A solid free-form (SFF) method is used to manufacture a component from successive layers of feedstock material with low ductility. A plasma stream is created by energizing a flowing gas using an arc electrode, the arc electrode having a variable magnitude current supplied thereto. The plasma stream is directed to a predetermined targeted region to preheat the predetermined targeted region prior to deposition. The current is adjusted and the feedstock material is introduced into the plasma stream to deposit molten feedstock in the predetermined targeted region. The current is adjusted and the molten feedstock is slowly cooled at an elevated temperature, typically above the brittle to ductile transition temperature of the feedstock material, in a cooling phase to minimize the occurrence of material stresses.

Deposition of materials with low ductility using solid free-form fabrication

A film that is formed from a biodegradable polymer blend of different aliphatic-aromatic copolyesters is provided. More specifically, the blend contains a first copolyester formed from a terephthalic acid monomer. The use of a terephthalic acid monomer results in a polymer chain containing 1,4- (para-) terephthalate units linked in a generally linear configuration (e.g., ~ 180°). The blend also contains a second aliphatic-aromatic copolyester formed from a phthalic acid and/or isophthalic acid monomer. The use of such a monomer results in a polymer chain containing 1,2- (ortho-) and/or 1,3- (meta-) linked units. The inclusion of 1,2- (ortho-) and/or 1,3- (meta-) linked units into the polymer backbone of the second copolyester introduces an angle or 'kink' (e.g., ~ 120° kink for a 1,3- linkage) into the otherwise linear polymer chain. The 'kinks' in the second copolyester backbone reduce its melting point and degree of crystallinity, which have an influence on its physical properties (e.g., toughness, tensile strength, and crystallization rate). Thus, the physical properties of the second copolyester may differ substantially from those of the first copolyester. In this regard, the 'kinked' second copolyester can provide flexibility for forming films with a wide range of properties that is superior to that which may be achieved using either of copolyesters alone.

Film formed from a blend of biodegradable aliphatic-aromatic copolyesters

A method for coating a substrate is disclosed The method includes applying a coating to a surface of the substrate and heating the applied coating and a first portion of the substrate The first portion includes the surface of the substrate and less than the entire substrate The method further includes cooling the applied coating and the first portion

Method for coating a substrate

A method for coating a substrate is disclosed. The method includes applying a coating to a surface of the substrate and heating the applied coating and the substrate to a temperature less then approximately 600° C. to create a tempered zone within the substrate. The method further includes cooling the applied coating and the substrate.

Multi-layer substrate and method of fabrication

A method of controlling spray distances in a spray unit for efficiently thermally managing one or more electronic devices. The method of controlling spray distances in a spray unit includes a first portion and a second portion positioned with the first portion. The first portion includes at least one first orifice for dispensing a first fluid flow towards at least one electronic device. A second portion is positioned within the first portion, wherein the second portion may be slidably positioned or non-movably positioned within the first portion. The second portion includes at least one second orifice for dispensing a second fluid flow towards at least one electronic device.

Method of controlling spray distances in a spray unit

A method for implementing post-heat treatment during spray forming to achieve stress control in the manufacture of a spray formed metallic tool involves applying a metallic spray-forming material onto a mold substrate and causing substantially homogenous metallic phase transformations from the austenite phase, for example, via manipulation of either or both of the substrate temperature and the spray forming cell environment temperature.

Method and arrangement for implementing heat treatment during the execution of spray-form techniques

Method and apparatus for controlling stresses in a spray form process makes use of one dimensional modeling in which characteristics of a geometrical point are quantified by iterative detection, such as taking a surface temperature reading using a pyrometer. This temperature information is used in a one dimensional simulation to predict characteristics for a column from the point down through a spray-formed article to an interface with a substrate. The modeling technique can used with a plurality of geometrical points to model the whole article, and the one dimensional simulation can be integrated with robotic spray-forming controls to minimize residual stress in the spray-formed article.

Method and arrangement for controlling stresses based on one-dimensional modeling in sprayform techniques

Method and apparatus for controlling a spray-forming process incorporating time, temperature, and transformation dependent stress relief techniques involves the manipulation of both temperature and time for strategic phase changes that result in a specific and planned volumetric increase. This manipulation is made based on controlling ongoing spray parameters to spray-form an article having a mixed-phase and interspersed makeup of metallic phases that minimizes residual stress in the article.

Mark Lusk

Papers

Method and arrangement for implementing heat treatment during the execution of spray-form techniques

Method and arrangement for controlling stresses based on one-dimensional modeling in sprayform techniques

Method and arrangement for affecting time, temperature and transformation dependent stress relief in sprayform techniques