The invention relates to a device and method for preparing a structure or object using an additive manufacturing process referred to as sequential cold spray laser sintering. The method includes depositing by cold spraying a plurality of sequential layers of material onto a substrate/build plate or particles of materials onto a compacted powder bed of material and employing an energy source to sinter or melt each of the plurality of sequential layers or powders to produce sequential sintered layers, wherein the number of additional layers is determined based on those needed to produce the final structure.

The invention relates to a device and method for preparing a structure or object using an additive manufacturing process referred to as sequential cold spray laser sintering. The method includes depositing by cold spraying a plurality of sequential layers of material onto a substrate/build plate or particles of materials onto a compacted powder bed of material and employing an energy source to sinter or melt each of the plurality of sequential layers or powders to produce sequential sintered layers, wherein the number of additional layers is determined based on those needed to produce the final structure.

Wire arc additive manufacturing-spinning combined machining device and method are provided. The machining device includes a spinning mechanism and a fused deposition modeling mechanism. The spinning mechanism includes a machine tool and a spinning head. The spinning head is installed on the machine tool by a main shaft, and the main shaft is configured to drive the spinning head to rotate to achieve the movement in three vertical directions. The spinning head includes a spinning base and balls. Each of the balls is installed in a corresponding one of arc grooves at a bottom of the spinning base. The fused deposition modeling mechanism includes a moving track, a robot and a heat source generator. The arc moving track is arranged around the machine tool in a surrounding mode. The robot is movably installed on the moving track. The heat source generator is installed at a tail end of the robot.

A method for producing an additively-manufactured article includes: a step for feeding a powdered material onto a base metal, the powdered material being obtained by mixing a first powder containing a stellite alloy and a second powder containing tungsten carbide; a nd a step for irradiating the fed powdered material with a laser beam while weaving the lase r beam, and depositing a cladding layer, obtained by melting and solidifying at least the pow dered material, on the base metal. The step for depositing the cladding layer is performed such that 20≤A≤35, 2.2≤B≤2.9, and 5 mass%≤R2≤15 mass% are satisfied, where A is a laser heat input index, B is a powder feeding rate index, and R2 is the ratio of the second powder contained in the powdered material.

A three-dimensional additive manufacturing device appropriately detects a manufacturing abnormality. The three-dimensional additive manufacturing device includes a powder supply unit that supplies powder, a light irradiation unit that irradiates the powder with a light beam to melt and harden the powder to manufacture a layered structure, an imaging unit that captures an image of a manufacturing site including a molten pool formed of a molten powder, a result acquisition unit that acquires a determination result as to whether manufacturing of the layered structure is abnormal by inputting the image to a learning model, and an information output unit that outputs information based on the determination result. The learning model is obtained by machine-learning a correspondence relationship between an image of the manufacturing site at the time of abnormality and an abnormality type of the image, and is used for determining whether the manufacturing of the layered structure is abnormal.

A three-dimensional additive manufacturing device appropriately detects a manufacturing abnormality. The three-dimensional additive manufacturing device includes a powder supply unit that supplies powder, a light irradiation unit that irradiates the powder with a light beam to melt and harden the powder to manufacture a layered structure, an imaging unit that captures an image of a manufacturing site including a molten pool formed of a molten powder, a result acquisition unit that acquires a determination result as to whether manufacturing of the layered structure is abnormal by inputting the image to a learning model, and an information output unit that outputs information based on the determination result. The learning model is obtained by machine-learning a correspondence relationship between an image of the manufacturing site at the time of abnormality and an abnormality type of the image, and is used for determining whether the manufacturing of the layered structure is abnormal.

A device for metering one or more powder(s) (A, B) to produce a flow (23) of powder(s) and of a carrier gas at a given volume flow rate, comprises: ⋅at least a first source (25) suitable for supplying a first flow (27) comprising a first powder (A) and a first carrier gas (G1) substantially at the given volume flow rate, ⋅a source (33) of a carrier gas suitable for supplying an adjustment carrier gas flow (35) substantially at the given volume flow rate, ⋅an outlet junction (49) for emitting said flow of powder(s) and of carrier gas, ⋅a first proportional valve (59), ⋅an adjustment proportional valve (75), and ⋅a control system (21) suitable for controlling at least the first proportional valve and the adjustment proportional valve so that the flow of powder(s) and of carrier gas has a volume flow rate substantially equal to the given volume flow rate.

Systems and methods for real time, nondestructive inspection of an object being formed by additive manufacturing is provided. The disclosed systems and methods can be used with any additive manufacturing system and can detect defects introduced during fabrication. In operation, additive manufacturing of the object can be paused and the object rotated within the build chamber. An x-ray pulse can then be directed through a linear aperture towards the object being formed inside the build chamber. A linear x-ray detector array can detect the x-ray pulse and an x-ray image of the object being formed can be created. By rotating the object being formed during exposure to the x-ray pulse at least one half of one full rotation, the entire volume of the object can be inspected.

A method for manufacture of a complex component includes construction of the component from a metal material in an additive manufacturing method with at least one cavity segment that has a cavity open on at least one side and defined by an interior surface of the component, formation of an auxiliary electrode during construction of the component, formation of one or a plurality of supporting structures that connect the auxiliary electrode to the interior surface of the component during the construction of the component, electrical insulation of the auxiliary electrode from the interior surface by separating the supporting structures from the interior surface or from the auxiliary electrode, and performance of an electro-polishing of the interior surface in an electrolyte bath by connecting the component and the auxiliary electrode to different poles of an electric voltage source.

In various embodiments, wire composed at least partially of arc-melted refractory metal material is utilized to fabricate three-dimensional parts by additive manufacturing.