A method for depositing an additively-manufactured object using three-dimensional shape data indicating a shape of the additively-manufactured object, includes: dividing the shape of the additively-manufactured object of the three-dimensional shape data, into a plurality of polygon faces; extracting a column of plural polygon faces and sequentially providing index numbers from a start polygon face; detecting a terminal polygon face based on directions of a pair of adjacent polygon faces; providing a bead formation ON flag to polygon faces other than the terminal polygon face, and a bead formation OFF flag to the terminal polygon face; producing a bead map in which the index numbers and the flags provided to the polygon faces are associated with one another; referring to the bead map to obtain a bead continuous formation pass; and continuously forming the bead along the bead continuous formation pass.

A metal laminating and molding method molds a 3-dimensional molded object formed by sequentially laminating a plurality of metal layers. The metal laminating and molding method is accomplished by repeatedly performing a unit process including a metal layer laminating process of laminating the metal layer constituted by welding beads formed through arc welding and a removal process of removing impurities from a surface of the metal layer laminated in the metal layer laminating process. When the unit process is repeated, the metal layer laminating process is performed again such that a new metal layer is laminated on the surface of the metal layer from which impurities have been removed in the removal process.

A system and method to correct for deposition errors during a robotic welding additive manufacturing process. The system includes a welding power source to sample instantaneous parameter pairs of welding output current and wire feed speed in real time during a robotic welding additive manufacturing process while creating a current weld layer of a 3D workpiece part. An instantaneous ratio of welding output current and wire feed speed are determined for each instantaneous parameter pair. A short term running average ratio is determined based on the instantaneous ratios. A relative correction factor is generated based on at least the short term running average ratio and is used in real time while creating the current weld layer to compensate for deviations in a deposit level from a desired deposit level for the current weld layer.

A component of a rotary machine extends to an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end of a core of a center of the component and to a second end at a radial limiting surface of the component and which is at least partially closed. A blank includes the core of the component and is limited by an outer surface in the radial direction. The blank is subtractively processed in a first subtractive process step, such that an outer contour is elaborated in the area of the outer surface, which extends in the radial direction, and a part of the channel is manufactured, which radially extends in the blank to the first end. The channel is formed by a build-up process on the blank.

A method for manufacturing a T-shaped structure includes depositing one or more layers of weld beads over a portion of a surface of a first component such that the one or more layers of weld beads develop a metallurgical bond with the portion. Also, the method includes placing an end of a second component over the one or more layers of weld beads such that the end develops a metallurgical bond with the one or more layers of weld beads. The one or more layers of weld beads define a fully penetrated weld joint between the end and the portion to form the T-shaped structure.

A welding program is created for performing spot welding by a program creation device. The program creation device includes a display unit configured to display an image, and an image generation unit configured to generate image data of a product model before being subjected to spot welding in accordance with shape data on a product and display the product model on the display unit, a display control unit configured to make a workpiece having a selected surface in the product model to be semitransparent, a welding portion setting unit configured to set welding portions to be allotted for the selected surface in the product model, and a program creation unit configured to create the welding program including related data for a welding robot with regard to the set welding portions.

A component of a rotary machine formed from a blank, the component includes a center, a boundary surface, and at least one inner passage extending from the center up to the boundary surface and being at least partly closed. The inner passage is formed by a first subtractive machining in which a part of the passage that at least includes an opening of the passage into the boundary surface as well as a cut-out in the top surface is manufactured by machining production, and subsequently the passage is completed by a build-up production on the blank.

A method for modifying an aperture in a component, a system for modifying flow through a component, and a turbine component are disclosed. The method includes providing a substrate having at least one aperture having an electrically-conductive surface, providing a deposition device including an ESD torch, the ESD torch including an aperture penetrating electrode including a conductive material, inserting the aperture penetrating electrode at least partially into the aperture, and generating an arc between the aperture penetrating electrode and the electrically-conductive surface to deposit electrode material within the aperture. The system includes the ESD torch removably supported in an electrode holder. The turbine component includes at least one aperture having an electrospark deposited material along an electrically-conductive surface, the electrospark deposited material providing modified fluid flow through the turbine component.

A gas turbine engine blade containment system is disclosed. The blade containment system may include a generally cylindrical casing being made of a first material, and a generally cylindrical ring being made of a second material coaxially surrounding the casing, at least some portion of the ring metallurgically bonded to the casing.

A thin-skin support member is provided. The thin-skin support member may include a semi-circular edge and a flat edge that define a hollow cavity. A cylindrical cavity may be adjacent the hollow cavity and at least partially defined by the semi-circular edge. The cylindrical cavity may be configured to retain a strut assembly. A mounting interface may be coupled to the semi-circular edge and the flat edge. A torsion interface may be disposed adjacent the cylindrical cavity and configured to receive a torsion link. The thin-skin support member may be made using additive manufacturing and thus may have a grain structure grown in the direction of material being added.