A method of making a part includes creating a computer file defining the part in layers and a model of a body blank to represent a space defined by a cavity in the part. The part is built using an additive manufacturing process. A layer of powdered material is deposited into a powder bed. The powder bed is preheated by applying a first beam current with a first energy. A second beam current with a second energy level greater than the first energy level is applied to a first region of the layer of the powder bed not including a portion of the cavity. A second region of the powdered material is selectively melted. The partially built part and layer of the powdered material are lowered. Steps are repeated for additional layers in accordance with the computer file to create the part.

A method of making a part includes creating a computer file defining the part in layers and a model of a body blank to represent a space defined by a cavity in the part. The part is built using an additive manufacturing process. A layer of powdered material is deposited into a powder bed. The powder bed is preheated by applying a first beam current with a first energy. A second beam current with a second energy level greater than the first energy level is applied to a first region of the layer of the powder bed not including a portion of the cavity. A second region of the powdered material is selectively melted. The partially built part and layer of the powdered material are lowered. Steps are repeated for additional layers in accordance with the computer file to create the part.

A bellows shaped spinal implant, comprising an upper plate, a lower plate and a bellows shaped shell extending between and joining the upper and lower plates. The bellows shaped shell is formed of titanium or an alloy comprising titanium and includes a wall extending therearound that defines a hollow interior. The wall has a thickness in the range of 0.5 mm to 1.0 mm to provide for radiographic imaging through the wall. The wall is angled or curved inwardly or outwardly between the upper and lower plates to provide stiffness mimicking the stiffness properties of a similarly sized polyetheretherketone (PEEK) implant. The upper and lower plates each comprise porous contact regions including a three-dimensional gyroid lattice structure defined by a plurality of struts and pores in communication with the hollow interior. The outer surfaces of at least a portion of the struts may comprise a laser ablated textured surface.

A tool includes a head that extends form the flexible section, an emitter within the head; and a nozzle to eject a cooling fluid therefrom. A method of additively manufacturing a component including delivering series of thermal shocks to a conglomerated powder within an internal passage of an additively manufactured component to facilitate removal of the conglomerated powder.

A method of forming a cooling hole structure on a turbine component. The turbine component has a component wall with inner and outer surfaces. A bore passes through the component wall and fluidly connects the inner surface and the outer surface. The method includes the steps of: A) forming a recess communicating with the bore and the outer surface; and B) using an additive manufacturing process to form an exit region in the recess.

In one aspect, methods of making freestanding metal matrix composite articles and alloy articles are described. A method of making a freestanding composite article described herein comprises disposing over a surface of the temporary substrate a layered assembly comprising a layer of infiltration metal or alloy and a hard particle layer formed of a flexible sheet comprising organic binder and the hard particles. The layered assembly is heated to infiltrate the hard particle layer with metal or alloy providing a metal matrix composite, and the metal matrix composite is separated from the temporary substrate. Further, a method of making a freestanding alloy article described herein comprises disposing over the surface of a temporary substrate a flexible sheet comprising organic binder and powder alloy and heating the sheet to provide a sintered alloy article. The sintered alloy article is then separated from the temporary substrate.

A method for manufacturing a metallic component includes the steps of providing a component preform of a metallic material, which constitutes the metallic component and a shaping means which defines the shape of the metallic component. The component preform is subjected to Hot Isostatic Pressing for a predetermined time at a predetermined temperature and a predetermined pressure. The shaping means is removed by contacting the component preform with a pickling agent. The step of providing the component preform includes providing the component preform with an acid resistant metal layer, wherein the acid resistant metal layer is applied with electroplating and wherein the acid resistant metal layer is arranged such that it protects the metallic material from contact with the pickling agent.

A method including: submerging a ceramic preform (10) in a layer (12) of powdered superalloy material (14), wherein the preform defines a desired shape of a channel (60, 62, 64, 78) to be formed in a layer (42) of superalloy material; melting the powdered superalloy material around the preform without melting the preform; and cooling and re-solidifying the superalloy material around the preform to form the layer of superalloy material with the preform defining the shape of the channel therein.

A nut plate (10) and a gang channel (78) are constructed of ceramic material. In one version, the nut plate (10) and gang channel (78) are constructed of aluminum oxide ceramic material reinforced with silicon-carbide crystal whiskers. In another version, the nut plate (10) and gang channel (78) are constructed of silicon-nitride. In a third version the nuts (54) are constructed of oxide ceramic material reinforced with silicon-carbide crystal whiskers or silicon-nitride and gage channel (78) are constructed of CMC (either oxide or non-oxide).

A method for forming a part includes: forming a first portion of the part at a first level; forming a second portion of the part at a second level; wherein forming the first and second portions includes exposing the first and second levels to a sintering process and portions of the first and second levels to an electron beam; causing a magnetorheological (MR) fluid to move into a passage inside the first and second portions; exposing the first and second portions to a magnetic field causing motion of particles in the MR fluid to move and break up sintered material in the passage; and removing some or all of the sintered material in the passage.