Provided are a three-dimensional shaped object production device and method capable of producing a predetermined three-dimensional shaped object by forming a ball at a leading end of a conductive wire through use of the conductive wire based on scanned data or designed data and aligning and stacking the balls. The three-dimensional shaped object production device includes: a plate (40), on which a three-dimensional shaped object is placeable; a ball forming section configured to form a ball (13) by applying high voltage between a leading end of a conductive wire (4) paid out from a leading end of a capillary (12) and a spark rod (19) and melting the leading end of the wire by discharge energy; a positioning device configured to position the plate and the ball forming section by moving the plate and the ball forming section relative to each other; and a bonding section configured to bond the ball formed at the leading end of the capillary to another ball (14) that has already been stacked on the plate, the forming of the ball by the ball forming section, the relative moving of the plate and the ball forming section by the positioning device, and the bonding of the ball formed at the leading end of the capillary to the another ball by the bonding section is repeated, to thereby produce a three-dimensional shaped object having a desired shape.

A method of refurbishing worn diaphragm rails for turbo machines. This method comprises machining the worn part of the diaphragm rails such that a clean and geometrically exact machined surface is achieved. Welding one or more layers on these machined surfaces builds up a cladding that overtops the nominal dimensions of new diaphragm. The method further comprises machining the cladding such that it has the nominal dimensions of a new diaphragm.

In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material.

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 method for manufacturing an additively-manufactured object in which deposition is performed by melting and solidifying a metal depending on three-dimensional shape data of a target shape, includes: acquiring the three-dimensional shape data; creating a deposition plan in which a formation track and a heating condition of the metal are determined; determining a difference between a shape of the additively-manufactured object that thermally contracts by cooling after deposition and a shape of the three-dimensional shape data by an operation; modifying the deposition plan until the difference falls within a predetermined allowable range; and additively manufacturing the additively-manufactured object based on the deposition plan in which the difference falls within the allowable range.

The invention provides a pneumatic conveying system having a series of supply lines with at least portions of the lines being wear resistant to extend the useful lifespan of an agricultural product delivery applicator. The wear resistant supply line(s) may be made from a hard material and have a curve(s) defined by angled or mitered segments that are welded or otherwise joined to collectively provide the curve(s) The wear resistant supply lines may be at least partially reinforced by way of, for example, welded or other build up wear resistant material(s) at high wear zones of the supply lines.

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.

Provided are a mount system and systems and methods using the mount system for manufacturing objects, especially titanium and titanium alloy objects, by directed energy deposition. The methods include thermally pre-bending the substrate onto which the object is to be manufactured to form a pre-bent substrate, attaching the pre-bent substrate to a jig using the mount system as an underlying support, pre-heating the substrate, and forming the object on the pre-heated, pre-bent substrate using a directed energy deposition technique.

The invention provides a method and apparatus for forming a freeform metal structure by wire feed additive manufacturing. In accordance with the method, a holding structure is moved in at least one moving direction, the holding structure holding the metal structure. A metal wire end is fed along an area of deposition on the metal structure in the at least one moving direction. The metal wire end is heated to a melting temperature using a heat source, with the metal wire end as melted being deposited on the metal structure as a metallic build-up material. The metallic build-up material after heating and during the cooling is subjected in the at least one moving direction behind the area of deposition to at least one pulsed magnetic field using a magnetic coil arranged after the heat source, the at least one pulsed magnetic field effecting plastic deformation of the build-up material.

Present embodiments include an additive manufacturing tool configured to receive a metallic anchoring material and to supply a plurality of droplets to a part, wherein each droplet of the plurality of droplets comprises the metallic anchoring material and a mechanical oscillation system configured to mechanically oscillate a structural component of the additive manufacturing tool toward and away from the part, wherein the mechanical oscillation system comprises a motor, a cam coupled to the motor, and a piston coupled to the cam, wherein the piston is fixedly attached to the structural component.