In some examples, an additive manufacturing process may be operated by a method that includes depositing a plurality of preliminary layers of build material over a build surface and applying thermal energy governed by closed-loop control to heat the preliminary layers. The method includes analyzing a temperature distribution across a layer of the preliminary layers to map the locations of any hot spots relative to the build surface. The method includes selecting a spray pattern to apply a cooling agent to the mapped locations.

In some examples, an additive manufacturing process may be operated by a method that includes depositing a plurality of preliminary layers of build material over a build surface and applying thermal energy governed by closed-loop control to heat the preliminary layers. The method includes analyzing a temperature distribution across a layer of the preliminary layers to map the locations of any hot spots relative to the build surface. The method includes selecting a spray pattern to apply a cooling agent to the mapped locations.

Some variations provide an aluminum alloy feedstock for additive manufacturing, the aluminum alloy feedstock comprising from 79.8 wt % to 88.3 wt % aluminum; from 1.1 wt % to 2.1 wt % copper; from 3.0 wt % to 4.6 wt % magnesium; from 7.1 wt % to 9.0 wt % zinc; and from 0.5 wt % to 2.8 wt % zirconium as a grain-refiner element. The aluminum alloy feedstock may be in the form of an ingot powder. In some variations, the aluminum alloy feedstock comprises from 81.3 wt % to about 87.8 wt % aluminum; from 1.2 wt % to 2.0 wt % copper; from 3.2 wt % to 4.4 wt % magnesium; from 7.3 wt % to 8.7 wt % zinc; and from 0.5 wt % to 2.8 wt % zirconium.

Disclosed are a method and apparatus of estimating a depth of a molten pool formed during a 3D printing process, and a 3D printing system. A surface temperature of the molten pool is measure by taking a thermal image of a laminated printing object during the 3D printing process with a thermal imaging camera. The measured surface temperature is compared with a melting point of the base material to determine a surface boundary of the molten pool. The maximum lengths in x-axis and y-axis directions of a surface region of the molten pool defined by the surface boundary of the molten pool are determined as a length and a width of the surface of the molten pool, respectively. A maximum depth in the z-axis direction of the molten pool is determined in real time based on the length and width of the surface region of the molten pool.

A method operates a three-dimensional (3D) metal object manufacturing system to compensate for errors that occur during object formation. In the method, thermal image data and dimensional image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object. Thermal conditions are identified from these data and compared to predetermined ranges corresponding to the identified thermal conditions to identify one or more errors. For identified errors outside a corresponding predetermined difference range, the method performs an error compensation technique. The error compensation includes modification of a surface data model, modification of machine-ready instructions, or operation of a subtractive device.

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.

A method of calibrating a laser of an additive manufacturing system involves processing a test pattern with the laser while varying one or more of laser power and/or scan speed. Thermal energy emitted from the resulting meltpool is measured while processing the test pattern. The power of the laser is calculated using a relationship between volumetric energy density and the thermal emissions, and the laser power is adjusted based on the calculated laser power. An additive manufacturing system for performing such a method may include a laser, a thermal sensor configured to measure meltpool thermal emissions, a processor configured to calculate a laser power based on the measured meltpool thermal emissions of the test pattern, and a controller configured to adjust the laser power based on the calculated laser power.

A method of calibrating a laser of an additive manufacturing system involves processing a test pattern with the laser while varying one or more of laser power and/or scan speed. Thermal energy emitted from the resulting meltpool is measured while processing the test pattern. The power of the laser is calculated using a relationship between volumetric energy density and the thermal emissions, and the laser power is adjusted based on the calculated laser power. An additive manufacturing system for performing such a method may include a laser, a thermal sensor configured to measure meltpool thermal emissions, a processor configured to calculate a laser power based on the measured meltpool thermal emissions of the test pattern, and a controller configured to adjust the laser power based on the calculated laser power.

A printer includes a heat control device configured to prevent a temperature of a part that is printed by the printer from decreasing by more than about 5° C. as a height of the part increases from about 0 mm to about 30 mm. The heat control device includes a gas curtain source that is configured to generate a gas curtain that at least partially surrounds at least a portion of the part.

A printer includes a heat control device configured to prevent a temperature of a part that is printed by the printer from decreasing by more than about 5° C. as a height of the part increases from about 0 mm to about 30 mm. The heat control device includes a gas curtain source that is configured to generate a gas curtain that at least partially surrounds at least a portion of the part.