A process for manufacturing an additively-manufactured part from a metal powder having a composition having the following elements, expressed in content by weight: 6%≤Ni≤14%, 5%≤Cr≤10%, 0.5%≤Si≤2.5%, 0.5%≤Ti≤2%, C≤0.04% and optionally containing 0.5%≤Cu≤2%, the balance being Fe and unavoidable impurities resulting from the elaboration, the metal powder having a microstructure including in area fraction more than 98% of a body-centered cubic crystalline phase, the process having a step during which at least a part of the metal powder is melted in an atmosphere substantially composed of an inert gas other than Argon or of a combination of inert gases other than Argon.

A process for manufacturing an additively-manufactured part from a metal powder having a composition having the following elements, expressed in content by weight: 6%≤Ni≤14%, 5%≤Cr≤10%, 0.5%≤Si≤2.5%, 0.5%≤Ti≤2%, C≤0.04% and optionally containing 0.5%≤Cu≤2%, the balance being Fe and unavoidable impurities resulting from the elaboration, the metal powder having a microstructure including in area fraction more than 98% of a body-centered cubic crystalline phase, the process having a step during which at least a part of the metal powder is melted in an atmosphere substantially composed of an inert gas other than Argon or of a combination of inert gases other than Argon.

Devices, systems, and methods for monitoring a powder layer in additive manufacturing are disclosed. A method of monitoring a powder layer includes receiving image data corresponding the powder layer supported by a powder bed within a build chamber from imaging devices, determining leading and trailing regions of interest located adjacent to a leading end and a trailing end of the moving powder distributor, respectively, the leading and trailing regions of interest moving according to movement of the moving powder distributor, selecting at least one point located in the leading region of interest from the image data, determining first characteristics of the point, when the point is located within the trailing region of interest, determining second characteristics of the point, and comparing the first characteristics to the second characteristics.

A method of manufacturing a metal member including a first part and a second part includes a first fabrication process of fabricating the first part through a three-dimensional metal stack fabrication by a powder bed method, and a second fabrication process of fabricating an outer circumference of the second part through the three-dimensional metal stack fabrication by the powder bed method, and then sintering metallic powder remaining in an inner portion of the second part by hot isostatic pressing so as to fabricate the second part.

A process for producing a powder witness coupon including additively manufacturing a container simultaneously with a primary part, filling at least a portion of the container with a feed material employed for the part simultaneously with the additive manufacturing of the primary part, and sealing the container during the additive manufacturing of the primary part. An in-situ feed material powder witness coupon including a container additively manufactured simultaneously with a primary part, and a plurality of individual chambers within the container, at least one of the chambers being removable intact from the container. Further, a method for enhancing examination of feed material in an additively manufactured part including additively manufacturing a container simultaneously with a primary part, capturing feed material, density and environment in the container, and sealing the container.

A process for producing a powder witness coupon including additively manufacturing a container simultaneously with a primary part, filling at least a portion of the container with a feed material employed for the part simultaneously with the additive manufacturing of the primary part, and sealing the container during the additive manufacturing of the primary part. An in-situ feed material powder witness coupon including a container additively manufactured simultaneously with a primary part, and a plurality of individual chambers within the container, at least one of the chambers being removable intact from the container. Further, a method for enhancing examination of feed material in an additively manufactured part including additively manufacturing a container simultaneously with a primary part, capturing feed material, density and environment in the container, and sealing the container.

The present disclosure provides three-dimensional (3D) printing systems, apparatuses, software, and methods for safe production of at least one requested 3D object, and for passivation of material accumulated on a filter of the 3D printing system.

The present disclosure provides three-dimensional (3D) printing systems, apparatuses, software, and methods for safe production of at least one requested 3D object, and for passivation of material accumulated on a filter of the 3D printing system.

A method for joining an additively-manufactured component includes welding a plurality of additively-manufactured components via a weld joint to fabricate an integral structure. The additively-manufactured components are built by repeatedly depositing a weld bead layer of a next layer on a weld bead layer formed of a weld bead obtained by melting and solidifying a filler metal by use of an arc, and the weld joint is built along with the deposition.

A method for joining an additively-manufactured component includes welding a plurality of additively-manufactured components via a weld joint to fabricate an integral structure. The additively-manufactured components are built by repeatedly depositing a weld bead layer of a next layer on a weld bead layer formed of a weld bead obtained by melting and solidifying a filler metal by use of an arc, and the weld joint is built along with the deposition.