A method is provided for manufacturing an article. The method comprises depositing by additive friction stir deposition a wear-resistant material on a surface of a preform to provide an intermediate article. The preform comprises a first composition and the wear-resistant material comprises a second composition. The second composition is substantially different from the first composition. The method also comprises machining the intermediate article to remove therefrom at least a portion of the wear-resistant material.

The invention relates to a rotatable, plungeable and free path travelable non-consumable tool (5) for production of a channel (2) and a weld joint (1). The tool (5) comprises a shoulder and a probe, the shoulder having a surface facing the material(s) of components (3) to be processed. The shoulder and the probe are arranged to have a simultaneous and synchronized action in the materials of at least two components (3) to be processed. The shoulder facing the at least two components (3) to be processed has a system of scrolls shaped to have an inward action and an outward action on the at least two components (3) to be processed. The probe has a cylindrical or conical surface having a top zone, provided with a profile having a push-up action on the components (3) to be processed in a direction towards the shoulder. The top zone ends at or in the vicinity of a bottom zone provided with a profile having a push-down action on the components (3) to be processed in a direction towards the tip. The tool (5) enables the production of a channel (2) and a weld (1), between said at least two components (3), in one single action.

A method of depositing an extrudate onto a substrate, the method including steps of rotating a stirring tool about an axis of rotation while urging a tool distal end of the stirring tool against the substrate, and wherein the stirring tool defines a bore, extending therethrough; positioning a die adjacent to the stirring tool, such that the stirring tool rotates relative to the die; and passing feedstock through the bore toward the tool distal end.

An additive manufacturing method includes: providing a metal substrate; pressing a plurality of first metal parts to weld the same on the metal substrate one by one using a welding unit through friction welding so as to form a first stacked layer laminated on the metal substrate; pressing a plurality of second metal parts to weld the same on the first stacked layer one by one using the welding unit through friction welding so as to form a second stacked layer laminated on the first stacked layer; and repeating formation of the second stacked layer until a required amount of the second stacked layers are additively laminated on the first stacked layer to obtain a final three-dimensional (3D) article.

A tool head assembly for a solid state additive manufacturing apparatus includes a tool head having a material passage configured to receive a material therein. The tool head is configured to deposit the material from the material passage onto a substrate of the solid state additive manufacturing apparatus to form at least one layer of the material on the substrate. The tool head includes a shoulder configured to contact the material such that rotation of the tool head frictionally stirs the material. The tool head assembly includes a barrier configured to extend along a side surface of the at least one layer as the at least one layer is deposited onto the substrate such that the barrier is configured to constrain the material from extruding past an edge of the shoulder.

A solid-state additive manufacturing additive manufacturing system applicable to building up 3D structures, coating and functionalizing surfaces, joining structures, adding customized features to objects, compounding proprietary compositions and repairing various structures is disclosed. The solid-state additive manufacturing system enables deposition of different fillers, viz. metals, metal alloys, MMCs, polymers, plastics, composites, hybrids and gradient compositions, as well as controls the resulting deposit structures, e.g. specific nano-/micro-, gradient- and porous-material structures. The system accommodates various feeding-, spindle- and tool-designs for depositing different forms of filler materials, viz. rods, wires, granules, powders, powder-filled-tubes, scrap pieces or their combination, and a working platform with multiple access points. One or multiple motors, driving and monitoring units control the movement of the workpiece, spindle and tool and move the filler through the feeding system, which passageway is in communication with the passageways of the spindle and the tool.

A manifold structure is formed using ultrasonic additive manufacturing and machining. The manifold structure includes a body having a base plate and a cover plate that define a flow passage therebetween, and a plurality of walls that segment the flow passage into a plurality of channels, wherein each of the walls has a height extending from the base plate to the cover plate and a non-linear length that is elongated relative to a width of the wall and extends in a direction normal to the height of the wall. The walls are wavy in shape to provide enhanced rigidity and stiffness during lamination over the channels.

A porous tool includes a mold body and an additively-manufactured film attached to a surface of the mold body. The film includes a porous layer and a nonporous support layer. The porous layer may include a surface having an array of surface pore openings, a network of interconnected passages in fluid communication with the surface pore openings, and one or more lateral edges that have an array of edge pore openings in fluid communication with the interconnected passages. Methods of forming a porous tool include depositing additive material on a build surface using a directed energy deposition system to form a film while simultaneously subtracting selected portions of the additive material from the film using laser ablation. Methods of forming a molded component include conforming a moldable material to a shape using a porous tool that includes a mold body and an additively-manufactured film, and evacuating outgas from the moldable material through a porous layer of the film.

An additive manufacturing method for performing additive manufacturing of a metallic powder material on a surface of a metallic base material includes a step of supplying the powder material onto the surface of the base material, a step of welding the powder material to the surface in an unmelted state through friction stir of the powder material and the surface, a step of supplying the powder material onto a welded portion formed by welding the powder material to the surface, and a step of welding the powder material to the welded portion in the unmelted state through friction stir of the powder material and the welded portion.

A cast cylinder block for an internal combustion engine includes a first and a second cylinder bore and a shared bore wall. The first cylinder bore includes a first bore wall and the second cylinder bore includes a second bore wall. The shared cylinder bore wall includes a first portion and a second portion. A portion of the first bore wall combines with a portion of the second bore wall to form the shared cylinder bore wall. The first portion of the shared bore wall is an as-cast portion. The second portion of the shared bore wall is a metal matrix composite.