A system and method of monitoring a powder-bed additive manufacturing process is provided where a layer of additive powder is fused using an energy source and electromagnetic emission signals are measured by a melt pool monitoring system to monitor the print process. The measured emission signals are analyzed to identify outlier emissions and clusters of outliers are identified by assessing the spatial proximity of the outlier emissions, e.g., using clustering algorithms, spatial control charts, etc. An alert may be provided or a process adjustment may be made when a cluster is identified or when a magnitude of a cluster exceeds a predetermined cluster threshold.

This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensing system that monitors two discrete wavelengths associated with a blackbody radiation curve of the layer of powder; determining temperature variations for an area of the build plane traversed by the scans based upon a ratio of sensor readings taken at the two discrete wavelengths; determining that the temperature variations are outside a threshold range of values; and thereafter, adjusting subsequent scans of the energy source across or proximate the area of the build plane.

A method for processing a resin member includes: irradiating a first member comprising a resin with first light of a first wavelength that causes electronic excitation of the resin; and irradiating the resin electronically excited through irradiation with the first light with second light of a second wavelength longer than the first wavelength. A wavelength range of the second wavelength is within a wavelength range in which light absorption of the resin increases through electronic excitation of the resin.

Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Certain aspects of the present disclosure provide a method for setting a working distance of an additive manufacturing system, including: moving a deposition element towards a build surface; detecting, via a contact detection system, a contact between the deposition element and the build surface; stopping the moving of the deposition element in response to detecting the contact between the deposition element and the build surface; and moving the deposition element away from the build surface a determined working distance.

A method for comparing laser machining systems is provided, wherein a laser machining system comprises a laser machining head and a sensor module having at least one photodiode for detecting process radiation, said method comprising: detecting radiation emitted from a light source by means of the photodiode and generating a corresponding intensity signal, wherein the radiation is guided from the light source to the photodiode by at least one optical element in the laser machining head and/or by at least one optical element of the sensor module; aligning the laser machining head and the light source with one another so that the intensity signal assumes a maximum value; and comparing the intensity signal with at least one predetermined reference value. A method for monitoring a laser machining process and an associated laser machining system are also provided.

A method of analyzing a welded connection during laser welding of workpieces includes acquiring a first measurement signal for a process radiation generated during laser welding, acquiring a second measurement signal for a laser radiation reflected by the workpieces, determining whether there is a gap between the workpieces based on the first measurement signal, and when it is determined that there is a gap, determining based on the second measurement signal whether there is a welded connection.

A deposition welding process monitoring device that includes an optical detector (10), a conversion unit (70) and an evaluation unit (60) with equipment (60a) configured to determine a monitoring region (61a) of an image (61), equipment (60b) configured to repeatedly detect a surface region (61b) of the monitoring region (61a) in which a temperature-dependent intensity distribution exceeds a specified minimum value (62), equipment (60c) configured to detect a time period (61c) during which the detected surface region (61b) in which the temperature-dependent intensity distribution exceeds the specified minimum value (62) is greater than a specified limit value (63), and equipment (60d) configured to discontinue the deposition welding process if the time period (61c), during which the detected surface region (61b) in which the temperature-dependent intensity distribution is greater than the specified limit value (63), is greater than a specified time value (64).

A method for monitoring a laser welding process for welding two workpieces using a laser wavelength, in which a pulsed laser beam is directed into the workpieces so as to melt a melting volume in a region of an interface of the two workpieces in order to produce a weld seam, and in which an intensity of a process radiation emitted by the melting volume is detected. According to the method for monitoring the lase welding process, in a first step, a detected intensity profile is evaluated with regard to at least one of the following features: (i) a depth of an intensity decrease, (ii) a duration of an intensity decrease, and (iii) a renewed increase in intensity after an intensity decrease. In a second step it is determined whether or not a gap between the two workpieces was bridged during the laser welding process based on the evaluation.

Device for the additive production of three-dimensional components (2), namely a laser melting device or laser sintering device, in which a component (2) is produced by successive solidifying of individual layers (3) made from solidifiable construction material, by the effect of radiation (4), through melting of the construction material (5), wherein the dimensions and/or temperature of the melt area (6) generated by a point-shaped or line-shaped energy input can be captured by a sensor device (8) of a process monitoring system, and sensor values for evaluation of a component quality can be deduced therefrom, wherein the radiation (9) created by the melt area and used for the generation of the sensor values passes through the scanner used for the melt energy input, and is guided from there to the sensor device (8) of the process monitoring system, wherein an optical focus tracking device (20) is arranged in the radiation path used for generation of the sensor values between the scanner (10) and the sensor device (8) of the process monitoring system, which optical focus tracking device can be controlled by electronic machine data for focus tracking.