A non-destructive testing method for lack-of-fusion (LOF) defects, and a testing standard part and a manufacturing method thereof, used for the non-destructive testing of LOF defects of an additive manufacturing workpiece. The manufacturing method of the LOF defect standard part comprises: step A, setting a LOF defect area of the standard part, in the LOF defect area, a proportion of the LOF defects in the LOF defect area is set as a first proportion value; step B, selecting an additive manufacturing forming process for manufacturing the LOF defect area to obtain a first process parameter of the additive manufacturing forming process corresponding to the first proportion value; step C, performing the additive manufacturing forming process based on the first process parameter to form the LOF defect area.

A method for displacing a continuous energy beam includes emitting a continuous energy beam in a direction of a powder material and displacing the energy beam by overlaying an optical deflection of the energy beam using of a deflection device and a mechanical deflection of the energy beam using of a scanner device. The mechanical deflection is configured to position the energy beam at a plurality of irradiation positions, and the optical deflection is configured to deflect the energy beam around each of the irradiation positions within a beam region of the deflection device onto at least one beam position in a sequence of beam positions. The optical deflection and the mechanical deflection are controlled such that the energy beam successively scans subsequences with an abrupt change of the optical deflection such that two spatially separated subsequences are successively adopted by the energy beam.

A method for displacing a continuous energy beam includes emitting a continuous energy beam in a direction of a powder material and displacing the energy beam by overlaying an optical deflection of the energy beam using of a deflection device and a mechanical deflection of the energy beam using of a scanner device. The mechanical deflection is configured to position the energy beam at a plurality of irradiation positions, and the optical deflection is configured to deflect the energy beam around each of the irradiation positions within a beam region of the deflection device onto at least one beam position in a sequence of beam positions. The optical deflection and the mechanical deflection are controlled such that the energy beam successively scans subsequences with an abrupt change of the optical deflection such that two spatially separated subsequences are successively adopted by the energy beam.

A high-rigidity iron-based alloy contains a matrix made of iron or a ferroalloy, and titanium boride dispersed in the matrix, in which an equivalent circle average particle diameter by an SEM image of the titanium boride is within a specific range.

Methods and apparatuses for manufacturing are disclosed, including (a) providing an apparatus having: a laser; scanner; powder injection system; powder spreading system; dichroic filter; imager-and-processor; and computer; (b) programming the computer with specifications of a sample; (c) using the computer to set initial parameters based on the sample specifications; (d) adjusting a stage to position the sample; (e) focusing and scanning electromagnetic radiation onto the sample while powder is concurrently injected onto the sample in order to deposit a layer; (f) capturing two-dimensional images of the sample and probing the sample to determine whether the deposited layer was manufactured per the specifications; (g) use the computer to adjust the three-dimensional manufacturing parameters based on the determination made in step (f) prior to additively manufacturing a subsequent layer or making repairs; and (h) repeating steps (d), (e), (f), and (g) until the manufacture is complete. Other embodiments are described and claimed.

The present disclosure relates to an apparatus for additively manufacturing a product in a layer-by-layer sequence, wherein the product is formed using powder particles deposited on an interface layer of a substrate. A laser generates first and second beam components. The second beam component has a higher power level and a shorter duration than the first beam component. A mask creates a 2D optical pattern in which only select portions of the second beam components can irradiate the powder particles. The first beam component heats the powder particles close to a melting point, where the particles experience surface tension forces relative to the interface layer. While the particles are heated, the second beam component further heats the particles and also melts the interface layer before the surface tension forces can act on and distort the particles, enabling the particles and the interface layer are able to bond together.

A device for additive manufacturing of a workpiece includes a production platform supporting a defined material layer of particulate material, a structuring tool, an inspection sensor, a control unit, and a position encoder. The inspection sensor has a line scan camera and a line light source and is movable along a movement direction relative to the production platform. The position encoder generates a position signal representing a respective instantaneous position of the inspection sensor relative to the production platform. The control unit generates a spatially resolved image of the defined layer using the line light source, the line scan camera, and the position signal. The control unit controls the structuring tool in order to produce a defined workpiece layer by selectively solidifying particulate material of the defined material layer based on the image of the defined material layer and/or an image of a previously produced workpiece layer.

A device for additive manufacturing of a workpiece includes a production platform supporting a defined material layer of particulate material, a structuring tool, an inspection sensor, a control unit, and a position encoder. The inspection sensor has a line scan camera and a line light source and is movable along a movement direction relative to the production platform. The position encoder generates a position signal representing a respective instantaneous position of the inspection sensor relative to the production platform. The control unit generates a spatially resolved image of the defined layer using the line light source, the line scan camera, and the position signal. The control unit controls the structuring tool in order to produce a defined workpiece layer by selectively solidifying particulate material of the defined material layer based on the image of the defined material layer and/or an image of a previously produced workpiece layer.

Disclosed is a method for controlling an energy input device of an additive manufacturing device. A beam bundle deflection center is assigned to each of the number of beam bundles from which this beam bundle is directed onto the build plane. Each beam bundle deflection center is assigned a projection center corresponding to a perpendicular projection of the position of the beam bundle deflection center onto the build plane. The directions of the movement vectors of the number of beam bundles when scanning the trajectories are defined such that at each of the solidification points in this section the movement vector has an angle with respect to a connection vector from this solidification point to the projection center of the beam bundle used, which angle is smaller than a predetermined maximum angle γ1.

Disclosed is a method for controlling an energy input device of an additive manufacturing device. A beam bundle deflection center is assigned to each of the number of beam bundles from which this beam bundle is directed onto the build plane. Each beam bundle deflection center is assigned a projection center corresponding to a perpendicular projection of the position of the beam bundle deflection center onto the build plane. The directions of the movement vectors of the number of beam bundles when scanning the trajectories are defined such that at each of the solidification points in this section the movement vector has an angle with respect to a connection vector from this solidification point to the projection center of the beam bundle used, which angle is smaller than a predetermined maximum angle γ1.