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 systems and methods of additive manufacturing are disclosed. In one embodiment, a metal deposition device (MDD) is configured to deposit a metal material during an additive manufacturing process. A controller is operatively coupled to the MDD and is configured to command the MDD to deposit the metal material on a base to form a contour of a part. The controller is configured to command the MDD to deposit the metal material on the base to form an infill pattern within a region outlined by the contour. The infill pattern is a wave shape having a wavelength. The controller is configured to command the metal deposition device to fuse the infill pattern to the metal contour at crossover points, where the infill pattern meets the contour, by applying energy at the crossover points and reducing a deposition rate of the metal material at the crossover points to prevent distorting the contour.

A tool bit with a surface layer metallurgically bonded on a substrate layer using electrospark deposition (ESD) that allows the tool bit to reduce camout and engage a fastener head for one-handed starting and removal. The surface layer has a rougher finish, compared to conventional tool bits, and therefore better grips engagement surfaces of a mating recess of the fastener during use. The reduction of camout provides greater durability to the tool bit and resists erosion and wear of the engagement surfaces of the fastener.

Methods of repairing and maintaining rotor blade tips are provided. Filler wire may be positioned at an angle to an electrode and positioned vertically above a blade tip. Filler wire may be deposited from vertically above a blade tip to be repaired. The melting and depositing may occur in an inert environment.

A system for producing an object is disclosed including a build device having a build area and a material bonding component to receive portions of a material that are used to produce the object, at least one gripper within the build area to contact the object to provide support and to provide for at least one of a heat sink for the object, a cold sink for the object, and electrical dissipation path from the object, and a movement mechanism to move the build device relative to the object to position the build device at a position to further produce the object. Another system and methods are also disclosed.

An agent engine allocates a collection of agents to scan the surface of an object model. Each agent operates autonomously and implements particular behaviors based on the actions of nearby agents. Accordingly, the collection of agents exhibits swarm-like behavior. Over a sequence of time steps, the agents traverse the surface of the object model. Each agent acts to avoid other agents, thereby maintaining a relatively consistent distribution of agents across the surface of the object model over all time steps. At a given time step, the agent engine generates a slice through the object model that intersects each agent in a group of agents. The slice associated with a given time step represents a set of locations where material should be deposited to fabricate a 3D object. Based on a set of such slices, a robot engine causes a robot to fabricate the 3D object.

Disclosed is a welding system configured to perform additive manufacturing, particularly a welding system to achieve a stable a laser metal deposition with hot wire process by controlling the contact point between the welding wire and the workpiece. For example, the resistance of the stick-out wire is measured and the measured resistance is converted to a distance signal, which can then be used for comparison to a desired distance. The distance between the contact tip and the workpiece can then be adjusted based on the comparison. The present disclosure also relates to using a constant enthalpy system to determine and control the contact tip to workpiece distance.

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.

A method for manufacturing a component of a rotary machine, the component extends in an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end in a center of the component to a second end at a radial limiting surface of the component and which is partially closed. A blank includes the center of the component and is limited by an outer surface in the radial direction. The maximum dimension of the outer surface in the radial direction is smaller than the dimension of the limiting surface in the radial direction, A first subtractive process step is performed such that a part of the channel is manufactured by a machining process, with the part extending from the first end of the channel to the outer surface of the blank. Afterwards the channel is finished by a build-up process on the blank.

A method of manufacturing a component of a rotary machine, the component has at least one inner passage that extends from a center up to a boundary surface of the component and is at least partly closed, and a blank is provided that includes the boundary surface and a top surface. The Method includes a first subtractive machining step that is carried out 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 are manufactured by machining production, and subsequently the passage is completed by build-up production on the blank.