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.

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 spool gun having a very unique look, due to its arrangement of external features. The spool gun has its wire spool compartment located below the handle and the user's hand, when the user is gripping the spool gun in an operational position. A gas/power cable is connected to the body of the spool gun forward of the handle.

A spool gun having a very unique look, due to its arrangement of internal and external features. The spool gun has its wire spool compartment located below the handle and the user's hand, when the user is gripping the spool gun in an operational position, thus providing a wire path through the handle to the body of the spool gear wherein the wire feed mechanism is located. The wire feed mechanism includes a 90-degree drive system, which can include a worm gear. A gas/power cable is connected to the body of the spool gun forward of the handle.

A spool gun having a very unique look, due to its arrangement of features. The spool gun has its wire spool compartment located below the handle and the user's hand, when the user is gripping the spool gun in an operational position. Operably connected to the wire spool compartment is wire spool brake configured to engage with the wire wraps. The brake can have a lock and/or a wire spool life indicator. The wire spool compartment has a cover that is non-threadedly engaged. The feed rate of the wire from the wire spool compartment can be adjusted by a control device, such as a knob, located proximate the user's hand, when the user is gripping the spool gun in the operational position.

An additive manufacturing system is disclosed including multiple conveying pipelines, a mixer and a nozzle. The multiple conveying pipelines are connected to respective material sources. The multiple conveying pipelines are connected to the mixer which is configured to mix in real time powder materials supplied via the multiple conveying pipelines during additive manufacturing. The mixer is connected via a supply pipeline to the nozzle which is configured to deliver mixed material onto a substrate to perform the additive manufacturing. Each of the multiple conveying pipelines is configured to change conveying amount or speed of the powder materials in real time. An additive manufacturing method for the above additive manufacturing system is also disclosed. The additive manufacturing system and method can adjust in real time types or proportions of the materials so as to meet different property requirements for different parts of a product.

A sprocket wheel has an annular shape. The sprocket wheel has a plurality of projections formed on an outer peripheral surface for transmitting a driving force to a track. The sprocket wheel includes a base made of a first metal, and an overlay including a second metal that covers the base so as to constitute at least a part of the outer peripheral surface. The overlay is formed with a metallic structure that is continuous in the circumferential direction so as to connect between adjacent ones of the projections.

A sprocket wheel, which is an example of the machine component, includes a base made of a first metal, and an overlay disposed in contact with the base to cover at least a part of a surface of the base. The overlay includes a matrix made of a second metal, and hard particles dispersed in the matrix. The surface of the overlay is a forged surface. The hard particles located in an overlay surface region within an average particle diameter of the hard particles from the surface of the overlay are arranged side by side while being embedded in the overlay.

Melting energy exemplified by an arc (24) is delivered to a metal alloy material (22, 23), forming a melt pool (26). A metal oxide material (34) is delivered (33) to the melt pool and dispersed therein. The melting energy and oxide deliveries are controlled (44) to melt the alloy material, but not to melt at least most of the metal oxide material. The deliveries may be controlled so that the melting energy does not intercept the metal oxide delivery. The melting energy may be controlled to create a temperature of the melt pool that does not reach the melting point of the metal oxide. Deliveries of the melting energy and the oxide may alternate so they do not overlap in time. A cold metal transfer apparatus (22) and process (18, 19, 20) may be used for example in combination with an oxide particle pulse delivery device (42, 46).

A method of build-up welding a powdery or wire-shaped material onto a workpiece, which is preferably a flat substrate, by means of a device which comprises a substantially rod-shaped electrode, the electrode having at least one material feed channel extending in its interior, the device comprising a nozzle surrounding the electrode, the method comprising the following steps: forming the arc as a transferred arc between the electrode and the workpiece or as a free-standing arc between the electrode and the nozzle, flooding the working gas area with a working gas to constrict the arc in the direction of the workpiece, feeding the powdery or wire-shaped material into the constricted arc and moving the device across the workpiece as the powdery or wire-shaped material is being fed into the constricted arc.