Systems and methods resolve stresses in additive manufacturing. A stress resolution profile including frequency and amplitude parameters of an ultrasonic input are determined based on physical properties of the product. Successive layers of a material are added and energy is applied to incorporate the material of each layer into the product. An ultrasonic input is applied with the determined parameters to resolve stress as the product is built up. The ultrasonic input is varied as a depth of the material incorporated into the product increases.

A method of manufacturing an inclined structure extending in an oblique direction from a surface of a base metal includes: forming a base portion by stacking a plurality of build-up layers on the surface of the base metal, each of the plurality of build-up layers being formed by a plurality of beads, the base portion including a reference surface inclined at an opposite side of the oblique direction across a perpendicular line of the surface of the base metal; and forming a projecting portion by stacking a plurality of build-up layers on the reference surface of the base portion, each of the plurality of build-up layers being formed by a plurality of beads, the projecting portion extending in the oblique direction from the base portion.

The disclosure relates to the field of wire arc additive manufacturing, and specifically discloses a wire arc additive manufacturing method for a high-strength aluminum alloy component, equipment and a product. A high-strength aluminum alloy is modified by using a MXene nanomaterial, and wire arc additive manufacturing is performed by using the modified high-strength aluminum alloy as a raw material, and a nanosecond laser beam is applied during the wire arc additive manufacturing to achieve an enhanced arc cathode atomization cleanup function to remove impurities, thus obtaining a high-strength aluminum alloy component without defects. The disclosure can solve the problem of very difficult forming in wire arc additive manufacturing of a high-strength aluminum alloy, and also solve the problems of many pores, liability to crack and lots of impurities during additive manufacturing of the high-strength aluminum alloy, so that a high-strength aluminum alloy component without defects can be produced.

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.

A method for producing a hardened wear plate to be used in mining or agricultural operations for transporting raw materials. The hardened wear plate is produced by providing a metal plate, overlaying a metal deposit, overlaying a flux, submerging a power head through the metal deposit and flux, and then arc-welding the arrangement to form a hardened wear plate. The hardened wear plate has a smooth, patternless surface with surface features resulting in the plate being resistant to abrasion and having few stress points making it less vulnerable to fracture or failure when in use.

Prior to manufacturing a product by additive manufacturing, a stress relief profile including frequency and amplitude parameters of an ultrasonic input is determined based on physical properties of the product, including resonant frequencies of the product and a material from which the product is manufactured. Successive layers of a material are added and energy is applied to incorporate the material of each layer into the product. A processor accesses stress relief profile parameters for each layer, determines whether a layer requires stress relief and determines a frequency and a power level for the stress relief at the layer. An ultrasonic input is applied with the determined parameters to relieve stress as the product is built up.

A method of manufacturing a metallic part in a weldable material by solid freeform fabrication comprising generating three dimensional model of the part, slicing the three dimensional model into a set of parallel, sliced layers and then dividing each layer into a set of one-dimensional pieces and, with reference to layered weld-bead geometry data, forming a computer-generated, direction specific, layered model of the part. The method also comprises uploading the layered model into a welding control system and directing the welding control system to deposit a sequence of one-dimensional weld beads of the weldable material onto the supporting substrate in a pattern required to form a first layer of the layered model and depositing a second welded layer onto the previous deposited layer in a configuration the same as the second layer, and repeating each successive weld bead until the entire part is completed. The method further includes displacing the atmosphere within the immediate vicinity of the heat source with an inert gas atmosphere which produces a required flow rate, and in which that inert atmosphere contains a maximum oxygen concentration, wherein the inert gas is delivered by an apparatus through a matrix of individual gas diffusers; and engaging an induction heating and closed loop cooling apparatus synergic to a welding control system and pre-heating the substrate material including the deposited weld beads, relevant to the type of weldable material, wherein induction heating and cooling cycles are applied constantly or pulsed from the first layer to the final layer, where optimal heating and/or cooling cycles of the weldable material are relative to the final desired part shape and microstructure.

An additively manufactured object formed by depositing weld bead layers, each of the weld bead layers being obtained by melting and solidifying a filler metal made of a mild steel, the additively manufactured object includes a plurality of the weld bead layers having a ferrite phase with an average grain diameter of 11 μm or less in a part except for a surface oxide film.

Disclosed is an additive manufacturing process for making shingles and roof tiles. The entire shingle, including the substrate, can be manufactured on location, or a substrate can be manufactured at a manufacturing plant and then colored and textured on location to provide a wide variety of shapes and colors of shingles and roof tiles. Costs for inventory and shipping are reduced and a greater variety of shapes and colors can be provided for the shingles and roof tiles. The additive manufacturing equipment can be mounted on a truck so that the additive manufacturing techniques can be a mobile application of the additive manufacturing technology.

A wire feeder assembly of the type generally associated with an electric arc welding machine including a driveshaft in rotatable communication with an individually servo motor at one end and a worm gear assembly at the other end is provided. Due to the assembly’s slim design, a series of assemblies can be deployed on a metal plate cladding machine spaced approximate 4 inches apart, which facilitates the construction of previously unattainable welding patterns.