A hardfacing process includes depositing a clad layer having a thickness greater than about 1 mm (0.04 in) on a surface of the component by arc welding, and creating a heat affected zone directly below the clad layer due to the depositing. The heat affected zone may be a region of the component where a lowest hardness is more than 40% lower than a base hardness of the component below the heat affected zone. The method may also include heat treating the component after the deposition such that the lowest hardness in the heat affected zone is restored to within about 15% of the base hardness of the component.

A process of welding a weld turbulator on an article includes forming a weld pool on a surface of the article using an arc welder, directing at least one beam of at least one beam welder to at least one fusion edge of the weld pool, and translating the arc welder and the beam welder in a weld direction to shape the weld pool into the weld turbulator extending in the weld direction and having the fusion edge. A turbulator welding system includes an arc welder arranged and disposed to provide an electric arc on a surface of an article to form a weld pool and at least one beam welder arranged and disposed to provide at least one beam to at least one fusion edge of the weld pool. A component includes an article having a surface and a weld turbulator on the surface of the article.

An additive manufacturing support device includes a building condition acquisition unit configured to acquire information on a shape model of an object and a load condition applied to the object; a stress analysis unit configured to determine a maximum principal stress direction generated in each portion of the object, by stress analysis based on the acquired shape model and load condition; and a trajectory determination unit configured to determine a forming direction of a weld bead on the basis of the maximum principal stress direction and the load condition.

Various embodiments of the teachings herein include a method for the additive manufacture of a component. The method may include: training a representation with datasets from a previously executed manufacturing process with a known process result; calculating output data from input data; and creating an adaptive anomaly detection model trained on a parameter-set-specific basis with available training data. The method may include transferring the machine code and the detection models to a control system; starting the manufacturing process; monitoring the process with sensors; evaluating sensor signals of the manufacturing process using the generalized anomaly detection model; training a specialized anomaly detection model in parallel from an adaptive anomaly detection model using process data of the running manufacturing process; and detecting anomalies in the manufacture of the component using the specialized anomaly detection model during the manufacturing process.

A fault-monitoring device includes: a shape profile acquisition unit that acquires a shape profile of the existing weld bead; a feature amount extraction unit that extracts a feature amount of a concave shape formed by the plurality of existing weld beads included in the shape profile; a fault position identification unit that identifies a fault candidate location where the welding fault is expected to occur according to the extracted feature amount; and a control unit that causes the shape profile acquisition unit to update the shape profile when the welding device newly forms the weld bead and repeatedly executes the extraction of the feature amount by the feature amount extraction unit and the identification of the fault candidate location by the fault position identification unit.

Embodiments of additive manufacturing systems are disclosed. In one embodiment, an additive manufacturing system includes an array of multiple electrodes for sequentially depositing material layer-by-layer to form a three-dimensional (3D) part. The system includes a power source to provide electrical power for establishing a welding arc for each electrode. The system includes a drive roll to drive each electrode. The system also includes a controller to operate the system at a first deposition rate to form first resolution contour portions of a layer of the part. The controller also operates the system at a second deposition rate to form second resolution fill portions of the layer of the part. The system provides variable width deposition at the second deposition rate using a variable number of the electrodes. The first deposition rate is lower than the second deposition rate, and the first resolution is higher than the second resolution.

A machine for the deposition of material for the production of pieces, with a structural housing including an inner chamber in which an arc torch operates in order to melt a strand of material with which pieces are formed on a supporting table; the arc torch is mounted on a frame positioned horizontally in the upper part of the chamber, on which the arc torch is mounted with a movement system driven by several actuation devices located on the outside of the structural housing. The supporting table is positioned below the frame in an assembly that can move towards or away from the frame, with a side sub-chamber located facing the supporting table and equipped with a cover that opens outwards, and towards which the supporting table can pivot for the removal of the pieces.

A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.

According to the invention, a method is provided for additively manufacturing a component, in particular a metallic component, said method having the steps of: ? providing at least one substrate (I), in particular a substrate plate, the substrate being formed from one or more metallic substrate materials which has a martensite start temperature (Ms) below 140? C., the martensite start temperature (Ms) being below the manufacturing temperature (Tp); ? building the component on a building surface (5) of the substrate (I) by layered application of at least one material at a manufacturing temperature (Tp) to form a component-substrate composite (7) over a boundary surface (6); ? after building of the component (3) is complete, cooling at least the substrate (I) in the component-substrate composite (7) to a temperature below the martensite start temperature (Ms), wherein, as a result of martensitic transformation and the associated volume expansion of the metallic substrate material, a transformation stress is induced in the substrate (I), at least in the boundary surface (6) to the component (3); and ? separating the component (3) from the substrate (I). The invention further relates to a substrate (I) for use in such a method.

A three-dimensional (3D) metal object manufacturing apparatus is configured to increase the oxidation of ejected melted metal drops for the formation of metal support structures during manufacture of a metal object with the apparatus. The oxidation can be increased by either increasing a distance between the ejector head and a platform supporting the metal object or by providing an air flow transverse to the direction of movement of the melted metal drops, or both.