An additive manufacturing method includes: forming first and second linear beads parallel to each other under a same predetermined formation condition such that a gap having a predetermined width is formed between the first and second linear beads; forming a third linear bead in the gap under the same formation condition; forming, after forming the third linear bead, the linear bead that is formed as an even-numbered line under the formation condition such that the linear bead is parallel to the first linear bead and a gap having a predetermined width is formed between the linear bead formed as an even-numbered line and a linear bead formed two lines before; and forming, after forming the third linear bead, the linear bead that is formed as an odd-numbered line in the gap between the linear bead formed immediately before and the linear bead formed three lines before under the formation condition.

A welded assembly includes a first object, a second object, and an interlayer. The interlayer is an ESD coating deposited on the first object, and the second object is welded to the coating. The second object may be a material that has thermally sensitive properties, such as a shape-memory material. The second weld may also be made by ESD. The interlayer may be made of more than one layer. The layer or layers may be deposited of a material chosen for its compatibility with one, the other, or both of the material of the first object and the material of the second object.

Embodiments of an alloy that can be resistant to cracking. In some embodiments, the alloy can be advantageous for use as a hardfacing alloys, in both a diluted and undiluted state. Certain microstructural, thermodynamic, and performance criteria can be met by embodiments of the alloys that may make them advantageous for hardfacing.

Embodiments of an alloy that can be resistant to cracking. In some embodiments, the alloy can be advantageous for use as a hardfacing alloys, in both a diluted and undiluted state. Certain microstructural, thermodynamic, and performance criteria can be met by embodiments of the alloys that may make them advantageous for hardfacing.

Molybdenum is alloyed into stainless steel surface by electro-spark deposition technique. Shielding gas is used during electro-spark deposition process to minimize the oxidation of materials. Control of electro-spark voltage, frequency, capacitance, time can determine the alloying depth of Molybdenum. The alloyed surface thickness varies from 5 μm to 80 μm depending on the electro-spark deposition parameters. The alloyed surface comprises, by weight, 15 to 40% of Molybdenum, 8 to 22% of Cr, 0-15% of other alloy elements and impurities. The molybdenum alloyed stainless steel surface exhibits improvement in micro-hardness, wear resistance, and especially corrosion resistance in sodium chloride solutions. Thus, the present invention would be utilized in marine and handling of brines application, as well as in other applications which better corrosion resistance of stainless steel is desired.

This disclosure relates to a method of producing a tool comprising a substrate and a hard-face coating metallurgically bonded to the substrate. The method comprises the steps of: providing a steel substrate; providing a composition of fully sintered granulate grains; and then applying the fully sintered granulate grains onto the substrate. The resultant cemented carbide material on the steel substrate comprises a specific composition and includes a metastable phase having a nanohardness of at least 12 GPa and a Palmqvist fracture toughness of below 7 MPa m½. The method includes heat-treating the hard-face coating to at least partially decompose the metastable phase, to increase the Palmqvist fracture toughness.

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.

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.

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.

A method for producing a built-up object by melting and solidifying a filler metal to form weld beads on a base surface along a track for a torch and form the built-up object formed by the weld beads is provided. The built-up object includes a bead formation portion where a gravitational influence is maximum. The method includes: forming a supporting bead having a higher viscosity during weld-bead formation than other weld beads in the bead formation portion; and forming the other weld beads overlying the supporting bead.