The present disclosure relates to new materials comprising Al, Co, Fe, and Ni. The new materials may realize a single phase field of a face-centered cubic (fcc) solid solution structure immediately below the solidus temperature of the material. The new materials may include at least one precipitate phase and have a solvus temperature of at least 1000° C. The new materials may include 4.4-11.4 wt. % Al, 4.9-42.2 wt. % Co, 4.6-28.9 wt. % Fe, and 44.1-86.1 wt. % Ni. In one embodiment, the precipitate is selected from the group consisting of the L1.sub.2 phase, the B2 phase, and combinations thereof. The new alloys may realize improved high temperature properties.

A manufacturing method includes a first repeating step of irradiating a base material with a pulse laser, having a spot diameter S, while relatively moving a laser head and the base material in a first direction, moving the laser head by a predetermined pitch width Pin a second direction that intersects the first direction, and repeating irradiation by the pulse laser along the first direction and movement of the laser head in the second direction, and a second repeating step of irradiating the base material with the pulse laser while relatively moving the laser head and the base material in the second direction, moving the laser head by the pitch width in the first direction, and repeating irradiation by the pulse laser along the second direction and movement of the laser head in the first direction, wherein S<P<100 μm.

Provided are a cladding alloy powder that can increase the wear resistance of a cladding alloy to be deposited and a counterpart member adapted to contact the cladding alloy, and a method for producing an engine valve using the cladding alloy powder. The cladding alloy powder includes 0.2 to 0.5 mass % C, 30 to 45 mass % Mo, 15 to 35 mass % Ni, 0.5 to 2.0 mass % Zr, and a balance including Co with unavoidable impurities. The method for producing an engine valve includes melting the cladding alloy powder, and cladding a valve face portion of an engine valve adapted to contact a valve seat with the melted cladding alloy powder.

A method of controlling operation of an electron beam gun and wire feeder during deposition of pools of molten matter onto a substrate to form beads upon solidification of the molten matter. The method includes providing a substrate and a wire source. A molten pool of liquid phase metal is formed on the substrate by melting the wire utilizing an electron beam generated by an electron beam gun. The liquid metal solidifies into a solid phase. A controller utilizes data from a sensor to adjust a process perimeter based, at least in part, on data generated by the sensor.

A method of making a light weight housing for an internal component is provided. The method including the steps of: forming a first metallic foam core into a desired configuration; forming a second metallic foam core into a desired configuration; inserting an internal component into the first metallic foam core; placing the second metallic foam adjacent to the first metallic core in order to secure the internal component between the first metallic foam core and the second metallic foam core; and applying an external metallic shell to an exterior surface of the first metallic foam core and the second metallic foam core.

Method and computer-readable model for additively manufacturing an injector assembly or a ducting arrangement including such assembles, as may be used in a combustion system of a gas turbine engine. The injector assembly may include a reactant-guiding structure (42) that may be configured to define a curvilinear flow path (47) to route a flow of reactants from a first flow direction (50) to a second flow direction (52) toward a cross-flow of combustion gases (60). A cross-flow guiding structure (54) may further define a flow path (58) to route a portion of the cross-flow of combustion gases toward an outlet side of the cross-flow guiding structure. Disclosed injector assemblies can be configured to reduce pressure loss while providing an effective level of mixing of the injected reactants with the passing cross-flow. Respective injector assemblies or the entire ducting arrangement may be formed as a unitized structure, such as a single piece using a rapid manufacturing technology, such as 3D Printing/Additive Manufacturing (AM) technology.

Methods for laser additive manufacture are disclosed in which a plurality of powder layers (48, 50 and 52) are delivered onto a working surface (54A) to form a multi-powder deposit containing at least two adjacent powders layers in contact, and then applying a first laser energy (74) to a first powder layer (48) and a second laser energy (76) to a second powder layer (52) to form a section plane of a multi-material component. The multi-powder deposit may include a flux composition that provides at least one protective feature. The shapes, intensities and trajectories of the first and second laser energies may be independently controlled such that their widths are less than or equal to widths of the first and second powder layers, their intensities are tailored to the compositions of the powder layers, and their scan paths define the final shape of the multi-material component.

A method and apparatus for direct writing of single crystal super alloys and metals. The method including heating a substrate to a predetermined temperature below its melting point; using a laser to form a melt pool on a surface of the substrate, wherein the substrate is positioned on a base plate, and wherein the laser and the base plate are movable relative to each other, the laser being used for direct metal deposition; introducing a superalloy powder to the melt pool; and controlling the temperature of the melt pool to maintain a predetermined thermal gradient on a solid and liquid interface of the melt pool so as to form a single crystal deposit on the substrate. The apparatus configured to generally achieve the aforementioned method.

The present disclosure provides a printer system based on high power, high brightness visible laser source for improved resolution and printing speeds. Visible laser devices based on high power visible laser diodes can be scaled using the stimulated Raman scattering process to create a high power, high brightness visible laser source.

Example systems may include an energy source, a material delivery device, and a computing device. The computing device, based on a target height of a layer deposited on a component by directed energy deposition, may control an energy source directed at a component and may control a material delivery device. Controlling the energy source may include advancing an energy beam along a first path to form an advancing molten pool on the component. Controlling the material delivery device may include delivering a material to the advancing molten pool. The material may combine with the advancing molten pool to form a first raised track having an actual height. The layer may include the first raised track. A deposited region of the component may include the layer. The actual height may affect a resultant microstructure within the deposited region.