Abstract: An additive manufacturing system includes an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component, a powder delivery device configured to direct a powder stream toward the melt pool, a machining device configured to machine the build surface, at least one topology sensor configured to generate topological data representative of a topology of the build surface, and a computing device configured to receive the topological data from the at least one topology sensor for a plurality of layers, identify differences between the topological data and specification data representative of a set of tolerances of the build surface, control the energy delivery device and the powder delivery device based on a set of deposition parameters, and control the machining device to machine the build surface based on the identified differences.

Abstract: An additive manufacturing system includes a first energy delivery device configured to deliver energy to a build surface of an additively-manufactured component to form a melt pool in the build surface of the component and a second energy delivery energy delivery device. The system also includes a powder delivery device and a heat sensor configured to measure a temperature of a portion of an additively-manufactured component. The system includes a computing device configured to receive data from the heat sensor captured at a first point in time and captured at a second point in time, determine a thermal history of the component based at least partially on the received data captured at the first point in time and the received data received data captured at the second point in time, and control the first energy delivery device or the second energy delivery device based on the determined thermal history.

Abstract: An additive manufacturing system includes an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component, a powder delivery device configured to direct a powder stream toward the melt pool, a gas delivery device configured to direct a gas stream toward or adjacent to the melt pool, at least one Schlieren imaging sensor configured to generate image data representative of a gas flow of one or more gas streams from the gas delivery device, and a computing device configured to receive the image data from the at least one Schlieren imaging sensor. The computing device is configured to determine a gas flow profile of the gas flow based on the image data and control the energy delivery device, gas delivery device and/or the powder delivery device based on the gas flow profile.

Abstract: An additive manufacturing system includes an energy delivery device configured to deliver, a powder delivery device, and one or more thermal sensors configured to measure a temperature of a first portion of the additively-manufactured component and a second portion of the additively manufactured component. The additive manufacturing system includes a computing device configured to receive data indicative of the temperature of the first portion and of the second portion, determine a residual stress of the additively-manufactured component based at least partially on the received thermal sensor data from the first portion of the additively-manufactured component and the received data from the second portion of the additively-manufactured component; and predict final dimensions of the additively-manufactured component based at least partially on the determined residual stress of the additively-manufactured component.

Abstract: An additive manufacturing system includes an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool, a powder delivery device configured to direct a powder stream toward the melt pool, a topology sensor configured to generate topographical data representative of a topology of the build surface, and a computing device configured to receive the topological data from the topology sensor for a first layer deposited according to an initial set of deposition conditions and determine a build height of the first layer based on the topological data, identify a difference between the build height and a target build height, determine an adjusted set of deposition parameters of a second layer based on the identified difference, and control the energy and powder delivery devices to deposit the second layer based on the adjusted set of deposition parameters.

Abstract: An additive manufacturing system includes an energy delivery device to deliver energy to a build surface of a deposit overlying a substrate to form a melt pool in the build surface, a powder delivery device to direct a powder stream toward the melt pool, and a computing device to determine a first set of deposition parameters for an innermost layer of the deposit overlying the substrate, determine a second set of deposition parameters for an inner plurality of layers of the deposit overlying the innermost layer, determine a third set of deposition parameters for an outer plurality of layers of the deposit overlying the inner plurality of layers, and control the energy delivery device and the powder delivery device to deposit the innermost layer, the inner plurality of layers, and the outer plurality of layers based on the respective first, second, and third sets of deposition parameters.

Abstract: An additive manufacturing system includes an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component, a powder delivery device configured to direct a powder stream toward the melt pool, a spatter monitoring system, and a computing device configured to receive image data from the spatter monitoring system. The spatter monitoring system is configured to capture image data indicative of spatter, wherein spatter is material ejected from the melt pool. The computing device is configured to identify a spatter event based on the received image data and control at least one of the energy delivery device or the powder delivery device based on the determined spatter event.

Abstract: An additive manufacturing system includes an energy delivery device configured to deliver energy to a build surface of an additively-manufactured component being manufactured to form a melt pool in the build surface of the component. The system further includes a powder delivery device, a melt pool monitor configured to observe the melt pool, and a computing device. The computing device is configured to receive, from the melt pool monitor, data indicative of one or more parameters of the melt pool and determine, based on the received data, a current position of the melt pool. The computing device is configured to determine a desired size of the melt pool based on the current position of the melt pool and control, based on the desired size of the melt pool, the energy delivery device to form the melt pool of the desired size in the build surface of the component.

Abstract: An additive manufacturing system may include an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component; a powder delivery device configured to direct a powder stream toward the melt pool; a plurality of mass sensors, each mass sensor associated with a portion of the additive manufacturing system; a plurality of heat sensors; and one or more computing devices. The computing device(s) are configured to receive data from the plurality of mass sensors; determine an overall mass flux based on the data from the mass sensors; control the powder delivery device based on the overall mass flux; receive data from the plurality of heat sensors; determine an overall heat flux based on the data from the heat sensors; and control the energy delivery device based on the overall heat flux.

Abstract: An additive manufacturing system includes an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component, a powder delivery device configured to direct a powder stream toward the melt pool, at least one sensor configured to generate sensor data, and a computing device. The computing device may be configured to receive the sensor data from the at least one sensor, determine, based on the sensor data, at least one powder flow characteristic, and generate a signal indicative of the at least one powder flow characteristic. The computing device may be further configured to control, based on the at least one powder flow characteristic, the energy delivery device and the powder delivery device to deposit a plurality of layers based on a set of deposition parameters.

Abstract: An additive manufacturing system includes an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component, a powder delivery device configured to direct a powder stream toward the melt pool, at least one sensor configured to generate sensor data representative of at least one process characteristic, and a computing device. The computing device is configured to receive the sensor data from the at least one sensor, determine, based on the sensor data and a predictive model data, at least one powder control parameter configured to achieve a predetermined powder feed rate of the powder stream, and control, based on the at least one powder control parameter, the energy delivery device and the powder delivery device to deposit a plurality of layers.

Abstract: An additive manufacturing system includes an energy delivery device configured to deliver energy to a build surface of an additively-manufactured component to form a melt pool and a powder delivery device configured to direct a powder stream toward the melt pool. The system further includes a powder flow monitoring system configured to observe the powder stream and an optical system configured to observe the melt pool. A computing device configured to receive data indicative of a position of the powder stream, and receive data indicative of a position of the melt pool. The computing device is configured to determine a relative position of the powder stream to the melt pool and control, based on the determined relative position of the powder stream to the melt pool, one or both of the powder delivery device and the energy delivery device.

Abstract: An additive manufacturing system includes an energy delivery device and a powder delivery device configured to form an as-deposited layer on a build surface of the component. The system includes a topology monitoring system configured to capture data indicative of a position of a surface of the as-deposited layer, and also includes a computing device. The computing device is configured to receive the data and determine an actual position of the surface of the as-deposited. The computing device is configured to compare the actual position to a modeled position of the surface of the as-deposited layer. The computing device is further configured to determine a difference between the actual position and the modeled position of the as-deposited layer and control at least one of the energy delivery device or the powder delivery device based on the difference between the actual position and the modeled position of the as-deposited layer.

Abstract: An additive manufacturing system includes a first energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component, a second energy delivery device configured to deliver energy to the build surface of the component; a stage configured to support an additively-manufactured component, at least one heat sensor configured to capture data indicative of a temperature of a portion of a component, and a computing device. The computing device is configured to receive data from the at least one heat sensor; and control the first or the second energy device based at least partially on the received data from the at least one heat sensor to provide functionally-graded characteristics to the additively-manufactured component, in-situ, through modification of an amount of thermal energy delivered by the first energy delivery device or the second energy delivery device.

Abstract: An additive manufacturing system includes an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component, a powder delivery device configured to direct a powder stream toward the melt pool, a microstructural monitoring device configured to capture data representative of a microstructure of at least a portion of the component; and a computing device. The computing device is configured to receive data from the microstructural monitoring device, and control at least one of the powder delivery device or the energy delivery device based at least partially on the data received from the microstructural monitoring device.

Abstract: An additive manufacturing system includes an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component, a powder delivery device configured to direct a powder stream toward the melt pool, at least one sensor configured to generate powder data, and a computing device. The computing device may be configured to receive the powder data from the at least one sensor, determine, based on the powder data, at least one particle characteristic, and generate a signal indicative of the at least one particle characteristic. The computing device may be further configured to control, based on the at least one particle characteristic, the energy delivery device and the powder delivery device to deposit a plurality of layers based on a set of deposition parameters.

Abstract: In some examples, systems and techniques for repairing or otherwise forming a blade of a bladed disk. In one example, a method including positioning a shield member around a perimeter of a partial blade extending from a rotor disk of a bladed disk, the shield member being positioned adjacent to a build surface of the partial blade; and depositing, with the shield member around the perimeter of the partial blade, a material on the build surface using an additive manufacturing technique to form a repaired portion on the build surface of the partial blade.

Abstract: A method may include cold spraying a masking material on selected locations of a component to form a masking layer, wherein the masking material comprises a metal or alloy; additively manufacturing an additively manufactured portion of the component at locations at which the masking layer is not present; and removing the masking layer from the component. The masking layer may be configured to protect portions of the component by covering or otherwise providing a physical barrier that reduces or prevents material from adhering to unwanted portions of the component during a subsequent manufacturing and/or repair technique. Additionally, the masking layer may be reflective to infrared radiation and/or intimately contact the component and function as a heat sink or thermally conductive layer to transfer heat from the component.

Abstract: An abradable sealing element comprises a substrate and a sealing structure. The sealing structure comprises one or more wall structures extending from the substrate and defining at least one open cell which is filled with abradable material. The one or more wall structures are formed by additive-layer, powder-fed, laser-weld deposition onto the substrate. The one or more wall structures are formed from nickel-based superalloy and constitute from about 10% to about 50% of the total volume of the sealing structure.

Abstract: A method may include cold spraying a masking material on selected locations of a component to form a masking layer, wherein the masking material comprises a metal or alloy; additively manufacturing an additively manufactured portion of the component at locations at which the masking layer is not present; and removing the masking layer from the component. The masking layer may be configured to protect portions of the component by covering or otherwise providing a physical barrier that reduces or prevents material from adhering to unwanted portions of the component during a subsequent manufacturing and/or repair technique. Additionally, the masking layer may be reflective to infrared radiation and/or intimately contact the component and function as a heat sink or thermally conductive layer to transfer heat from the component.