Methods for reworking structures and reworked cellular core panels, reworked structures comprising the reworked cellular core panels, and guides and cutting apparatuses for reworking cellular acoustic panels and reworking cellular acoustic and non-acoustic panels are disclosed.

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.

In an aluminum foil rolling process, first and second aluminum foils are provided, each having first and second faces, one face between the first and second faces is lubricated to obtain a first lubricated face. The foils are coupled to obtain a coupled foil having two outer faces and rolling the coupled foil, reducing the thickness of the coupled foil. One face between the two outer faces of the coupled foil is lubricated to obtain a coupled foil having a second lubricated face. The coupled foil is then wound to obtain a wound coupled foil. The coupled foil is partially separated by unwinding one of the first and second foils, to obtain a wound coupled foil. The wound coupled foil is unwound and rolled to obtain a coupled foil with reduced thickness and is then separated to obtain first and second foils with respective first and second reduced thicknesses.

Disclosed herein is a method. The method includes identifying a first location on a first part to place a first shim tab to form a first portion of a compound shim. The method also includes applying the first shim tab to the first location on the first part with an end-effector. The method also includes identifying a second location directly adjacent to the first location on the first part to place a second shim tab. The method also includes applying the second shim tab to the second location on the first part with the end-effector to form a second portion of the compound shim. The method also includes applying a third shim tab to the second shim tab at the second location to increase a thickness of the second portion of the compound shim.

Methods for reworking structures and reworked cellular core panels, reworked structures comprising the reworked cellular core panels, and guides and cutting apparatuses for reworking cellular acoustic panels and reworking cellular non-acoustic panels are disclosed.

A lamination manufacturing method for large-sized metal components with complicated structures is provided, relating to a part manufacturing method to solve the problem that traditional machining, entire plastic forming and the existing additive manufacturing method are difficult to manufacture large-sized metal components with complicated special-shape structure and high-performance requirement. The manufacturing method includes the steps: step 1. obtaining a three-dimensional digital model of a large-sized metal component with complicated structure, and dividing the model into a plurality of slice layers; step 2. selecting the actually available metal sheet corresponding to the thickness of each slice layer divided in step 1, and machining each metal sheet to obtain a shaped sheet consistent with the model of each slice layer in step 1; step 3. stacking the shaped sheets obtained through machining of step 2 according to the order of the corresponding slice layers in step 1; and step 4. obtaining a required large-sized metal component with complicated structure after all the shaped sheets are connected into a whole. The present invention is used for shaping large-sized components with complicated deep cavity and inner hole structures.

An additive manufacturing system includes a foil supply drum, a melting energy source, and a processor. The foil supply drum is configured to be rotated for dispensing a foil sheet over a substrate surface supported by a build element. The melting energy source is configured to direct at least one melting energy beam onto a non-melted region of the foil sheet located over the substrate surface. The processor is configured to execute computable readable program instructions based on a three-dimensional digital definition of the object, and control the melting energy beam to selectively melt at least some of the non-melted region into melted portions forming a material layer of the object onto the substrate surface while separating the melted portions from non-melted portions, and command rotation of the foil supply drum for dispensing the foil sheet during manufacturing of the object in correspondence with the digital definition.

Disclosed herein is a method. The method includes identifying a first location on a first part to place a first shim tab to form a first portion of a compound shim. The method also includes applying the first shim tab to the first location on the first part with an end-effector. The method also includes identifying a second location directly adjacent to the first location on the first part to place a second shim tab. The method also includes applying the second shim tab to the second location on the first part with the end-effector to form a second portion of the compound shim. The method also includes applying a third shim tab to the second shim tab at the second location to increase a thickness of the second portion of the compound shim.

A method for the additive manufacturing of an object and a system for manufacturing an object. The method includes depositing a second foil sheet onto the first foil sheet, wherein the first foil sheet and the second foil sheet each comprise a structural layer, forming a layer stack comprising the first foil sheet and the second foil sheet, the layer stack comprising an object section and at least one support section configured to enclose the object section in the layer stack, and applying at least one of heat or pressure to opposite sides of the layer stack with a first plate and a second plate, wherein applying the at least one of heat or pressure increases the temperature of the layer stack to a temperature lower than the melting temperature of the structural layer, and the at least one of heat or pressure bonds the first foil sheet to the second foil sheet in the layer stack, the first plate and the second plate are in contact with the at least one support section, and the at least one support section is configured to conduct the at least one of heat or pressure through the layer stack to the object section.

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.