A method and system for laser metal powder deposition using beam wobbling. The system may include a fiber laser configured to generate a laser beam and a laser head, the laser head configured to receive the laser beam from the fiber laser and including a collimator configured to collimate the laser beam, a wobbler module having first and second movable mirrors, and a focus lens configured to focus the collimated laser beam through a powder nozzle device such that a focal point location of the focused collimated laser beam is positioned below a workpiece surface. The powder nozzle device delivers metal powder to a region on the workpiece surface that is heated by the focused collimated laser beam.

An additive manufacturing system includes an additive manufacturing unit configured to shape an object including a plurality of layers, a measurement unit configured to measure a state of each of the plurality of layers, and a control unit. The control unit includes a storage unit configured to store reference information based on internal defect information indicating a defect existing inside a sample object shaped by the additive manufacturing unit and including the plurality of layers, based on an electromagnetic wave which has passed through the sample object, and sample measurement information indicating a measurement result of the plurality of layers of the sample object measured by the measurement unit, and an estimation unit configured to estimate whether a defect occurs inside the object, based on measurement information indicating a measurement result of the plurality of layers of the object measured by the measurement unit and the reference information.

An airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member including an upper skin; a lower skin; and a support network having a plurality of interconnected support members in a lattice arrangement and/or a reticulated arrangement, the support network being configured to provide tailored characteristics of the airfoil member. Also provided are methods and systems for repairing an airfoil member.

A tooling assembly for mounting a plurality of components, such as compressor blades, in a powder bed additive manufacturing machine to facilitate a repair process is provided. The tooling assembly includes component fixtures configured for receiving each of the compressor blades, a mounting plate for receiving the component fixtures, and a magnet assembly operably coupling the component fixtures to the mounting plate in a desired position and orientation to facilitate an improved printing process.

Disclosed herein is an additive manufacturing system that includes an energy source, a powder supply, and a build chamber. The build chamber includes a base plate and two or more variable build plates coupled to the base plate. The two or more variable build plates each have one or more adjustable features. The two or more variable build plates are configurable to position two or more parts at different heights relative to a top level of the build chamber. The additive manufacturing system also includes a control system configured to control the energy source to fuse material from the powder supply to at least one of the two or more parts while the two or more parts are respectively positioned by the two or more variable build plates at different heights relative to the top level of the build chamber.

A method of furnace-less brazing of a substrate is provided. The method includes providing a substrate having a braze region thereon; disposing braze precursor material containing a nickel powder, an aluminum powder, and a platinum group metal powder on the braze region; and initiating an exothermic reaction of the braze precursor material such that the exothermic reaction produces a braze material that reaches a braze temperature above the solidus temperature of the braze material. A braze precursor material is also provided.

A method for preparing the prefabricated crack defects includes defining a defect area, defining a volume percentage of the crack defects in the defect area, adjusting the proportion of spherical powder, the proportion of hollow powder and process parameters of defect preparation according to the volume percentage of the crack defects, based on the technique of laser melting deposition, printing the defect area layer by layer by using the defect preparation powder and the process parameters of defect preparation, wherein the particle size of the defect preparation powder is between 45 μm and 150 μm, the proportion of spherical powder≥93% and the proportion of hollow powder<0.5%, the process parameters of defect preparation including: laser power of 450W-550W, scanning rate of 600 mm/min-1200 mm/min, powder feeding rate of 4 g/min-12 g/min, spot diameter of 1 mm-1.2 mm, scanning spacing of 0.5 mm-0.8 mm and layer thickness of 0.08 mm-0.2 mm.

A method for prefabricating a poor fusion defect by controlling a LMD process, including: obtaining a model, with a shaping zone and a defect prefabricated zone that has a preset defect; and performing a layerwise slicing process on the model. For each deposition layer of the defect prefabricated zone, the preset defect has a maximum dimension a0 in a perpendicular direction; for the shaping zone, performing a shaping process under predetermined shaping process parameters of the LMD process; and for the defect prefabricated zone, controlling shaping process parameters as follows: when a0<D, with respect to the shaping zone, changing a scan pitch between shaping paths and a powder feed rate in the deposition layer, thereby prefabricating the poor fusion defect; and when a0≥D, with respect to the shaping zone.

A method for preparing prefabricated gas pore defects includes: defining a defect area, defining a volume percentage of the gas pore defects in the defect area, adjusting the proportion of satellite powder, the proportion of hollow powder and the process parameters of defect preparation according to the volume percentage of the gas pore defects, based on the technique of laser melting deposition, printing the defect area layer by layer by using the defect preparation powder and the process parameters of defect preparation, wherein the particle size of the defect preparation powder is between 45 μm and 106 μm, the proportion of satellite powder is 55-65% and the proportion of hollow powder is 2.9-3.1%, the process parameters of defect preparation comprises: laser power of 600W-1000W, scanning rate of 400 mm/min-800 mm/min, powder feeding rate of 12 g/min-20 g/min, spot diameter of 1 mm-2 mm, scanning spacing of 0.5 mm-1 mm and layer thickness of 0.15 mm-0.2 mm.

Aspects of this disclosure include a method for repairing a component having narrow passage, a three-dimensional printer, and composition for three-dimensional printing. One embodiment of the method may comprise mixing a filler material for three-dimensional printing with a carrier fluid, and applying a controlled electromagnetic field to bias the filler material towards a repair location in a narrow passage of a component. The method may further comprise coating a ferromagnetic material with the filler material to form a microcapsule, wherein the ferromagnetic material is adapted to interact with the controlled electromagnetic field to attract the microcapsule to the repair location. 3D printing techniques may be used to coat the ferromagnetic core with the filler material.