A composite member is manufactured by a manufacturing method including adding, on a surface of a base member composed of a first material, a second material different from the first material, using additive manufacturing employing directed energy deposition as an additive manufacturing process. The manufacturing method is performed by placing the base member in a machining area of a machine tool configured to perform subtractive machining. Accordingly, a composite member can be obtained that is manufactured through additive manufacturing and that is in a state in which the composite member can be promptly machined.

A High Energy Beam Processing (HEBP) system provides feedback signal monitoring and feedback control for the improvement of process repeatability and three-dimensional (3D) printed part quality. Signals reflecting process parameters and the quality of the fabricated parts are analyzed by monitoring feedback signals from artifact sources with a process controller which adjusts process parameters. In this manner, fabricated parts are produced more accurately and consistently from powder feedstock by compensating for process variation in response to feedback signals.

An additive manufacturing system may include an energy source, an optical system to modify and direct an energy beam from the energy source toward a component to form a melt pool, and a material delivery device to deliver material to the melt pool. The optical system may form an annular energy beam, direct the annular energy beam toward the component, receive at least a portion of thermal emissions produced by the annular energy beam and the melt pool, and direct the portion of the thermal emissions toward an imaging device, which may be used to control the energy source.

Devices, systems, and methods for calibrating for an electron beam additive manufacturing system. The electron beam manufacturing system includes electron beam guns. A calibration system includes an optical pyrometer. The optical pyrometer captures thermal radiation emitted from raw material. An analysis component is communicatively coupled to the optical pyrometer. The analysis component is programmed to determine calibration parameters from information from the optical pyrometer and a phase transition temperature.

A method for additive manufacturing an object is disclosed. The method includes, for a first portion of the object to be built in a first overlapping field region of a plurality of melting beams of a metal powder AM system, sequentially forming each layer of the first portion by: forming only a border section of the first portion of the object using a first melting beam of the plurality of melting beams in the first overlapping field region; and forming an internal section of the first portion of the object within the border section using at least one second, different melting beam from the first melting beam in the first overlapping field region. An entirety of an internal edge of the border section of the first portion of the object is overlapped with an entirety of an external edge of the internal section of the first portion of the object.

A method for selectively irradiating a powder layer in additive manufacturing of a component. The method including: determining an irradiation pattern of the layer for additive manufacturing, wherein a first partial pattern is defined which is intended for continuous irradiation and comprises a plurality of irradiation vectors and wherein a second partial pattern is defined, which is intended for a pulsed irradiation, with the first and the second partial pattern being selected in such a manner that the second partial pattern connects irradiation vectors of the first partial pattern, and irradiating the layer in accordance with the irradiation patterns defined. A computer program product, an irradiating device, and a control unit for controlling an irradiating device are included.

A method for healing surface irregularities in a weld joint includes generating a healing energy beam by a focused energy device, where the healing energy beam includes a predefined energy density. The method also includes scanning the healing energy beam along at least a portion of a periphery of the weld joint, where the weld joint includes at least an upper layer and a lower layer. The method also includes melting less than half a thickness of the upper layer of the weld joint. The predefined energy density of the healing energy beam is based on the thickness of the upper layer of the weld joint.

An electron beam source including a cathode, an anode, a means for deflecting an electron beam over a target surface and at least one vacuum pump, the electron beam source further including a contraction area arranged between the anode and the means for deflecting the electron beam where a hole in the contraction area is aligned with a hole in the anode with respect to the cathode, a first vacuum pump is arranged between the contraction area and the anode and a second vacuum pump is arranged above the anode, a gas inlet is provided between the contraction area and the means for deflecting the electron beam, wherein a first crossover of the electron beam is arranged between the cathode and the anode and a second crossover is arranged at or in close proximity to the contraction area.

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, and systems using, inter alia, a controller that regulates formation of at least one 3D object (e.g., in real time during the 3D printing); and a non-transitory computer-readable medium facilitating the same. For example, a controller that regulates a deformation of at least a portion of the 3D object. The control may be in situ control. The control may be real-time control during the 3D printing process. For example, the control may be during a physical-attribute pulse. The present disclosure provides various methods, apparatuses, systems and software for estimating the fundamental length scale of a melt pool, and for various tools that increase the accuracy of the 3D printing.

A pump features a trimmed impeller having a trimmed impeller diameter that is less than a standard full-sized diameter of a standard full-sized impeller for a standard full-sized casing, and having a circumferential outer edge; and a modified standard full-sized casing having dimensions corresponding to the standard full-sized casing and configured to house the trimmed impeller for pumping a fluid, having an outer peripheral wall, and having an inner annular volute portion between the circumferential outer edge of the trimmed impeller and the outer peripheral wall configured with a volume of material deposited using an additive manufacturing process so as to fill in vacant space otherwise caused by the trimmed impeller diameter being less than the standard full-sized impeller diameter. The additive manufacturing process is a directed energy deposition.