A computing device for controlling the operation of an additive manufacturing machine comprises a memory element and a processing element. The memory element is configured to store a three-dimensional model of a part to be manufactured, wherein the three-dimensional model defines a plurality of cross sections of the part. The processing element is in communication with the memory element. The processing element is configured to receive the three-dimensional model, determine a plurality of paths, each path including a plurality of parallel lines, determine a radiation beam power for each line, such that the radiation beam power varies non-linearly according to a length of the line, and determine a radiation beam scan speed for each line, such that the radiation beam scan speed is a function of a temperature of a material used to manufacture the part, the length of the line, and the radiation beam power for the line.

A computing device for controlling the operation of an additive manufacturing machine comprises a memory element and a processing element. The memory element is configured to store a three-dimensional model of a part to be manufactured, wherein the three-dimensional model defines a plurality of cross sections of the part. The processing element is in communication with the memory element. The processing element is configured to receive the three-dimensional model, determine a plurality of paths, each path including a plurality of parallel lines, determine a radiation beam power for each line, such that the radiation beam power varies non-linearly according to a length of the line, and determine a radiation beam scan speed for each line, such that the radiation beam scan speed is a function of a temperature of a material used to manufacture the part, the length of the line, and the radiation beam power for the line.

A method of repairing a rod guide assembly of a fuel control unit of an aircraft engine is provided. The method comprises disconnecting a used spring seat from the rod of the rod guide assembly and welding a replacement spring seat to the rod using an electron beam controlled using a circular beam deflection pattern.

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved optical systems supporting beam combining, beam steering, and both patterned and unpatterned beam recycling and re-use are described.

An aluminum alloy precursor composition and method for fusion processing is provided which reduces hot cracking, improves compositional control, reduces porosity, and/or enhances the mechanical properties of the fusion processed article. The precursor material and fusion process using the same may be utilized for forming an article that meets compositional specifications for aluminum 6061 alloy, while minimizing defects and meeting desired strength and ductility requirements. The fusion process may include a leading energy beam for liquefying the precursor material to form a melt pool, and a trailing energy beam directed toward a trailing region of the melt pool. The trailing energy beam may be configured to enhance agitation and/or redistribution of liquid in the melt pool to prevent hot cracking, reduce porosity, or improve other characteristics of the solidified part. The method also may improve processing parameters, such as adjusting vacuum level to prevent volatilization of alloying elements.

An aluminum alloy precursor composition and method for fusion processing is provided which reduces hot cracking, improves compositional control, reduces porosity, and/or enhances the mechanical properties of the fusion processed article. The precursor material and fusion process using the same may be utilized for forming an article that meets compositional specifications for aluminum 6061 alloy, while minimizing defects and meeting desired strength and ductility requirements. The fusion process may include a leading energy beam for liquefying the precursor material to form a melt pool, and a trailing energy beam directed toward a trailing region of the melt pool. The trailing energy beam may be configured to enhance agitation and/or redistribution of liquid in the melt pool to prevent hot cracking, reduce porosity, or improve other characteristics of the solidified part. The method also may improve processing parameters, such as adjusting vacuum level to prevent volatilization of alloying elements.

A method of additive manufacture is disclosed. The method may include restricting, by an enclosure, an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure. The method may further include running multiple machines within the enclosure. Each of the machines may execute its own process of additive manufacture. While the machines are running, a gas management system may maintain gaseous oxygen within the enclosure at or below a limiting oxygen concentration for the interior.

A method of additive manufacture is disclosed. The method may include creating, by a 3D printer contained within an enclosure, a part having a weight greater than or equal to 2,000 kilograms. A gas management system may maintain gaseous oxygen within the enclosure atmospheric level. In some embodiments, a wheeled vehicle may transport the part from inside the enclosure, through an airlock, as the airlock operates to buffer between a gaseous environment within the enclosure and a gaseous environment outside the enclosure, and to a location exterior to both the enclosure and the airlock.

Gas is introduced into molten metal during an additive metal fabrication process and/or during a metal fusion process. The gas may comprise a process gas that flows through a tubular feed wire. The amount of process gas introduced can be controlled to vary the composition and/or material properties of metal deposits formed from a molten metal. Material properties such as yield strength, hardness, and fracture toughness can be increased or decreased in specific regions to provide material property gradients that closely correspond to expected requirements of components fabricated utilizing additive and/or fusion processes.

Gas is introduced into molten metal during an additive metal fabrication process and/or during a metal fusion process. The gas may comprise a process gas that flows through a tubular feed wire. The amount of process gas introduced can be controlled to vary the composition and/or material properties of metal deposits formed from a molten metal. Material properties such as yield strength, hardness, and fracture toughness can be increased or decreased in specific regions to provide material property gradients that closely correspond to expected requirements of components fabricated utilizing additive and/or fusion processes.