An additive manufacturing system includes an electrode head comprising an array of electrodes for depositing material to form a three-dimensional part. The array includes a first plurality of electrodes formed from a first metallic material having a first ductility and a first hardness, and a second plurality of electrodes formed from a second metallic material having a second ductility and a second hardness, wherein the first ductility is greater than the second ductility and the second hardness is greater than the first hardness. A power source provides electrical power for establishing a welding arc for each electrode. A drive roll system drives each electrode. A controller is connected to the power source to control operations of the additive manufacturing system to form an interior portion of the part using the first plurality of electrodes, and control the operations of the additive manufacturing system to form an exterior portion of the part using the second plurality of electrodes, such that ductility of the interior portion of the part is greater than ductility of the exterior portion of the part.

An additively manufacturing method includes: measuring a filler metal feed speed at which the filler metal is fed to the welding torch during the formation of the weld bead; acquiring a reference welding speed that is a moving speed of the welding torch corresponding to the measured filler metal feed speed; measuring a height of the formed weld bead; acquiring a welding speed correction value with which the height of the weld bead to be formed is adjusted based on a difference between the measured height of the weld bead and a height of a tip of the filler metal that protrudes from the tip of the welding torch; correcting the reference welding speed with the welding speed correction value and determining a welding speed at which the weld bead is formed; and forming the weld bead at the determined welding speed.

A piercing plug includes a plug main body, and a sprayed coating which is formed on a surface of the plug main body and includes iron and iron oxide. A chemical composition of the sprayed coating includes, in addition to the iron and the iron oxide, by mass %, C: 0.015% to 0.6%, Si: 0.05% to 0.5%, Mn: 0.1% to 1.0%, and Cu: 0 to 0.3%.

An improved hammer mill hammer constructed by forming a groove in an edge of the grinding end of a hammer for receiving hard facing material and placing hard facing in the groove.

The embodiments relate to a method for additive manufacturing of a component made from a metal matrix composite for a vehicle. In a step of the method, a plurality of elongated filaments is provided. In another step, metallic powder is provided. In a further step, the metal matrix composite component is additively manufactured by melting the metallic powder.

A method and related system and apparatus for refurbishing worn rail transit rails to a desired refurbished rail surface profile substantially similar to the surface profile of a newly-manufactured rail, comprising: depositing a first line of fill material along a lower-inside section to be refurbished; in N1 successive iterations thereafter, progressing circumferentially from the lower-inside section to be refurbished to an upper-outside section to be refurbished, depositing an n+1.sup.th line of fill material adjacent an n.sup.th line of fill material wherein the n.sup.th line of fill material substantially provides a flow barrier against the n+1.sup.th line of fill material flowing past the n.sup.th line of fill material.

Improved free-swinging hammermill hammer configurations are disclosed and described for comminution of materials such as grain and refuse. The hammer configurations of the present disclosure are adaptable to most hammer mill or grinders having free-swinging systems. The configurations as disclosed and claimed are non-forged and incorporate a saddle or hammer mouth. The merging of a hammer and saddle improves strength to reduce or maintain the weight of the hammer while increasing the amount of force delivered to the material to be comminuted. The improved configurations incorporate comminution edges having increased hardness for longer operational run times. The improved configurations improve installing, removing, and cleaning hammer components within the hammermill. The improved configurations may incorporate hammermill rod hole of varying shapes and sizes and saddles of varying shapes and sizes or the use of non-planar hammer bodies that have a recessed or protruding surface.

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 tool welding system is disclosed that includes a table that heats a tool. A multi-axis robot includes a welding head that is moved relative to the table in response to a command. A controller is in communication with the robot and generates the command in response to welding parameters. The weld parameters are based upon a difference between an initial tool shape and a desired tool shape. The difference between the initial tool shape and the desired tool shape corresponds to a desired weld shape. The desired weld shape is adjusted based upon initial tool shape variations, which includes thermal growth of the tool. The tool is welded to provide the desired weld shape to achieve a desired tool shape.

A processing head assembly is disclosed. In some examples, the processing head assembly comprises a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles. In some examples, the fabrication energy source includes the wire feedstock surrounded by the shield. A method of depositing material on a substrate using a processing head assembly for use with a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles is disclosed. In some examples, the method comprises projecting a fabrication energy beam from the fabrication energy source onto the substrate at a spot, projecting the wire feedstock surrounded by the shield onto the substrate at the spot and projecting the one or more filler feedstocks surrounded by the one or more nozzles onto the substrate close to the spot.