A computational method for controlling a powder particle uptake by a shielding gas in a laser additive manufacturing system. The computational method includes receiving a gas fluid domain, a powder bed domain, and an inlet shielding gas flow velocity of the laser additive manufacturing system. The method further includes determining a maximum gas flow velocity within the gas fluid domain based on the inlet shielding gas flow velocity and the gas fluid domain. The method also includes determining a threshold uptake flow velocity within the gas fluid domain based on the inlet shielding gas flow velocity and the powder bed domain. The method also includes controlling the powder particle uptake of the shielding gas in the laser additive manufacturing system in response to the maximum gas flow velocity and the threshold uptake flow velocity.

A computational method for controlling a powder particle uptake by a shielding gas in a laser additive manufacturing system. The computational method includes receiving a gas fluid domain, a powder bed domain, and an inlet shielding gas flow velocity of the laser additive manufacturing system. The method further includes determining a maximum gas flow velocity within the gas fluid domain based on the inlet shielding gas flow velocity and the gas fluid domain. The method also includes determining a threshold uptake flow velocity within the gas fluid domain based on the inlet shielding gas flow velocity and the powder bed domain. The method also includes controlling the powder particle uptake of the shielding gas in the laser additive manufacturing system in response to the maximum gas flow velocity and the threshold uptake flow velocity.

An apparatus includes a control system that defines a test part having multiple features of multiple feature types. The control system controls an additive manufacturing (AM) machine to print multiple copies of the test part, with each copy being printed according to a respective set of values used as printing parameters. A measurement system obtains a computed tomography (CT) image of each of the copies of the test part. An analysis system, for each of the plurality of feature types, analyzes the CT images to identify a selected set of values for the printing parameters. The analysis system identifies a portion of the CT image related to a first feature and assesses its density based on an average grayscale value. The AM machine is then controlled to print production parts according to, for each feature type of the production parts, the selected set of values for the printing parameters.

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

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

An inspection system for in situ evaluation of an additive manufacturing (AM) build part is provided. The inspection system comprises a build plane induction coil sensor configured and positionable so that during construction of the build part, the sensor's magnetization and sensor coils surround at least the last-produced layer of the AM build part in the build plane. The inspection system further comprises an energization circuit and a central processing system. The central processing system comprises a communication processor configured for sending command signals to the energization circuit and receiving impedance data from the build plane induction coil sensor, and energization controller configured for determining energization commands for transmission to the energization circuit, and an induction data analyzer configured for processing build part impedance data using complex impedance plane analysis and for identifying anomalies in the AM build part.

An inspection system for in situ evaluation of an additive manufacturing (AM) build part is provided. The inspection system comprises a build plane induction coil sensor configured and positionable so that during construction of the build part, the sensor's magnetization and sensor coils surround at least the last-produced layer of the AM build part in the build plane. The inspection system further comprises an energization circuit and a central processing system. The central processing system comprises a communication processor configured for sending command signals to the energization circuit and receiving impedance data from the build plane induction coil sensor, and energization controller configured for determining energization commands for transmission to the energization circuit, and an induction data analyzer configured for processing build part impedance data using complex impedance plane analysis and for identifying anomalies in the AM build part.

An inspection system for in situ evaluation of an additive manufacturing (AM) build part is provided. The inspection system comprises a build plane induction coil sensor configured and positionable so that during construction of the build part, the sensor's magnetization and sensor coils surround at least the last-produced layer of the AM build part in the build plane. The inspection system further comprises an energization circuit and a central processing system. The central processing system comprises a communication processor configured for sending command signals to the energization circuit and receiving impedance data from the build plane induction coil sensor, and energization controller configured for determining energization commands for transmission to the energization circuit, and an induction data analyzer configured for processing build part impedance data using complex impedance plane analysis and for identifying anomalies in the AM build part.

The present invention relates to a method for generating a tool path (20; 82) for an application tool (12) for additive manufacturing, in particular for additive manufacturing using buildup welding, of a substantially rotationally symmetric workpiece (28; 328), comprising the following steps: a) providing cross-sectional contour data describing at least a portion of a cross-sectional contour (42; 342; 442; 542) of the workpiece (28; 328); b) providing axis data describing a rotation axis (R) of the rotationally symmetric workpiece (28; 328); c) generating a continuous cross-sectional path (54; 354; 355; 454; 554), taking into account the cross-sectional contour data, the cross-sectional path (54; 354; 355; 454; 554) being inscribed in the portion of the cross-sectional contour (42; 342; 442; 542); d) generating the tool path (20; 82) with a helical or/and spiral course revolving around the rotation axis (R), wherein the tool path (20; 82) intersects the cross-sectional path (54; 354; 355; 454; 554), preferably with each revolution around the rotation axis (R).

The present invention relates to a method for generating a tool path (20; 82) for an application tool (12) for additive manufacturing, in particular for additive manufacturing using buildup welding, of a substantially rotationally symmetric workpiece (28; 328), comprising the following steps: a) providing cross-sectional contour data describing at least a portion of a cross-sectional contour (42; 342; 442; 542) of the workpiece (28; 328); b) providing axis data describing a rotation axis (R) of the rotationally symmetric workpiece (28; 328); c) generating a continuous cross-sectional path (54; 354; 355; 454; 554), taking into account the cross-sectional contour data, the cross-sectional path (54; 354; 355; 454; 554) being inscribed in the portion of the cross-sectional contour (42; 342; 442; 542); d) generating the tool path (20; 82) with a helical or/and spiral course revolving around the rotation axis (R), wherein the tool path (20; 82) intersects the cross-sectional path (54; 354; 355; 454; 554), preferably with each revolution around the rotation axis (R).