A process includes forming a printed article having an external surface and at least one microfeature with an internal surface by additive manufacture, coating the external surface and the internal surface of the printed article with a metallic microlayer to form a coated article, and densifying the coated article to form a component. After formation, the printed article has a porosity such that the printed article is not at full density. A densified component includes a printed article having an external surface and at least one microfeature with an internal surface and a metallic microlayer coating the external surface and the internal surface of the printed article. The printed article is formed by additive manufacture.

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 vehicular differential device includes a differential case, a ring gear, and a welded portion positioned on an abutting surface where the differential case and the ring gear are in contact with each other. The welded portion is configured to join the differential case and the ring gear for integral rotation of the differential case and the ring gear around a rotation axis of the vehicular differential device. The welded portion includes a plurality of welding surfaces positioned at predetermined intervals along a circumferential direction around the rotation axis.

A powder material for an additive manufacturing process and a method of manufacturing a three-dimensional article via an additive manufacturing process. The powder material comprises an iron-based alloy including alloying elements of carbon (C) and copper (Cu). The iron-based alloy may be formulated to achieve a precipitation strengthened microstructure comprising a lath martensite matrix phase and a Cu precipitate phase. The iron-based alloy may have a Cu weight fraction and a nickel (Ni) weight fraction, and the Ni weight fraction may be less than the Cu weight fraction of the iron-based alloy.

A method for layer-by-layer manufacturing of a three-dimensional metallic work piece, comprising the steps of: delivering a metallic feed material in a substantially solid state into a feed region; emitting an electron beam; and translating the electron beam through a first predetermined raster pattern frame in an x-y plane. The method may also include monitoring a condition of one or both of the feed region or the substrate region in real time for the occurrence of any deviation from a predetermined condition; upon detecting of any deviation, translating the electron beam through at least one second predetermined raster pattern frame in the x-y plane that maintains the melting beam power density level substantially the same as the first predetermined raster pattern frame, but alters the substrate beam power density level.

A method of additive manufacture is disclosed. The method may include restricting, by an enclosure, an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure. The method may further include running multiple machines within the enclosure. Each of the machines may execute its own process of additive manufacture. While the machines are running, a gas management system may maintain gaseous oxygen within the enclosure at or below a limiting oxygen concentration for the interior.

An additive manufacturing method for making a metal matrix composite component includes melting a powdered mixture with an electron beam. The powdered mixture comprises powdered tungsten carbide in an amount of 45 wt % to 72 wt % of the powdered mixture and a powdered binder in an amount of 28 wt % to 55 wt % of the powdered mixture. The powdered binder comprises boron, silicon, and nickel.

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 method for producing a welded metal blank (16) includes cutting a first initial metal sheet (1) and a second initial metal sheet (3) from a first and second metal strip (4); joining the first and second initial metal sheets (1,3) by welding so as to obtain an initial welded metal blank (9), the initial welded metal blank (9) comprising a weld joint (10) joining the first and the second initial metal sheets (1,3); and cutting said initial welded metal blank (9) by a process involving metal melting so as to obtain at least one final welded metal blank (16) comprising a first metal blank portion (17) and a second metal blank portion (18) joined by a weld joint portion (19) consisting of a portion of the weld joint (10) obtained during the joining step.

A method and an apparatus pertaining to recycling and reuse of unwanted light in additive manufacturing can multiplex multiple beams of light including at least one or more beams of light from one or more light sources. The multiple beams of light may be reshaped and blended to provide a first beam of light. A spatial polarization pattern may be applied on the first beam of light to provide a second beam of light. Polarization states of the second beam of light may be split to reflect a third beam of light, which may be reshaped into a fourth beam of light. The fourth beam of light may be introduced as one of the multiple beams of light to result in a fifth beam of light.