A process and apparatus for free form fabrication of a three-dimensional work piece comprising (a) feeding raw material in a solid state to a first predetermined location: (b) depositing the raw material onto a substrate as a molten pool deposit under a first processing condition; (C) monitoring the molten pool deposit for a preselected condition; (d) comparing information about the preselected condition of the monitored molten pool deposit with a predetermined desired value for the preselected condition of the monitored molten pool deposit; (e) solidifying the molten pool deposit; (f) automatically altering the first processing condition to a different processing condition based upon information obtained from the comparing step (d); and repeating steps (a) through (f) at one or more second locations for building up layer by layer a three-dimensional work piece. The apparatus is characterized by a detector that monitors a preselected condition of the deposited material and a closed loop electronic control device for controlling operation of one or more components of the apparatus in response to a detected condition by the detector.

A process and apparatus for free form fabrication of a three-dimensional work piece comprising (a) feeding raw material in a solid state to a first predetermined location: (b) depositing the raw material onto a substrate as a molten pool deposit under a first processing condition; (C) monitoring the molten pool deposit for a preselected condition; (d) comparing information about the preselected condition of the monitored molten pool deposit with a predetermined desired value for the preselected condition of the monitored molten pool deposit; (e) solidifying the molten pool deposit; (f) automatically altering the first processing condition to a different processing condition based upon information obtained from the comparing step (d); and repeating steps (a) through (f) at one or more second locations for building up layer by layer a three-dimensional work piece. The apparatus is characterized by a detector that monitors a preselected condition of the deposited material and a closed loop electronic control device for controlling operation of one or more components of the apparatus in response to a detected condition by the detector.

A method of controlling operation of an electron beam gun and wire feeder during deposition of pools of molten matter onto a substrate to form beads upon solidification of the molten matter. The method includes providing a substrate and a wire source. A molten pool of liquid phase metal is formed on the substrate by melting the wire utilizing an electron beam generated by an electron beam gun. The liquid metal solidifies into a solid phase. A controller utilizes data from a sensor to adjust a process perimeter based, at least in part, on data generated by the sensor.

A method of controlling operation of an electron beam gun and wire feeder during deposition of pools of molten matter onto a substrate to form beads upon solidification of the molten matter. The method includes providing a substrate and a wire source. A molten pool of liquid phase metal is formed on the substrate by melting the wire utilizing an electron beam generated by an electron beam gun. The liquid metal solidifies into a solid phase. A controller utilizes data from a sensor to adjust a process perimeter based, at least in part, on data generated by the sensor.

A method and an apparatus of a powder bed fusion additive manufacturing system that enables a quick change in the optical beam delivery size and intensity across locations of a print surface for different powdered materials while ensuring high availability of the system. A dynamic optical assembly containing a set of lens assemblies of different magnification ratios and a mechanical assembly may change the magnification ratios as needed. The dynamic optical assembly may include a transitional and rotational position control of the optics to minimize variations of the optical beam sizes across the print surface.

A method and an apparatus of a powder bed fusion additive manufacturing system that enables a quick change in the optical beam delivery size and intensity across locations of a print surface for different powdered materials while ensuring high availability of the system. A dynamic optical assembly containing a set of lens assemblies of different magnification ratios and a mechanical assembly may change the magnification ratios as needed. The dynamic optical assembly may include a transitional and rotational position control of the optics to minimize variations of the optical beam sizes across the print surface.

A method for electron-beam welding of nickel-based superalloys includes joining two components of a component to be produced of nickel-based superalloys by electron radiation in which the electron radiation is guided with a feed rate of 12 mm/min to 120 mm/min, in particular of 40 mm/min to 80 mm/min, over a joining zone of the two components. A device for the electron-beam welding of two components to form a component of nickel-based alloys, which has at least a vacuum chamber, in which an electron radiation or laser radiation is generated and is directed onto a joining zone of two components to be joined.

A method for electron-beam welding of nickel-based superalloys includes joining two components of a component to be produced of nickel-based superalloys by electron radiation in which the electron radiation is guided with a feed rate of 12 mm/min to 120 mm/min, in particular of 40 mm/min to 80 mm/min, over a joining zone of the two components. A device for the electron-beam welding of two components to form a component of nickel-based alloys, which has at least a vacuum chamber, in which an electron radiation or laser radiation is generated and is directed onto a joining zone of two components to be joined.

A method for electron-beam welding of nickel-based superalloys includes joining two components of a component to be produced of nickel-based superalloys by electron radiation in which the electron radiation is guided with a feed rate of 12 mm/min to 120 mm/min, in particular of 40 mm/min to 80 mm/min, over a joining zone of the two components. A device for the electron-beam welding of two components to form a component of nickel-based alloys, which has at least a vacuum chamber, in which an electron radiation or laser radiation is generated and is directed onto a joining zone of two components to be joined.

The invention relates to a build chamber (1) for an additive manufacturing apparatus (100) for forming a three-dimensional article layer by layer from a powder. The build chamber (1) comprising a build chamber base body (2) and the build chamber base body (2) is formed by at least two segments (4) telescopically coupled together. Associated with the telescopically coupled segments are one or more bellows assemblies, further coupled to support structure configured to raise and/or lower the build table. An associated method is also provided.