The present disclosure provides a method for printing a three-dimensional object, comprising calculating at least one deposition parameter based on a computational representation of the 3D object, and using a print head to initiate printing in accordance with the deposition parameter. The printing comprises subjecting at least one feedstock to heating upon flow of electrical current through the feedstock and into the base, or vice versa. Next, (i) one or more properties of the 3D object or feedstock may be measured and (ii) whether the one or more properties of the 3D object measured in (i) meet one or more predetermined properties of the 3D object or the feedstock may be determined. The deposition parameter may be adjusted upon determining that the properties measured do not meet the predetermined properties. The print head and the adjusted deposition parameter may be used to continue to print the 3D object.

Provided is a metal laminating and modeling method including sequentially carrying out a step of laminating metal layer to form a modeled article, in which the step of laminating a metal layers includes a step of forming blocking beads that are continuous along the outer peripheral shape of the modeled article by arc welding on at least one end portion in the width direction of a target surface, on which the metal layers are to be formed, and a step of forming inner beads by arc welding with a current higher than the current in the step of forming blocking beads so as to fill a space on the inside of the blocking beads in the width direction of the target surface.

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.

A method of manufacturing a metallic part in a weldable material by solid freeform fabrication unrestricted in size and open to the ambient atmosphere. The method comprises generating a computer-generated, three dimensional model of the part, slicing the computer-generated three dimensional model into a set of computer-generated, parallel, sliced layers and then dividing each layer into a set of computer-generated, virtual, 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 direction specific, layered model of the part into a welding control system able to control the position and activation relative to a support substrate, of an electric arc delivered by a high energy tungsten arc welding torch, a plasma transferred arc welding torch, and/or a gas metal arc welding torch, and a system for feeding a consumable wire placed in an open area build space relevant to the substrate unrestricted in size and open to the ambient atmosphere. The method also comprises 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 computer-generated, direction specific, layered model of the part, and depositing a second welded layer by sequencing one-dimensional weld beads of the weldable material onto the previous deposited layer in a configuration the same as the second layer of the computer-generated direction specific layered model of the part, and repeating each successive weld bead layer of the computer-generated, direction specific, layered model of the part until the entire part is completed. The method further includes one or both of 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/or a filter; 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.

A method for producing a built-up object, includes: producing maps beforehand, the maps indicating bead heights BH and bead widths BW corresponding to a base-surface inclination angle and a track inclination angle , in which the base-surface inclination angle is an angle between a base surface on which the weld beads are to be formed and a vertical direction, and the track inclination angle is an angle between a track direction of the torch and a vertical direction on the base surface; selecting a bead height BH.sub.0 and a bead width BW.sub.0 from the maps correspondingly to the base-surface inclination angle and the track inclination angle in forming a weld bead on the base surface; and forming the weld bead based on the selected bead height BH.sub.0 and bead width BW.sub.0.

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.

In some embodiments, a method of welding includes welding at least one fill bead to fill at least one gap on a substrate with arc scanning by an arc welder. The gap is defined by at least one weld bead on the substrate. The weld beads are non-overlapping. A welded article includes a substrate including a crack-prone superalloy and at least one weld bead and at least one fill bead welded on the substrate. The fill bead, the weld bead, and a heat-affected zone of the substrate are micro-crack-free and macro-crack-free. In some embodiments, a method of welding includes welding weld beads on a substrate and welding fill beads on the substrate with an arc welder while arc scanning. The fill beads fill the gaps between neighboring pairs of weld beads. The fill beads are welded in a non-sequential order.

A die-casting sleeve comprising an outer cylinder made of a low-thermal-expansion metal material, and an inner cylinder shrink-fit into the outer cylinder; an outer peripheral surface of the outer cylinder being provided with a flange for fixing the die-casting sleeve to a stationary die block of a die-casting machine; the inner cylinder being constituted by a front member of a low-thermal-expansion metal material arranged on the injection opening side, and a rear member of silicon-nitride-based ceramics arranged in close contact with a rear end surface of the front member; the outer cylinder having an average thermal expansion coefficient .sub.A of 110.sup.6/ C. to 510.sup.6/ C. between 20 C. and 200 C.; the front member having an average thermal expansion coefficient .sub.B of 110.sup.6/ C. to 510.sup.6/ C. between 20 C. and 200 C.; the difference between .sub.A and .sub.B being 110.sup.6/ C. to 110.sup.6/ C.; and the axial length L.sub.1 (mm) and inner diameter D.sub.in (mm) of the front member, and the distance L.sub.2 (mm) from a tip end of the outer cylinder to a rear end of the flange meeting D.sub.inL.sub.1L.sub.2+20.

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 m or less in a part except for a surface oxide film.

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.