Methodologies and manufacturing processes to manufacture components by electron beam melting additive manufacturing, particularly components of molybdenum or a molybdenum-based alloy and particularly of complex nuclear component geometries. Input parameters are provided for controlling electron beam melting additive manufacturing equipment, such as electron beam melting machines. The input parameters relate to various process steps, including build set-up, initial thermal treatment, initial layering of powder, pre-consolidation thermal treatment, consolidation, post-consolidation thermal treatment, indexing of layers, and post-build thermal treatment. The methodologies and manufacturing processes allow manufacture of components of molybdenum having a purity of ≥99.0% and a density of ≥99.75%. Metallographic cross-sections of the manufactured molybdenum components were porosity-free and crack-free.

Methodologies and manufacturing processes to manufacture components by electron beam melting additive manufacturing, particularly components of molybdenum or a molybdenum-based alloy and particularly of complex nuclear component geometries. Input parameters are provided for controlling electron beam melting additive manufacturing equipment, such as electron beam melting machines. The input parameters relate to various process steps, including build set-up, initial thermal treatment, initial layering of powder, pre-consolidation thermal treatment, consolidation, post-consolidation thermal treatment, indexing of layers, and post-build thermal treatment. The methodologies and manufacturing processes allow manufacture of components of molybdenum having a purity of ≥99.0% and a density of ≥99.75%. Metallographic cross-sections of the manufactured molybdenum components were porosity-free and crack-free.

A device (1) for the generative production of a three-dimensional object (2) by selectively solidifying construction material layers made of solidifiable construction material (3) layer by layer in a successive manner using at least one laser beam (5), comprising at least one device (4) for generating at least one laser beam (5) in order to selectively solidify individual construction material layers made of solidifiable construction material (3) layer by layer. The device (4) comprises at least one laser diode element (10) that is arranged or can be arranged directly over the construction plane (9) on which solidified construction material layers or construction material layers to be solidified are selectively formed and is designed to generate a laser beam (5) directed directly onto the construction plane, and/or the device (4) comprises at least one laser diode element (10) and at least one optical element (27).

An additive manufacturing device manufactures an additively manufactured article by preheating a powder material by irradiating the powder material with a charged particle beam and then melting the powder material by irradiating the powder material with the charged particle beam. The additive manufacturing device includes a beam emitting unit emitting the charged particle beam and irradiating the powder material with the charged particle beam, and a position detection unit detecting a position of scattering of the powder material when the powder material scatters by being irradiated with the charged particle beam. When the powder material scatters by being irradiated with the charged particle beam, the beam emitting unit emits the charged particle beam such that a thermal dose of the preheating is increased at the position of scattering.

An additive manufacturing device manufactures an additively manufactured article by preheating a powder material by irradiating the powder material with a charged particle beam and then melting the powder material by irradiating the powder material with the charged particle beam. The additive manufacturing device includes a beam emitting unit emitting the charged particle beam and irradiating the powder material with the charged particle beam, and a position detection unit detecting a position of scattering of the powder material when the powder material scatters by being irradiated with the charged particle beam. When the powder material scatters by being irradiated with the charged particle beam, the beam emitting unit emits the charged particle beam such that a thermal dose of the preheating is increased at the position of scattering.

An apparatus includes a build plate, a powder application apparatus that applies metal powder onto the build plate to form a powder layer, a beam irradiation apparatus that irradiates the powder layer with an electron beam, and a control unit that controls the powder application apparatus and the beam irradiation apparatus. When the powder layer is preheated by irradiation with the electron beam, the control unit sets a beam size and an irradiation position of the electron beam such that lines of the electron beam do not overlap each other at least at a start of preheating, and controls the beam irradiation apparatus to gradually increase at least one of a beam current and the beam size of the electron beam from the start of preheating to an end of preheating.

An apparatus includes a build plate, a powder application apparatus that applies metal powder onto the build plate to form a powder layer, a beam irradiation apparatus that irradiates the powder layer with an electron beam, and a control unit that controls the powder application apparatus and the beam irradiation apparatus. When the powder layer is preheated by irradiation with the electron beam, the control unit sets a beam size and an irradiation position of the electron beam such that lines of the electron beam do not overlap each other at least at a start of preheating, and controls the beam irradiation apparatus to gradually increase at least one of a beam current and the beam size of the electron beam from the start of preheating to an end of preheating.

An apparatus includes a build plate, a powder application apparatus that applies metal powder onto the build plate to form a powder layer, a beam irradiation apparatus that irradiates the powder layer with an electron beam, and a control unit that controls the powder application apparatus and the beam irradiation apparatus. When the powder layer is preheated by irradiation with the electron beam, the control unit sets a beam size and an irradiation position of the electron beam such that lines of the electron beam do not overlap each other at least at a start of preheating, and controls the beam irradiation apparatus to gradually increase at least one of a beam current and the beam size of the electron beam from the start of preheating to an end of preheating.

Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.

Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.