layer produced in the first step by a friction pin which rotates about a rotation axis and which is pressed with a predetermined force onto an outer surface of the component layer opposite the base surface and which is moved along the entire outer surface of the component layer. Finally, in a third step, the first step is repeated on the outer surface as a base surface.