A system for additively manufacturing a composite part is disclosed. The system may include a vat configured to hold a supply of resin, and a build surface disposed inside the vat. The system may also include a print head configured to discharge a matrix-coated continuous reinforcement onto the build surface, and an energy source configured to expose resin on a surface of the matrix-coated continuous reinforcement to a cure energy.

A high-quality porous aluminum sintered compact, which can be produced efficiently at a low cost; has an excellent dimensional accuracy with a low shrinkage ratio during sintering; and has sufficient strength, and a method of producing the porous aluminum sintered compact are provided. The porous aluminum sintered compact is the porous aluminum sintered compact that includes aluminum substrates sintered each other. The junction, in which the aluminum substrates are bonded each other, includes the TiAl compound and the eutectic element compound capable of eutectic reaction with Al. It is preferable that the pillar-shaped protrusions projecting toward the outside are formed on outer surfaces of the aluminum substrates, and the pillar-shaped protrusions include the junction.

A rotary valve includes a valve body defining an inlet, an outlet, and a fluid flow path connecting the inlet and the outlet, and a valve shaft is disposed in the valve body. A control element includes a first side, a second side, and defines a pivot axis. The control element operatively connected to the valve shaft, disposed in the fluid flow path, and is rotatable by the valve shaft about the pivot axis between an open position, in which the control element permits fluid flow between the inlet and the outlet, and a closed position, in which the control element limits flow between the inlet and the outlet of the valve body. A portion of the control element includes a lattice structure including a plurality of connected lattice members. The lattice structure defines one or more channels extending across the first side of the control element.

A rotary valve includes a valve body defining an inlet, an outlet, and a fluid flow path connecting the inlet and the outlet, and a valve shaft is disposed in the valve body. A control element includes a first side, a second side, and defines a pivot axis. The control element operatively connected to the valve shaft, disposed in the fluid flow path, and is rotatable by the valve shaft about the pivot axis between an open position, in which the control element permits fluid flow between the inlet and the outlet, and a closed position, in which the control element limits flow between the inlet and the outlet of the valve body. A portion of the control element includes a lattice structure including a plurality of connected lattice members. The lattice structure defines one or more channels extending across the first side of the control element.

According to one aspect, embodiments of the invention provide a method of 3D printing, comprising depositing a model material in successive layers to form a part, the model material being a metal composite including greater than 50% by volume metal powder and less than 50% by volume a first removable binder, depositing the model material in successive layers to form a support structure adjacent the part, depositing a sinterable separation material between a surface of the part and a surface of the support structure, the sinterable separation material formed from 10-40% by volume ceramic powder and greater than 50% by volume a second removable binder, debinding the first removable binder of the model material and the second removable binder of the sinterable separation material, and sintering the part, the support structure, and the sinterable separation material at a temperature profile that sinters the model material and the sinterable separation material.

According to one aspect, embodiments herein provide a method of reducing distortion in an additively manufactured part comprising forming a shrinking platform from a composite including metal particles embedded in a first matrix, forming shrinking supports from the composite, forming a part from the composite upon the shrinking platform and shrinking supports, forming an interior structure in at least one of the shrinking platform, the shrinking supports, and the part having a plurality of chambers with interconnections therebetween, forming from the shrinking platform, the sintering supports, and the part a portable assembly, and debinding the first matrix in the portable assembly to form a portable assembly in a brown state, wherein debinding the first matrix includes penetrating a fluid debinder into the interior structure of the at least one of the shrinking platform, the shrinking supports, and the part to debind the first matrix from within the interior structure.

A seal assembly for a component of a turbomachine and method of assembly thereof is provided. The seal assembly includes at least one mating face positioned adjacent to the component and a seal coupled to the mating face. The seal includes an outer shell defining an interior space; an inner matrix filling the interior space comprising a plurality of unit cells comprising one or more metamaterials, wherein at least a portion of the plurality of unit cells are identical, and wherein the plurality of unit cells are repeated throughout the inner matrix; and one or more support struts extending throughout the inner matrix. The method of building the seal assembly may include selecting a first material for the outer shell and selecting the one or more metamaterials for the inner matrix based on the first material.

A dissimilar metal joint structure includes a first and second joining materials and a three-dimensional structural body. The structural body is joined to the top of the first joining material. Spaces in the structural body are filled with the second joining material, so that the second joining material is geometrically integrated with the structural body. The structural body is joined to the first joining material at an interface. The second joining material is charged into the spaces in the structural body and is integrated with the structural body. The first and second joining materials are joined together via the structural body. Because the second joining material is charged into the spaces in the structural body, the second joining material and the structural body are strongly joined and integrated together by the anchor effect. Inducing metallurgical reaction at the interface between the first and second joining materials can increase bonding strength.

According to one aspect, embodiments herein provide a method comprising forming a shrinking platform of model material above a build plate, the model material including sinterable metal particles and a first binder, forming a support structure of the model material extending up from the shrinking platform, forming a first portion of the part from successive layers of the model material above the support structure, forming a release layer intervening between a surface of the part and an opposing surface of the support structure or between a surface of the shrinking platform and an opposing surface of the build plate, the release layer including a dispersed ceramic powder and a second binder, and supporting the part, the release layer, and the support structure upon the shrinking platform to form a platform-integrating part assembly, the support structure being configured to prevent the first portion from distorting from gravitational force during sintering.

A method comprising forming a shrinking platform of layers of a composite, the composite including a metal particulate filler in a first matrix, forming a shrinking support of layers of the composite upon the shrinking platform, forming a first release layer of a release material upon the shrinking support, the release material including a ceramic particulate and a second matrix, and forming a part of the composite upon the shrinking support to form a portable assembly from the combined shrinking platform, shrinking support, release layer and part, wherein substantially horizontal portions of the part are vertically supported by the shrinking platform, wherein the first release layer is configured, after sintering, to separate the part from the shrinking support and to allow the part to be readily removed from the shrinking support, and wherein the shrinking support is configured to prevent the part from distorting during sintering.