A method of forming a metal workpiece is disclosed herein. The method includes applying a concentrated energy to a core wire to form melted material, and forming a metallic component from the melted material based on the concentrated energy. The core wire comprises at least two internal compartments. A first internal compartment of the at least two internal compartments comprises a first powdered material. A second internal compartment of the at least two internal compartments comprises a second powdered material. The electric current heats the core wire, the first powdered material, and the second powdered material to generate the melted material.

Provided are a systems and methods for manufacturing objects by solid freeform fabrication, especially titanium and titanium alloy objects, wherein the deposition rate is increased by using two separate heat sources, one heat source for heating the deposition area on the base material and one heat source for heating and melting a metallic material, such as a metal wire or a powdered metallic material.

Methods of additively manufacturing a manufactured component and systems that perform the methods. The methods include determining an energy application parameter at an addition location on a previously formed portion of the manufactured component. The energy application parameter includes an overlap volume between a virtual geometric shape, which is positioned at the addition location, and the previously formed portion of the manufactured component. The methods also include supplying a feedstock material to the addition location. The methods further include delivering, from an energy source and to the addition location, an amount of energy sufficient to form a melt pool of the feedstock material at the addition location. The amount of energy is based, at least in part, on the energy application parameter. The methods also include consolidating the melt pool with a previously formed portion of the manufactured component to form an additional portion of the manufactured component.

Wire arc additive manufacturing-spinning combined machining device and method are provided. The machining device includes a spinning mechanism and a fused deposition modeling mechanism. The spinning mechanism includes a machine tool and a spinning head. The spinning head is installed on the machine tool by a main shaft, and the main shaft is configured to drive the spinning head to rotate to achieve the movement in three vertical directions. The spinning head includes a spinning base and balls. Each of the balls is installed in a corresponding one of arc grooves at a bottom of the spinning base. The fused deposition modeling mechanism includes a moving track, a robot and a heat source generator. The arc moving track is arranged around the machine tool in a surrounding mode. The robot is movably installed on the moving track. The heat source generator is installed at a tail end of the robot.

An iron-based alloy composition including: boron (B): 1.6-2.4 wt. %; carbon (C): 1.7-3.0 wt. %; molybdenum (Mo): 16.0-19.5 wt. %; nickel (Ni): 3.5-6.5 wt. %; manganese (Mn): below 0.8 wt. %; silicon (Si): 0.2-3.0 wt. %; vanadium (V): 10.8-13.2 wt. %; and balanced with iron (Fe). Also, an item including a substrate portion and a hardfacing coating bonded to the substrate portion, wherein the hardfacing coating is made by an overlay welding process using the iron-based alloy composition.

A control method for an additive manufacturing device includes specifying a space amount indicating a size of a space of an opening portion and a representative position of the opening portion according to a shape profile, determining whether the opening portion is closed based on at least one of a comparison between the space amount and a design value of a bead shape, a comparison between information on the representative position and a target position of a welding bead included in a additive condition, and whether a penetration bead is formed, for a closing path for closing the opening portion with a welding bead to be formed based on the additive condition, and correcting the additive condition of the closing path when it is determined that the opening portion is not capable of being closed by the closing path.

A metal 3D printing apparatus and methods using tiny metal wires as the printing material, designed to be compact and portable, with an innovative printing head and metal wire feeder system are provided. The printing head includes a non-consumable tungsten electrode encased in a protective tube made of copper or copper alloy, a cylindrical ceramic protective gas cap surrounding the protective tube and separated from the protective tube by a gap between them, and two layers of protective gas. The novel metal wire feeder system may feed tiny wires efficiently and smoothly at high speed with precise positioning, utilizing sensor and motor feedback control to manage the droplet transfer mechanism on the melt pool surface. During the printing process, the product may be printed in a printing chamber defined by a sealed enclosure filled with inert gas, which helps achieve high-quality printing.

A method of metallurgically bonding a plurality of tracks to a surface of an elongate metallic body including bonding a first track to the surface of the elongate metallic body, the first track extending between a first initial area and a first terminal area; bonding a second track to the surface of the elongate metallic body, starting from a part of the elongate body that includes the first terminal area and moving toward the area comprising the first initial area.

Disclosed is a welding system configured to perform additive manufacturing, particularly by employing an additive manufacturing tool to build up a part by employing welding-type programs. In some examples, control circuitry controls the additive manufacturing tool to operate in a first welding-type program of a plurality of welding-type programs in response to a determination that the measured temperature is below a first threshold temperature of one or more threshold temperatures, and control the additive manufacturing tool to operate in a second welding-type program of the plurality of welding-type programs in response to a determination that the measured temperature is above the first threshold temperature.

Disclosed are systems and methods to plan a path to form a part using an additive manufacturing system. The additive manufacturing system may include one or more additive manufacturing tools. The additive manufacturing tools may include arc welding tools and non-arc welding tools. The system may also manufacture the part based on the planned path.