Abstract: An exemplary system generally includes an additive manufacturing machine, an optics assembly, a first sensor, a second sensor of a different configuration from the first sensor, and a controller. The additive manufacturing machine is configured to selectively scan a build beam across a region of interest to thereby add material to a workpiece at a moving build point located in the region of interest. The optics assembly is configured to separate electromagnetic radiation emitted from the region of interest into a first beam and a second beam. The first sensor is configured to receive the first beam and to generate first information related to the first beam. The second sensor is configured to receive the second beam and to generate second information related to the second beam. The controller is configured to calibrate the second sensor based upon the first information and the second information.

Abstract: An exemplary method generally includes reflecting, by a movable reflector, electromagnetic radiation from a field of view in a region of interest of an additive manufacturing machine to an optics assembly; splitting, by a beam splitter of the optics assembly, the electromagnetic radiation into a plurality of beams; directing the plurality of beams to a plurality of optical sensors such that each optical sensor of the plurality of optical sensors receives a corresponding and respective beam of the plurality of beams; generating, by the plurality of optical sensors, a plurality of outputs, each output including information related to a corresponding and respective beam; and controlling, by a controller, the movable reflector to move the field of view to maintain a predetermined relationship between the field of view and a moving build point within the region of interest.

Abstract: An exemplary method generally includes reflecting, by a movable reflector, electromagnetic radiation from a field of view in a region of interest of an additive manufacturing machine to an optics assembly; splitting, by a beam splitter of the optics assembly, the electromagnetic radiation into a plurality of beams; directing the plurality of beams to a plurality of optical sensors such that each optical sensor of the plurality of optical sensors receives a corresponding and respective beam of the plurality of beams; generating, by the plurality of optical sensors, a plurality of outputs, each output including information related to a corresponding and respective beam; and controlling, by a controller, the movable reflector to move the field of view to maintain a predetermined relationship between the field of view and a moving build point within the region of interest.

Abstract: A method for predicting process parameters for optimization and control of microstructure in metal and alloy products of hot working fabrication processes is described. The method uses state-space material behavior models and hot deformation process models for calculating optimal strain, strain rate and temperature trajectories for processing the material. Using the optimal trajectories and appropriate optimality criteria, suitable process parameters such as ram velocity and die profile for processing the material are determined to achieve prescribed strain, strain rate and temperature trajectories.