A welded assembly includes a first object or substrate, an interlayer, and a subsequent layer deposited on the interlayer. The interlayer is an ESD coating deposited on the first object, and the subsequent layer is deposited by ESD on the interlayer. The subsequent layer is made of a different materials from the substrate. Both the interlayer and the subsequent layer are subject to peening. In one case the interlayer has a lower either a lower thermal conductivity or a lower electrical conductivity than the substrate and the subsequent layer. In another example, the subsequent layer has a cermet content of greater than 40% by wt.

Prior to manufacturing a product by additive manufacturing, a stress relief profile including frequency and amplitude parameters of an ultrasonic input is determined based on physical properties of the product, including resonant frequencies of the product and a material from which the product is manufactured. Successive layers of a material are added and energy is applied to incorporate the material of each layer into the product. A processor accesses stress relief profile parameters for each layer, determines whether a layer requires stress relief and determines a frequency and a power level for the stress relief at the layer. An ultrasonic input is applied with the determined parameters to relieve stress as the product is built up.

The present disclosure provides a system for printing a three-dimensional (3D) object. The system may comprise a source of at least one feedstock, a support for supporting at least a portion of the 3D object, a feeder for directing such feedstock from the source towards the support, and a power supply for supplying electrical current. The system may comprise a controller operatively coupled to the power supply. The controller may receive a computational representation of the 3D object. The controller may direct such feedstock through a feeder towards the support and may direct electrical current through such feedstock and into the support. The controller may subject such feedstock to heating such that at least a portion of such feedstock may deposit adjacent to the support. The controller may direct deposition of additional portions adjacent to the support and may direct an additional feedstock through such feeder and subject to heating.

Provided are a three-dimensional shaped object production device and method capable of producing a predetermined three-dimensional shaped object by forming a ball at a leading end of a conductive wire through use of the conductive wire based on scanned data or designed data and aligning and stacking the balls. The three-dimensional shaped object production device includes: a plate (40), on which a three-dimensional shaped object is placeable; a ball forming section configured to form a ball (13) by applying high voltage between a leading end of a conductive wire (4) paid out from a leading end of a capillary (12) and a spark rod (19) and melting the leading end of the wire by discharge energy; a positioning device configured to position the plate and the ball forming section by moving the plate and the ball forming section relative to each other; and a bonding section configured to bond the ball formed at the leading end of the capillary to another ball (14) that has already been stacked on the plate, the forming of the ball by the ball forming section, the relative moving of the plate and the ball forming section by the positioning device, and the bonding of the ball formed at the leading end of the capillary to the another ball by the bonding section is repeated, to thereby produce a three-dimensional shaped object having a desired shape.

A member includes a first metallic region made of a first material; a second metallic region made of a second material that is a different from the first material; and a mix region made of mixture of the first and second materials between the first and second metallic region. In a cross-sectional view, an interface between the first metallic region and the mix region is represented by a line having a first curved line protruding toward the first metallic region and a second curved line protruding toward the first metallic region, and an angle at a cross point of the first and second curved lines, the angle being made by a tangent line of the first curved line and a tangent fine of the second curved line in a region of the first metallic region, is equal to or larger than 70 degrees and smaller than 180 degrees.

The invention relates to a welding process for producing a component (10) by depositing multiple layers (100) of a metal material in layers, said layers lying one on top of the other. In said process, the base (10a) of the component (10) is placed in a liquid coolant (6) such that the coolant contacts the base (6), and a surface (10b) of the base (6) lies above the coolant level (3). A first layer (100) of the material is deposited onto the surface (10b) by welding the material to the surface (10b), and each subsequent layer (100) is deposited onto a temporary component surface (10bb) formed by the previously deposited layer (100) by welding the material to the temporary component surface (10bb), wherein the heat resulting from welding the material is absorbed by the coolant (6). The invention additionally relates to a device (1) for carrying out the method.

A system for producing an object is disclosed including a build device having a build area and a material bonding component to receive portions of a material that are used to produce the object, at least one gripper within the build area to contact the object to provide support and to provide for at least one of a heat sink for the object, a cold sink for the object, and electrical dissipation path from the object, and a movement mechanism to move the build device relative to the object to position the build device at a position to further produce the object. Another system and methods are also disclosed.

A method of manufacturing a tube is provided. The method includes: selecting a core pipe having a thickness that is initially less than a desired thickness of the tube; and building-up an outer layer over an exterior surface of the core pipe via additive manufacturing so as to increase the thickness of the core pipe such that the thickness of the core pipe is equal to the desired thickness of the tube.

An additive manufacturing apparatus makes it unnecessary to use a heater power supply, and makes it possible to attempt to reduce the cost, by effectively using an electron beam, includes: a conductive stage in a vacuum chamber; a conductive base plate on a top side of the stage; a metal-material supply device that supplies a metal material onto a top side of the base plate; an electron beam gun that irradiates, with an electron beam, the metal material supplied by the metal-material supply device, and melts and solidifies the metal material; a grounding circuit that grounds the stage and the base plate; and a controller that controls the metal-material supply device and the electron beam gun. The additive manufacturing apparatus includes a resistance heating element that is arranged between the stage and the base plate, and generates heat by a current produced by electron-beam emission from the electron beam gun.

A porous tool includes a mold body and an additively-manufactured film attached to a surface of the mold body. The film includes a porous layer and a nonporous support layer. The porous layer may include a surface having an array of surface pore openings, a network of interconnected passages in fluid communication with the surface pore openings, and one or more lateral edges that have an array of edge pore openings in fluid communication with the interconnected passages. Methods of forming a porous tool include depositing additive material on a build surface using a directed energy deposition system to form a film while simultaneously subtracting selected portions of the additive material from the film using laser ablation. Methods of forming a molded component include conforming a moldable material to a shape using a porous tool that includes a mold body and an additively-manufactured film, and evacuating outgas from the moldable material through a porous layer of the film.