This disclosure provides systems, methods, and tooling for additive manufacturing on a build surface of a pre-existing component. An additive manufacturing tool successively positions layers of powdered materials and selectively fuses the layers of powdered materials to create an additive component on the build surface of the pre-existing component. The pre-existing component is secured in a build plate by a thermal expansion fit during the additive manufacturing process.

A method for powder-bed-based additive manufacturing of a component, includes setting irradiation vectors for a layer to be irradiated for the component, wherein, irradiation vectors are irradiated below a length of 1 mm in a pulsed irradiation operation; and a pulse frequency below 3 kHz and a scan speed below 250 mm/a are selected. A correspondingly manufactured component is produced.

A method for powder-bed-based additive manufacturing of a component, includes setting irradiation vectors for a layer to be irradiated for the component, wherein, irradiation vectors are irradiated below a length of 1 mm in a pulsed irradiation operation; and a pulse frequency below 3 kHz and a scan speed below 250 mm/a are selected. A correspondingly manufactured component is produced.

The present disclosure relates to techniques for stress relief in additive layer manufacturing (ALM). Example embodiments include a method for additive layer manufacturing of a metallic component, comprising the steps of: providing a substrate (20); depositing a first layer (22) of material on the substrate (20); depositing a plurality of second layers of material on the first layer (22) to form the metallic component (21), wherein the first layer (22) forms a stress relieving layer between the plurality of second layers and the substrate (20), the stress relieving layer having a lower shear stiffness compared to the metallic component (21).

The present invention relates to a device (1) for sintering by pulsating current, the device (1) comprising: a sintering cell (4) comprising two walls (14a, 14b) facing each other and defining between them a cavity (C) for receiving material to be sintered, a press (2) arranged for moving one of the walls (14a, 14b) towards the other wall, so as to compress the material, when the material is received in the cavity (C), means (10a, 10b) of rotating one of the walls (14a, 14b) relative to the other wall, so as to apply a torsional force to the material, when the material is compressed in the cavity (C).

The present invention relates to a device (1) for sintering by pulsating current, the device (1) comprising: a sintering cell (4) comprising two walls (14a, 14b) facing each other and defining between them a cavity (C) for receiving material to be sintered, a press (2) arranged for moving one of the walls (14a, 14b) towards the other wall, so as to compress the material, when the material is received in the cavity (C), means (10a, 10b) of rotating one of the walls (14a, 14b) relative to the other wall, so as to apply a torsional force to the material, when the material is compressed in the cavity (C).

An additive manufacturing machine (10) comprises: a manufacturing chamber (12), the manufacturing chamber being formed by at least one working plane (20), a front wall (22), a rear wall (24), a left-hand lateral wall (26), a right-hand lateral wall, and an upper wall (30), at least one of these walls supporting a source of energy or heat (14); an inner skin (32) that is positioned inside the manufacturing chamber (12) in front of each wall of this chamber supporting the source of energy or heat (14) and at a non-zero distance from these walls so as to create a circulation volume (V) for a flow of gas (F); and a device (52) for generating the flow of gas (F) that is connected to the circulation volume (V).

An additive manufacturing machine (10) comprises: a manufacturing chamber (12), the manufacturing chamber being formed by at least one working plane (20), a front wall (22), a rear wall (24), a left-hand lateral wall (26), a right-hand lateral wall, and an upper wall (30), at least one of these walls supporting a source of energy or heat (14); an inner skin (32) that is positioned inside the manufacturing chamber (12) in front of each wall of this chamber supporting the source of energy or heat (14) and at a non-zero distance from these walls so as to create a circulation volume (V) for a flow of gas (F); and a device (52) for generating the flow of gas (F) that is connected to the circulation volume (V).

A building time for building an additively-manufactured object is calculated on the basis of the inter-pass time and the welding pass time and is compared with a preset upper limit value, and welding conditions in a depositing plan are repeatedly modified until the building time is equal to or less than the upper limit value. Alternatively, corrections are repeatedly performed until the shape difference between a building shape of built-up object shape data relating to the additively-manufactured object created on the basis of the inter-pass time and the inter-pass temperature, and a building shape of three-dimensional shape data, is smaller than a near net value.

A building time for building an additively-manufactured object is calculated on the basis of the inter-pass time and the welding pass time and is compared with a preset upper limit value, and welding conditions in a depositing plan are repeatedly modified until the building time is equal to or less than the upper limit value. Alternatively, corrections are repeatedly performed until the shape difference between a building shape of built-up object shape data relating to the additively-manufactured object created on the basis of the inter-pass time and the inter-pass temperature, and a building shape of three-dimensional shape data, is smaller than a near net value.