A method of reprocessing a metal product includes a welding step for welding a dummy member to the metal product, a reprocessing step for reprocessing the metal product in a state where the metal product is supported by a first support unit and the dummy member is supported by a second support unit, and a removal step for removing the dummy member from the metal product after the reprocessing step. The reprocessing of the metal product while the metal product is fixed is thus enabled without restriction from the shape of the metal product.

In order to improve a usage of machine tool components, it is provided that the machine tool component is formed at least partially, in particular essentially, or alternatively completely from an amorphous metal. It is provided that the tool component is produced using injection molding or 3D printing or plastic deformation.

A manufacturing process may comprise: stacking a plurality of friction discs together, each friction disc comprising a lug defining a surface; and depositing a composition to bond to the surface of a first friction disc in the plurality of friction discs to form a wear pad defining a wear surface.

A powder flow monitoring system may include a computing device configured to receive image data representing illuminated powder of a powder stream between a powder delivery device and a build surface of a component, generate a representation of the powder stream based on the image data, and output the representation of the powder stream for display at a display device.

An additive manufacturing system may include a powder delivery device configured to direct a powder stream toward a build surface of a component, and a powder flow monitoring system. The powder delivery device defines a longitudinal axis oriented toward the build surface. The powder flow monitoring system includes an illumination device configured to illuminate at least some powder the powder stream between the powder delivery device and the build surface; and an imaging device configured to image the illuminated powder at an image plane that intersects the longitudinal axis. The illumination device and the imaging device may be registered to the powder delivery device in a plane substantially orthogonal to the longitudinal axis.

An additive manufacturing system may include an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component; a powder delivery device configured to direct a powder stream toward the melt pool; a plurality of mass sensors, each mass sensor associated with a portion of the additive manufacturing system; a plurality of heat sensors; and one or more computing devices. The computing device(s) are configured to receive data from the plurality of mass sensors; determine an overall mass flux based on the data from the mass sensors; control the powder delivery device based on the overall mass flux; receive data from the plurality of heat sensors; determine an overall heat flux based on the data from the heat sensors; and control the energy delivery device based on the overall heat flux.

A system may include one or more computing devices configured to receive image data representing illuminated powder of a powder stream between a powder delivery device of an additive manufacturing system and a build surface of a component; determine at least one metric associated with the powder stream based on the received image data; determine whether the at least one metric indicates an abnormal state of the at least one metric; and cause the additive manufacturing system to perform at least one action in response to determining that the at least one metric indicates the abnormal state.

A tubular joint includes a tubular substrate extending along an axis. The substrate has a first inner diameter. A first tubular brace member is additively manufactured on the substrate and is connected thereto at a proximal end of the first tubular brace member. A second tubular brace member is additively manufactured on the substrate and is connected thereto at a proximal end of the second tubular brace member. At respective distal ends of the brace members, the first tubular brace member and the second tubular brace member have a circular cross-sectional shape having a distal wall thickness and a second inner diameter that is smaller than the first inner diameter. At the proximal ends the of brace members, the first tubular brace member and the second tubular brace member have respective proximal wall thicknesses that are greater than the distal wall thickness.

This invention teaches a quality assurance system for additive manufacturing. This invention teaches a multi-sensor, real-time quality system including sensors, affiliated hardware, and data processing algorithms that are Lagrangian-Eulerian with respect to the reference frames of its associated input measurements. The quality system for Additive Manufacturing is capable of measuring true in-process state variables associated with an additive manufacturing process, i.e. those in-process variables that define a feasible process space within which the process is deemed nominal. The in-process state variables can also be correlated to the part structure or microstructure and can then be useful in identifying particular locations within the part likely to include defects.

A method for manufacturing structural steel components with local reinforcement is provided. The method comprises selecting at least a zone of the component to be reinforced, providing a steel blank and deforming the blank in a press tool to form a product, wherein the blank and/or the product comprises a groove in the zone to be reinforced, the groove comprising an inner surface and an outer surface. The method further comprises depositing a reinforcement material on the inner surface of groove and locally heating the reinforcement material and the groove of the steel blank or product, to mix the melted reinforcement material with the melted portion of the steel blank or product.