The present disclosure generally relates to methods for additive manufacturing (AM) for fabricating multi-walled structures. A multi-walled structure includes a first wall having a first surface and a second wall having a second surface facing the first surface to define a passage having a width between the first surface and the second surface in a first direction. The multi-walled structure also includes an enlarged powder removal feature connecting the first wall and the second wall. The enlarged powder removal feature has an inner dimension greater than the width in the first direction and at least one open end in a direction transverse to the first width.

A method of manufacturing a TiAl alloy impeller includes a blank preparation step in which a blank of the TiAl alloy impeller is prepared, wherein the blank has a shaft portion and a plurality of blades, and a thickness of an outer edge of each of the blades of the blank is set so as to be larger than a thickness of an outer edge of a blade of the TiAl alloy impeller, and an additional work step in which an additional work is performed on each of the blades of the blank. In the additional work step, the additional work is performed on a first surface of a portion that includes at least the outer edge of each of the blades or the first surface and a second surface of the portion thereof.

A method of manufacturing a TiAl alloy impeller includes a blank preparation step in which a blank of the TiAl alloy impeller is prepared, wherein the blank has a shaft portion and a plurality of blades, and a thickness of an outer edge of each of the blades of the blank is set so as to be larger than a thickness of an outer edge of a blade of the TiAl alloy impeller, and an additional work step in which an additional work is performed on each of the blades of the blank. In the additional work step, the additional work is performed on a first surface of a portion that includes at least the outer edge of each of the blades or the first surface and a second surface of the portion thereof.

A laser beam is irradiated onto material powder on a manufacturing table to solidify the material powder and form a solidified layer. The material powder is further deposited on the solidified layer and the laser beam is irradiated onto one part of the material powder to solidify the material powder. They are repeated to manufacture a manufactured object. An irradiation output value of the laser beam is determined based on measurement information regarding a deposition surface before depositing the material powder or regarding a surface state of the material powder after deposition that is acquired by a camera. Alternatively, the aforementioned irradiation output value is determined based on parity information regarding a number of solidified layers that were already solidified by irradiation of the energy beam, or determined in accordance with an irradiation output value used when solidifying a solidified layer solidified prior to deposition of the deposited material powder.

Aluminum alloys, fabricated by a rapid solidification process, with high strength, high ductility, high corrosion resistance, high creep resistance, and good weldability.

A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a first layer formation step of forming a first layer on a support by supplying a first composition containing first particles and a binder, a second layer formation step of forming a second layer composed of one layer or a plurality of layers on the first layer by supplying a second composition containing second particles and a binder, and a separation step of separating the second layer from the support through the first layer, wherein after the separation step, a sintering step of sintering the second layer is performed.

A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a first layer formation step of forming a first layer on a support by supplying a first composition containing first particles and a binder, a second layer formation step of forming a second layer composed of one layer or a plurality of layers on the first layer by supplying a second composition containing second particles and a binder, and a separation step of separating the second layer from the support through the first layer, wherein after the separation step, a sintering step of sintering the second layer is performed.

Provided is a method for manufacturing an Ni-based alloy member in which the equilibrium amount of γ′ phase precipitation at 700° C. is from 30 to 70 volume %. The method includes the steps of preparing an Ni-based alloy powder having a predetermined chemical composition; forming a precursor body wherein an average grain diameter of the γ phase grains is 50 μm or less, by using the Ni-based alloy powder; and heating the precursor body to a temperature at least the γ′ phase solvus temperature and subsequently slow-cooling the heated precursor body from the temperature to a temperature at least 100° C. lower than the γ′ phase solvus temperature at a cooling rate of 100° C./h or lower. There is obtained a softened body in that the γ′ phase particles of at least 20 volume % precipitate between/among the γ phase grains having an average grain diameter of 50 μm or less.

A method operates a three-dimensional (3D) metal object manufacturing system to compensate for errors that occur during object formation. In the method, thermal image data and dimensional image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object. Thermal conditions are identified from these data and compared to predetermined ranges corresponding to the identified thermal conditions to identify one or more errors. For identified errors outside a corresponding predetermined difference range, the method performs an error compensation technique. The error compensation includes modification of a surface data model, modification of machine-ready instructions, or operation of a subtractive device.

A method operates a three-dimensional (3D) metal object manufacturing system to compensate for errors that occur during object formation. In the method, thermal image data and dimensional image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object. Thermal conditions are identified from these data and compared to predetermined ranges corresponding to the identified thermal conditions to identify one or more errors. For identified errors outside a corresponding predetermined difference range, the method performs an error compensation technique. The error compensation includes modification of a surface data model, modification of machine-ready instructions, or operation of a subtractive device.