Abstract: The present disclosure relates to a fabrication and evaluation process for testing new metallic alloy chemistries and compositions for laser powder bed fusion (L-PBF). The new methodology is efficient and effective for new compositions with a minimal investment of generating large quantities of powder feedstock for required in conventional AM processing. The method allows for subsurface melting of the new alloy composition by varying the depth of penetration by a control of the input power level, power deposition rate, and rastering scan strategy. Post-mortem analysis of the subsurface microstructure permits an analysis of the durability and suitability of the new metallic alloy for this manufacturing mode. The method utilizes available infrastructure, technology, and characterization techniques.

Abstract: Laser powder bed fusion additive manufacturing of parts is provided. The method comprises converting a 3D geometry for a part into a number of 2D layers, wherein the 2D layers contain information about the local 3D geometry. A number of laser scan parameters are specified according to preexisting empirical melt pool data for a specified build material. Laser energy levels are specified according to unique characteristics of a specific powder bed fusion machine. Laser and laser beam steering are controlled in the specific powder bed fusion machine according to the specified laser scan parameters and specified laser energy levels to additively manufacture the part from the specified build material.

Abstract: A test artifact for additive manufacturing is provided. The artifact comprises an additively manufactured singular continuous body between 100 cc and 6 cc in bounding box volume and between 50 cc and 3 cc in solid body. The body comprises at least three fiducials positioned for identification of locations in cross-section after sectioning of the artifact and at least three geometries that are unique from each other when exposed in cross section.

Abstract: A test artifact for additive manufacturing is provided. The artifact comprises an additively manufactured singular continuous body between 100 cc and 6 cc in bounding box volume and between 50 cc and 3 cc in solid body. The body comprises at least three fiducials positioned for identification of locations in cross-section after sectioning of the artifact and at least three geometries that are unique from each other when exposed in cross section.

Abstract: A method of additive manufacturing is provided. The method comprises first forming a part injecting a first gas into a build chamber and depositing a first layer of metal-containing powder over a build platform. The first layer of powder is melted a laser and then cooled. The above steps can be optionally repeated to build additional layers. A coating is formed on the surface of the part by injecting a second, different gas into the chamber over the surface of the part. A portion of the surface is selectively heated with a second laser device, thereby chemically altering the heated portion to form the coating. After forming the coating, an additional aliquot of the first gas is injected into the chamber while venting the second gas from the chamber.