Various embodiments include an acoustic-energy deposition and repair system that includes at least one Directed Acoustic Energy Deposition (DAED) tool configured to apply acoustic energy to feedstock material in at least one of three vibrational modes; and a drive system to move the DAED tool in at least one of three-coordinate positions. In various examples, the acoustic-energy deposition and repair system further includes at least one in-situ metrology tool mounted proximal to the DAED tool to measure a grain size of deposited material. Other methods, devices, apparatuses, and systems are disclosed.

In an example implementation, a method of printing a multi-structured three-dimensional (3D) object includes forming a layer of sinterable material. The method includes processing a first portion of the sinterable material using first set of processing parameters and processing a second portion of the sinterable material using a second set of processing parameters. The processed first and second portions form, respectively, parts of a first and second structure of a multi-structured 3D object.

A method of metallurgical processing includes, providing a workpiece that has been formed by additive manufacturing of a nickel-chromium based superalloy. The workpiece has an internal porosity and a microstructure with a columnar grain structure and delta phase. The workpiece is then hot isostatically pressed to reduce the internal porosity and to at least partially retain the columnar grain structure and the delta phase. The workpiece is then heat treated to at least partially retain the columnar grain structure and the delta phase.

A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, which parts correspond to successive cross sections of the three-dimensional article, the method comprising the steps of: providing a model of the at least one three-dimensional article; applying a first powder layer on a work table; directing a first energy beam from a first energy beam source over the work table causing the first powder layer to fuse in first selected locations according to corresponding models to form a first cross section of the three-dimensional article, where the first energy beam is fusing at least a first region of a first cross section with parallel scan lines in a first direction; varying a distance between two adjacent scan lines, which are used for fusing the powder layer, as a function of a mean length of the two adjacent scan lines.

A sensor may be to detect a property indicative of a print dead zone caused by a defect of build material to be used for generating the three-dimensional object or a malfunction of a heater that is to heat the build material, a build material distributor that is to provide the material, or a carriage. A processor may be to receive, from the sensor, dead zone data relating to the print dead zone, and to prevent the malfunction of the heater, the build material distributor, or the carriage, or to modify data representing the three-dimensional object to cause the three-dimensional object to be shifted such that three-dimensional object is to be printed outside the print dead zone.

A dissimilar material joined three-dimensional laminated and shaped object is shaped using a three-dimensional laminating and shaping apparatus. The three-dimensional laminating and shaping apparatus includes a material supplier that supplies materials of a three-dimensional laminated and shaped object to a shaping surface, an irradiator that irradiates the materials with a light beam, and a controller that controls the material supplier. The three-dimensional laminated and shaped object is a joined member obtained by joining dissimilar materials. The controller controls the material supplier to form a graded composition of the materials in a boundary region between the dissimilar materials of the three-dimensional laminated and shaped object.

A dissimilar material joined three-dimensional laminated and shaped object is shaped using a three-dimensional laminating and shaping apparatus. The three-dimensional laminating and shaping apparatus includes a material supplier that supplies materials of a three-dimensional laminated and shaped object to a shaping surface, an irradiator that irradiates the materials with a light beam, and a controller that controls the material supplier. The three-dimensional laminated and shaped object is a joined member obtained by joining dissimilar materials. The controller controls the material supplier to form a graded composition of the materials in a boundary region between the dissimilar materials of the three-dimensional laminated and shaped object.

In one example, a 3D printing system includes a support structure generator to identify a breakaway support to temporarily support part of the object, to design a wedge shaped groove between a portion of the object and the support, the groove ending at a line along which the support intersects the object, and to generate a digital object model that includes the support and the groove. The system also includes a 3D printer to print the object, support and groove based on the object model.

Simulation system for selecting an alloy and a production process for a workpiece to be produced having amorphous properties, wherein the system includes : an input unit, for inputting a requirements profile for the workpiece to be produced, at least one memory unit, to store information data, wherein the information data specifies information concerning physical and/or chemical and/or mechanical properties of a number of alloys for manufacturing workpieces having amorphous properties and information concerning production processes, an analysis unit, to simulate a number of workpieces according to the requirements profile and the information data to create simulation data, to assess the simulated workpieces on the basis of the simulation data and the requirements profile, to select an alloy and a production process for the workpiece to be produced from assessment, and an output unit, to output the selected alloy and the selected production process.

A method of repairing a component using an additive manufacturing process is presented. The method includes submerging the component into a powder bed so that a portion of the component to be repaired is level with a surface of the powder bed and a protruding portion of the component protrudes above the surface of the powder bed, positioning a split wiper that includes a first wiper segment and a second wiper segment in the powder bed at the surface, advancing a quantity of powder by translating the first wiper segment and the second wiper segment across the surface of the powder bed, and directing a laser beam across the surface to fuse powder particles of the powder bed to the underlying substrate forming a layer of the component. Each of the first wiper segment and the second wiper segment follow a different contour of the protruding portion at the surface.