Abstract:
A self-monitoring additive manufacturing system and method of operation utilizes a surface imaging monitor to image a surface of a slice of a workpiece for storage and processing of the image to detect surface anomalies. The monitoring may operate in real time and in unison with an energy gun of the system for correction of the anomalies in real-time by re-melting of the anomaly.
Abstract:
A system is provided for additively manufacturing a part. This additive manufacturing system includes a base, a solidification device and a detection device. The base is adapted to support material; e.g., powder material. The solidification device is adapted to solidify at least a portion of the supported material to form at least a portion of the part. The detection device is adapted to detect emissions produced by the solidification of at least a portion of the material.
Abstract:
An additive manufacturing system includes an energy gun having a plurality of energy source devices each emitting an energy beam. A primary beam melts a selected region of a substrate into a melt pool and at least one secondary beam heat-conditions the substrate proximate the melt pool to reduce workpiece internal stress and/or enhance micro-structure composition of the workpiece.
Abstract:
A self-monitoring additive manufacturing system and method of operation utilizes a surface imaging monitor to image a surface of a slice of a workpiece for storage and processing of the image to detect surface anomalies. The monitoring may operate in real time and in unison with an energy gun of the system for correction of the anomalies in real-time by re-melting of the anomaly.
Abstract:
An additive manufacturing system includes an energy gun having a plurality of energy source devices each emitting an energy beam. A primary beam melts a selected region of a substrate into a melt pool and at least one secondary beam heat-conditions the substrate proximate the melt pool to reduce workpiece internal stress and/or enhance micro-structure composition of the workpiece.
Abstract:
A system is provided for additively manufacturing a part. This additive manufacturing system includes a base, a solidification device and a detection device. The base is adapted to support material; e.g., powder material. The solidification device is adapted to solidify at least a portion of the supported material to form at least a portion of the part. The detection device is adapted to detect emissions produced by the solidification of at least a portion of the material.
Abstract:
A method of operating an additive manufacturing system (20) utilizing a layer-by-layer thermo-mechanical analysis system (68) includes the steps of pre-modeling a structure or workpiece (38) into a plurality of slices (42) stacked from a bottom slice (42C) to a top slice (42A) of the plurality of slices (42), assuming a second slice (42B) modeled immediately below a first slice (42A) is a rigid substrate, and run a response force analysis for the first slice (42A). The analysis system may reiterate this process for each slice (42A-42C) calculating a force distribution map (72) for each slice (42A-42C), and adding the force distribution maps (72) to a total response force map (70) of the entire structure (38). The additive manufacturing system (20) may then use the total response force map (70) to optimize material properties for selected regions of each slice (42A-42C) to a sacrificial support structure (74S) and/or the final product.