An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.

An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.

Provided is a method for manufacturing material powder for metal laminating modelling, in which a virgin material is manufactured based on the particle size distribution of the virgin material being an unused material powder, and the fluidity of an unsintered reused material after the virgin material is reused a predetermined number of times by a metal laminating modelling device, so that the particle size distribution of the virgin material corresponds to the fluidity of the reused material that is equal to or greater than a predetermined standard value. Silica particles may be added to the virgin material.

A method of and system for surface finishing an additive manufactured part. A part having a surface roughness with macroasperities is placed in a chamber with an electrolyte and an electrode. A pulse/pulse reverse power supply is connected to the part rendering it anodic and connected to the electrode rendering it cathodic. The power supply is operated to decrease the surface roughness of the part by applying a first series of waveforms including at least two waveforms where a diffusion layer is maintained at a thickness to produce a macroprofile regime relative to the macroasperities, the first series of waveforms having anodic voltages applied for anodic time periods before cathodic voltages applied for cathodic time periods to effect part surface smoothing to a first surface roughness with minimal material removal and applying a final waveform where the diffusion layer represents a microprofile regime, the final waveform having a final anodic voltage applied for a final anodic time period before a final cathodic voltage applied for a final cathodic time period to effect part surface smoothing to a final surface roughness with minimal material removal.

A method of and system for surface finishing an additive manufactured part. A part having a surface roughness with macroasperities is placed in a chamber with an electrolyte and an electrode. A pulse/pulse reverse power supply is connected to the part rendering it anodic and connected to the electrode rendering it cathodic. The power supply is operated to decrease the surface roughness of the part by applying a first series of waveforms including at least two waveforms where a diffusion layer is maintained at a thickness to produce a macroprofile regime relative to the macroasperities, the first series of waveforms having anodic voltages applied for anodic time periods before cathodic voltages applied for cathodic time periods to effect part surface smoothing to a first surface roughness with minimal material removal and applying a final waveform where the diffusion layer represents a microprofile regime, the final waveform having a final anodic voltage applied for a final anodic time period before a final cathodic voltage applied for a final cathodic time period to effect part surface smoothing to a final surface roughness with minimal material removal.

A heat exchanger includes a first set of fins, a second set of fins, and an exterior wall. The first set of fins extend radially and are coaxial with each other. The first set of fins forms a first set of channels. The second set of fins extend radially and are coaxial with each other. The second set of fins forms a second set of channels. Channels of the first and second sets of channels are disposed in an alternating pattern in a circumferential direction of the heat exchanger. The first and second sets of fins are integrally formed together. A cross-sectional width of a channel of at least one of the first set of channels and the second set of channels increases as a radial distance from a centerline axis of the heat exchanger increases.

A system and method for controlling an additive manufacturing system to form a multi-material component. Operating parameter values may be determined for the additive manufacturing system based on a first material and a second material used to form the multi-material component to ensure a requisite level of bonding between particles of a gradient between the first and second materials. Data or models for the first and second materials, along with observed data from a plurality of sample multi-material components formed from the first and second materials may be utilized to determine the operating parameter values. In some cases, the operating parameter values may be tuned to form a multi-material component having predetermined values for parameter objectives along the gradient of the multi-material component. The additive manufacturing system may be a selective laser melting system.

A method for manufacturing a blade with a first portion and a second portion, the method includes forming the first portion that includes forming a model of the first portion from removable material, forming a first shell mould from the model of the first portion, and forming the single-crystal or columnar first portion m a first metal alloy in the first shell mould from a single-crystal seed, and forming the second portion in which the second portion is formed on the first portion, and in which the first portion and the second portion are made from different materials, the second portion being polycrystalline and formed from a second metal alloy. The blade includes a single-crystal or columnar first portion made from a first metal alloy and a polycrystalline second portion made from the second metal alloy different from the first metal alloy.

A method for manufacturing a blade with a first portion and a second portion, the method includes forming the first portion that includes forming a model of the first portion from removable material, forming a first shell mould from the model of the first portion, and forming the single-crystal or columnar first portion m a first metal alloy in the first shell mould from a single-crystal seed, and forming the second portion in which the second portion is formed on the first portion, and in which the first portion and the second portion are made from different materials, the second portion being polycrystalline and formed from a second metal alloy. The blade includes a single-crystal or columnar first portion made from a first metal alloy and a polycrystalline second portion made from the second metal alloy different from the first metal alloy.

Methods and systems for producing feedstock powders, suitable for use in laser-based additive manufacturing, use laser ablation to vaporize a source material, which may be in bulk solid or solid coarse grain form. The source material is vaporized by a laser (or other focused energy source) in a vaporization chamber that is temperature controlled to provide a vertical thermal gradient. The vertical thermal gradient may be controlled to, in turn, control the nucleation, coagulation, and agglomeration of the vaporized molecules, enabling formation of microparticles that may then be used as feedstock powders in laser-based additive manufacturing. The produced feedstock powder particles may be of uniform composition, of uniform shape (e.g., substantially spherical), and of uniform phase or homogeneously-mixed phases.