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Title:
SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING
Document Type and Number:
WIPO Patent Application WO/2020/112175
Kind Code:
A1
Abstract:
Systems and methods for additive manufacturing are provided. The method comprises depositing a layer of feedstock in a material deposition region of an additive manufacturing apparatus. At least a selected region of the layer is affixed together in the selected region. More specifically, energy is emitted from an energy source. The emitted energy is shaped utilizing an aperture. The shaped energy is transmitted to contact feedstock in the selected region in the material deposition region.

Inventors:
KULOVITS ANDREAS (US)
Application Number:
PCT/US2019/042731
Publication Date:
June 04, 2020
Filing Date:
July 22, 2019
Export Citation:
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Assignee:
ARCONIC INC (US)
International Classes:
B29C64/264; B22F1/052; B29C64/141; B33Y10/00; B33Y30/00
Domestic Patent References:
WO2017085469A12017-05-26
Foreign References:
US20170120538A12017-05-04
US20120063131A12012-03-15
US20150048553A12015-02-19
US20150201500A12015-07-16
Attorney, Agent or Firm:
SOVESKY, Robert J. et al. (US)
Download PDF:
Claims:
CLAIMS

What is claimed is:

1. An additive manufacturing system comprising: a material deposition region adapted to receive a feedstock and comprising a material deposition surface;

a material deposition module adapted to dispose the feedstock in the material deposition region; and an energy module adapted to affix at least a selected region of the feedstock disposed in the material deposition region, the energy module comprising:

an energy source adapted to emit energy comprising at least one of electromagnetic radiation and an electron beam; and a first aperture in electromagnetic communication with the energy source, the first aperture comprising:

a body adapted to absorb at least a portion of the energy emitted by the energy source; and

a first opening within the body, the first opening adapted to shape the energy emitted by the energy source and transmit energy emitted by the energy source into the material deposition region to selectively contact feedstock disposed in the material deposition region.

2. The system of claim 1, further comprising a lens intermediate the energy source and the material deposition region, the lens adapted to refract the energy emitted by the energy source.

3. The system of claim 2, wherein the lens comprises a convex shape.

4. The system of any one of claims 2-3, wherein the lens is disposed at a distance Di from the material deposition region according to the equation:

1 _ 1 1

1 ~ D + D wherein Di is the distance energy travels from the first aperture to the lens and Di is greater than /;

wherein D2 is the distance energy travels from the lens to the material deposition region; and

/is the focal length of the lens.

5. The system of any one of claims 1-4, further comprising a mirror adapted to receive energy emitted by the energy source and direct the received energy to the material deposition region.

6. The system of any one of claims 1-5, wherein the first opening in the first aperture comprises a shape selected from one of an ellipse and a rectangle.

7. The system of any one of claims 1-6, wherein the first opening in the first aperture comprises an elongated shape having a width larger than a length of the elongated shape.

8. The system of claim 7, wherein at least one of the width and the length of the elongated shape has a dimension smaller than a dimension of a cross section of the energy emitted by the energy source.

9. The system of claim 8, wherein the energy module is adapted to scan energy transmitted by the first opening across feedstock disposed in the material deposition region in a direction substantially parallel to the length of the elongated shape.

10. The system of any one of claims 8-9, wherein the energy module is adapted to scan energy transmitted by the first opening in the aperture across a direction substantially perpendicular to the length of the elongated shape.

11. The system of any one of claims 1-10, wherein the first aperture further comprises a second opening.

12. The system of any one of claims 1-11, wherein the first aperture further comprises a first layer disposed adjacent to the body, the first layer comprises material transparent to the energy emitted by the energy source, and the first layer is adapted to receive the energy from the energy source and transmit the energy to the first opening.

13. The system of any one of claims 1-12, wherein the body of the first aperture comprises a material adapted to withstand the absorbed energy without melting of the body.

14. The system of any one of claims 1-13, wherein the body of the first aperture comprises quartz.

15. The system of any one of claims 1-14, further comprising a cooling module adapted to cool the first aperture.

16. The system of any one of claims 1-15, wherein the first opening in the first aperture is adapted to create an interference pattern from the energy emitted by the energy source.

17. The system of claim 16, wherein the first aperture is adapted to diffract energy emitted by the energy source into a zero beam and a diffracted beam, wherein a power concentration of the diffracted beam is equal to or lower than a power concentration of the zero beam.

18. The system of claim 17, wherein the power concentration of the zero beam is adapted to heat feedstock in the material deposition region to a temperature at least as great as a liquidus temperature of the feedstock.

19. The system of any one of claims 17-18, wherein the power concentration of the diffracted beam is adapted to heat feedstock in the powder deposition region to a temperature less than a liquidus temperature of the feedstock.

20. The system of any one of claims 1-19, further comprising a second aperture in electromagnetic communication with the energy source, the second aperture disposed between the first aperture and the material deposition surface, the second aperture comprising:

a second body adapted to absorb at least a portion of the energy transmitted by the first opening; and

a second opening within the second body, the second opening adapted to transmit energy onto the material deposition surface.

21. The system of claim 20, wherein the first opening comprises an elliptical shape and the second opening comprises an elongated shape.

22. The system of any one of claims 1-21, wherein the emitted energy from the energy source is not focused.

23. The system of any one of claims 1-22, further comprising at least two energy sources, including the energy source.

24. The system of any one of claims 1-23, further comprising a beam splitter in electromagnetic communication with the energy source.

25. The system of any one of claims 1-24, wherein the feedstock comprises at least one of powder and a sheet.

26. A method for additive manufacturing comprising:

depositing a layer of feedstock in a material deposition region of an additive manufacturing apparatus; affixing at least a selected region of the layer together in the selected region, the affixing comprising:

emitting energy from an energy source;

shaping the emitted energy utilizing an aperture; and

transmitting the shaped energy to contact feedstock in the selected region in the material deposition region.

27. The method of claim 26, further comprising repeating depositing a layer and affixing at least a selected region of the layer as needed to provide an additively manufactured part in the material deposition region of the additive manufacturing apparatus.

28. The method of any one of claims 26-27, further comprising focusing the energy emitted from the energy source through a lens after shaping the emitted energy.

29. The method of any one of claims 26-28, further comprising positioning the lens at a distance equal to Di from the at least one selected region according to the equation:

1 _ 1 1

1~D + D2~ wherein Di is the distance emitted energy travels from the aperture to the lens and Di is greater than /;

wherein D2 is the distance energy travels from the lens to the material deposition region; and

/is the focal length of the lens.

30. The method of any one of claims 26-29, further comprising directing energy emitted from the energy source to the material deposition region utilizing a mirror.

31. The method of any one of claims 26-30, wherein energy transmitted onto the material deposition region has a cross sectional shape of at least one of an ellipse and a rectangle.

32. The method of any one of claims 26-31, wherein the aperture comprises an opening comprising an elongated shape comprising a width larger than a length of the elongated shape.

33. The method of claim 32, further comprising scanning energy transmitted onto the selected region in a direction substantially parallel to the length of the elongated shape.

34. The method of any one of claims 32-33, further comprising scanning energy transmitted onto the selected region in a direction substantially perpendicular to the length of the elongated shape.

35. The method of any one of claims 26-34, further comprising cooling the aperture.

36. The method of any one of claims 26-35, wherein shaping the emitted energy further comprises diffracting, by the aperture, energy emitted by the energy source into a zero beam and a diffracted beam, wherein a power concentration of the diffracted beam is equal to or lower than a power concentration of the zero beam.

37. The method of claim 36, further comprising heating the feedstock with the zero beam to a temperature at least as great as a liquidus temperature of the feedstock.

38. The method of any one of claims 36-37, further comprising heating the feedstock with the diffracted beam to a temperature less than a liquidus temperature of the feedstock.

39. The method of any one of claims 26-38, wherein the feedstock comprises at least one of powder and a sheet.

40. The method of any one of claims 26-39, wherein the emitted energy from the energy source is not focused.

Description:
TITLE

SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING

CROSS-REFERENCE

[0001] This application claims priority to U.S. Provisional Patent Application No.

62/772,999, which was filed on November 29, 2018. The contents of which is incorporated by reference into this specification.

FIELD OF USE

[0002] The present disclosure relates to systems and methods for additive manufacturing.

BACKGROUND

[0003] Various parameters can affect the build of additively manufactured parts throughout the manufacturing process. Obtaining acceptable physical properties in additively manufactured parts can present challenges. The present disclosure addresses certain of those challenges.

SUMMARY

[0004] According to one aspect of the present disclosure, an additive manufacturing system is provided. The additive manufacturing system comprises a material deposition region, a material deposition module, and an energy module. The material deposition region is adapted to receive a feedstock and comprises a material deposition surface. The material deposition module is adapted to dispose the feedstock in the material deposition region. The energy module is adapted to affix at least a selected region of the feedstock disposed in the material deposition region. The energy module comprises an energy source and a first aperture. The energy source is adapted to emit energy comprising at least one of

electromagnetic radiation and an electron beam. The first aperture is in electromagnetic communication with the energy source and comprises a body and a first opening. The body is adapted to absorb at least a portion of the energy emitted by the energy source. The first opening is within the body and is adapted to shape the energy emitted by the energy source. The first opening transmits energy emitted by the energy source into the material deposition region to selectively contact feedstock disposed in the material deposition region. [0005] According to another aspect of the present disclosure, a method for additive manufacturing is provided. The method comprises depositing a layer of feedstock in a material deposition region of an additive manufacturing apparatus. At least a selected region of the layer is affixed together in the selected region using an energy source. More specifically, energy comprising at least one of electromagnetic radiation and an electron beam is emitted from the energy source. The emitted energy is shaped utilizing an aperture. The shaped energy is transmitted to contact feedstock in the selected region of the layer in the material deposition region.

[0006] It is understood that the inventions disclosed and described in this specification are not limited to the aspects summarized in this Summary. The reader will appreciate the foregoing details, as well as others, upon considering the following detailed description of various non-limiting and non-exhaustive aspects according to this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The features and advantages of the examples, and the manner of attaining them, will become more apparent, and the examples will be better understood, by reference to the following description of embodiments taken in conjunction with the accompanying drawings, wherein:

[0008] FIG. 1 a schematic representation of a front elevational view of a non-limiting embodiment of an additive manufacturing system according to the present disclosure;

[0009] FIG. 2A is a schematic representation of a perspective view of non-limiting embodiment of a energy module according to the present disclosure;

[0010] FIG. 2B is a non-limiting schematic representation of at least one of electromagnetic radiation and electrons being scanned across the material deposition region in a first direction according to the present disclosure;

[0011] FIG. 2C is a non-limiting schematic representation of at least one of electromagnetic radiation and electrons being scanned across the material deposition region in a second direction according to the present disclosure; [0012] FIG. 3 is a schematic representation of a perspective view of aspects of a non-limiting embodiment of a laser module comprising a lens and a mirror according to the present disclosure;

[0013] FIG. 4 is a schematic representation of a perspective view of a non-limiting embodiment of aspects of a laser module adapted to create an interference pattern according to the present disclosure;

[0014] FIG. 5 is a schematic representation of a perspective view of aspects of a non-limiting embodiment of a laser module comprising two apertures according to the present disclosure;

[0015] FIG. 6 is a schematic representation of a front-elevational view of aspects of a non limiting embodiment of diffracted beams scanning across a material deposition region in a first direction according to the present disclosure;

[0016] FIGs. 7A-B are graphs depicting beam intensity versus position of the beam according to non-limiting embodiments of the present disclosure;

[0017] FIG. 8 is a schematic representation of a front-elevational view of a non-limiting embodiment of diffracted beams scanning across a material deposition region in a second direction according to the present disclosure;

[0018] FIG. 9 is a schematic representation of a perspective view of aspects of a non-limiting embodiment of a cooled aperture according to the present disclosure; and

[0019] FIGs. 10A-B are a flow chart illustrating a non-limiting embodiment of a method for additive manufacturing according to the present disclosure.

[0020] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate certain embodiments, in one form, and such exemplifications are not to be construed as limiting the scope of the appended claims in any manner.

DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0021] Various non-limiting embodiments are described and illustrated herein to provide an overall understanding of the structure, function, and use of the disclosed methods, systems, and parts. The various non-limiting embodiments described and illustrated herein are non- limiting and non-exhaustive. Thus, the invention is not limited by the description of the various non-limiting and non-exhaustive embodiments disclosed herein. Rather, the invention is defined solely by the claims. The features and characteristics illustrated and/or described in connection with various non-limiting embodiments may be combined with the features and characteristics of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. As such, the claims may be amended to recite any features or characteristics expressly or inherently described in, or otherwise expressly or inherently supported by, this specification. Further, Applicant reserves the right to amend the claims to affirmatively disclaim features or characteristics that may be present in the prior art. The various non-limiting embodiments disclosed and described in this specification can comprise, consist of, or consist essentially of the features and characteristics as variously described herein.

[0022] Any patent, publication, or other disclosure material identified herein is incorporated herein by reference in its entirety unless otherwise indicated but only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material expressly set forth in this specification. As such, and to the extent necessary, the express disclosure as set forth in this specification supersedes any conflicting material incorporated by reference herein. Any material, or portion thereof, that is said to be incorporated by reference into this specification, but which conflicts with existing definitions, statements, or other disclosure material set forth herein, is only incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. Applicant reserves the right to amend this specification to expressly recite any subject matter, or portion thereof, incorporated by reference herein.

[0023] Any references herein to“various non-limiting embodiments,”“some embodiments,” “one embodiment,”“an embodiment,” or like phrases, mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases“in various non-limiting embodiments,” “in some embodiments,”“in one embodiment,”“in an embodiment,” or like phrases, in the specification do not necessarily refer to the same embodiment. Furthermore, the particular described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features, structures, or characteristics of one or more other embodiments without limitation. Such modifications and variations are intended to be included within the scope of the present embodiments.

[0024] In this specification, unless otherwise indicated, all numerical parameters are to be understood as being prefaced and modified in all instances by the term“about,” in which the numerical parameters possess the inherent variability characteristic of the underlying measurement techniques used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0025] Also, any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, a range of“1 to 10” includes all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range subsumed within the ranges expressly recited. All such ranges are inherently described in this specification.

[0026] The grammatical articles“a,”“an,” and“the,” as used herein, are intended to include “at least one” or“one or more,” unless otherwise indicated, even if“at least one” or“one or more” is expressly used in certain instances. Thus, the foregoing grammatical articles are used herein to refer to one or more than one (i.e., to“at least one”) of the particular identified elements. Further, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of the usage requires otherwise.

[0027] As used herein,“additive anufacturing” means“a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies,” as defined in ASTM F2792-12a, entitled“Standard

Terminology for Additively Manufacturing Technologies.” Non-limiting examples of additive manufacturing processes useful in producing products from feedstocks include, for example, BJAM (binder jet additive manufacturing), DMLS (direct metal laser sintering), SLM (selective laser melting), SLS (selective laser sintering), and EBM (electron beam melting).

[0028] As used herein,“powder” refers to a material comprising a plurality of particles. Powder may be used in a powder bed in an additive manufacturing system or process to produce a tailored alloy product via additive manufacturing. Powder, as used herein, may comprise a single material or a blend of two or more materials. In certain embodiments, powder can comprise shavings.

[0029] As used herein, a“median particle size” of a powder refers to the diameter at which 50% of the volume of the particles in the powder has a smaller diameter (e.g., Dso). Dio of a powder refers to the diameter at which 10% of the volume of the particles in the powder has a smaller diameter. D90 of a powder refers to the diameter at which 90% of the volume of the particles in the powder has a smaller diameter. As used herein, median particle size, Dio, and D90 are determined in accordance with ASTM standard B822.

[0030] When producing a part with an additive manufacturing system or method, the part may comprise, for example, feedstock that is not sufficiently fused or otherwise joined together, and the part may require further processing to produce the part. For example, there may be challenges to ensure that a molten pool of feedstock created by an energy module during additive manufacturing has a consistent level of turbulence such that upon

solidification of the molten pool the resulting part does not, for example, exhibit an unacceptable tendency to crack, spall, or erode. Systems and methods for additive manufacturing are provided herein that can stabilize turbulence in the molten pool and/or consistently heat the molten pool during additive manufacturing to reduce, if not eliminate, the tendency of the resulting additively manufactured part to crack, spall, or erode.

[0031] Referring to FIG. 1, a schematic representation of a front-el evational view of a non limiting embodiment of an additive manufacturing system 100 according to the present disclosure is provided. The additive manufacturing system 100 can comprise a material deposition region 102, including a material deposition surface 104, a material deposition module 106, and an energy module 108. The material deposition region 102 is adapted to receive a feedstock. [0032] The feedstock can comprise at least one of a metallic material, a polymeric material, and a ceramic material. In certain non-limiting embodiments, the feedstock can comprise at least one of titanium, a titanium alloy, aluminum, an aluminum alloy, nickel, a nickel alloy, iron, an iron alloy, cobalt, a cobalt alloy, copper, a copper alloy, molybdenum, a

molybdenum alloy, magnesium, a magnesium alloy, tantalum, a tantalum alloy, tungsten, a tungsten alloy, zinc, a zinc alloy, silver, a silver alloy, chromium, a chromium alloy, tin, a tin alloy, gold, a gold alloy, platinum, a platinum alloy, zirconium, and a zirconium alloy.

[0033] The feedstock can comprise powder and/or sheet. In certain embodiments, where the feedstock is a powder, the feedstock can comprise at least one of metallic (e.g., metal or metal alloy) particles, polymer particles (e.g., plastic particles), and ceramic particles. In various non-limiting embodiments, each of the powders are metallic particles selected from at least one of titanium particles, titanium alloy particles, aluminum particles, aluminum alloy particles, nickel particles, nickel alloy particles, iron particles, iron alloy particles, cobalt particles, cobalt alloy particles, copper particles, copper alloy particles, molybdenum particles, molybdenum alloy particles, magnesium particles, magnesium alloy particles, tantalum particles, tantalum alloy particles, tungsten particles, tungsten alloy particles, zinc particles, zinc alloy particles, silver particles, silver alloy particles, chromium particles, chromium alloy particles, tin particles, tin alloy particles, gold particles, gold alloy particles, platinum particles, platinum alloy particles, zirconium particles, and zirconium alloy particles. In certain non-limiting embodiments, the ceramic particles can be at least one of oxide particles and non-oxide particles. In various non-limiting embodiments, the ceramic particles can comprise at least one of an oxide, a carbide, a nitride, and a boride.

[0034] The median particle size of the powder can be adapted for powder bed additive manufacturing. For example, the median particle size of the powder can be adapted so that the powder will spread as a uniform layer across the material deposition surface 104 or on a previously deposited layer in the material deposition region 102. In certain embodiments, the powder can have a median particle size not greater than 325 pm, such as, for example, not greater than 200 pm, not greater than 275 pm, not greater than 250 pm, not greater than 225 pm, not greater than 200 pm, not greater than 175 pm, not greater than 150 pm, not greater than 125 pm, not greater than 100 pm, not greater than 90 pm, not greater than 70 pm, not greater than 10 pm, not greater than 5 pm, or not greater than 1 pm. In certain embodiments, the powder can have a median particle size of at least 50 nm, such as, for example, at least 1 mih, at least 5 mih, at least 10 mih, at least 70 mih, at least 90 mih, at least 100 mih, at least 125 mih, at least 150 mih, at least 175 mih, at least 200 mih, at least 225 mih, at least 250 mih, at least 275 mih, or at least 300 mih. In certain embodiments, the powder can have a median particle size in a range of 50 nm to 325 pm, such as, for example, 1 pm to 300 pm, 5 pm to 300 pm, 5 pm to 100 pm, 10 pm to 180 pm, 100 pm to 180 pm, 10 pm to 100 pm, 105 pm to 180 pm, 20 pm to 50 pm, 60 pm to 90 pm, 50 pm to 100 pm, 10 pm to 50 pm, 10 pm to 80 pm, 10 pm to 20 pm, or 25 pm to 50 pm.

[0035] The median particle size of the powder can be compatible with a thickness of a layer formed from the powder in the material deposition region 102. For example, the powder layer thickness can be from 1 time to 10 times the median particle size of the powder in the layer, such as, for example, 2 to 8 times the median particle size, or 2 to 4 times the median particle size. In some embodiments, the layer thickness can be 3 times the median particle size. The layer thickness can be, for example, from 100 nm to 3250 pm, such as, for example, 1 pm to 2000 pm, 10 pm to 2000 pm, 10 pm to 1000 pm, or 50 pm to 300 pm. In various non-limiting embodiments, the layer thickness can be 1000 pm. The layer thickness can be selected such that a layer can be melted by the energy source 220.

[0036] The material deposition module 106 is adapted to dispose feedstock in the material deposition region 102. In various non-limiting embodiments, the material deposition module 106 can comprise at least one of a re-coater, a roller, a brush, a hopper, and a conveyor to facilitate deposition of feedstock in the material deposition region 102. In various non limiting embodiments, the material deposition module 106 can be adapted to deposit layers of powder in the material deposition region 102. For example, the material deposition module 106 can comprise a powder deposition module including a re-coater, which can spread powder from a reservoir on the material deposition surface 104 or on a previously applied powder. In various non-limiting embodiments the powder deposition module can initially deposit feedstock powder on the material deposition surface 104, and can subsequently deposit powder feedstock on a powder layer or layers previously deposited in the powder deposition region 102 by the powder deposition module. In various non-limiting

embodiments, the material deposition surface 104 is adapted to translate vertically to move the powder bed, comprising the feedstock powder deposited in the powder deposition region 102, and facilitate deposition of further powder layers in the material deposition region 102. [0037] The material deposition module 106 can move feedstock to the material deposition region 102 and deposit a first layer 112a in the material deposition region 102. The material deposition module 106 can deposit a second layer 112b in the material deposition region 102 on a top surface of the first layer 112a. In various non-limiting embodiments, the material deposition module 108 can repeat the deposition of layers of feedstock as necessary to create layers of an additively manufactured part.

[0038] At least a selected region 116 of the feedstock in first layer 112a in the material deposition region 102 can be affixed (e.g., bound and/or fused) together by the energy module 108. In addition, at least a selected region 118 of the feedstock in the second layer 112b in the material deposition region 102 can be affixed together by the energy module 108. Affixing the feedstock in the selected region 118 can affix at least the selected region 118 of the second layer 112b to the first layer 112a. For example, the selected region 118 in the second layer 112b can be affixed to the selected region 116 in the first layer 112a. The bound selected regions 116, 118 can each form a build layer of the additively manufactured part.

[0039] Each build material layer in the additively manufactured part can be individually affixed by the energy module 108 or, alternatively, two or more layers can be affixed simultaneously. For example, the material deposition module 108 can deposit a single layer of feedstock or a plurality of layers of feedstock. Next, the energy module 108 can affix a selected region or regions in the material deposition region 102, including an exposed region. In various non-limiting embodiments, feedstock in at least a selected region 116 of the first layer 112a in the material deposition region 102 can be affixed together by the energy module 108 prior to deposition of the feedstock forming the second layer 112b. In various non limiting embodiments, feedstock in at least the selected region 116 of the first layer 112a and the selected region 118 of the second layer 112b are affixed simultaneously. In various non limiting embodiments, the energy module 108 can affix the first layer 112a at least partially to the material deposition surface 104.

[0040] The energy module 108 can be adapted to affix (e.g., bind and/or fuse) at least a selected region of the feedstock disposed in the material deposition region 102. The energy module 108 can comprise, for example, at least one of a laser module and an electron beam module. For example, a laser module 108 can be adapted to direct a laser beam onto and heat at least a selected region of an exposed layer of feedstock in the material deposition region 102 to fuse feedstock in the selected region together and to an immediately adjacent underlying layer (e.g., of feedstock or previously affixed feedstock) or to the material deposition surface 104. An electron beam module can be adapted to generate electrons and direct an electron beam onto and heat at least a selected region of an exposed layer of feedstock in the material deposition region 102 to fuse feedstock in the selected region together and to an immediately adjacent underlying layer (e.g., of feedstock or previously affixed feedstock) or to the material deposition surface 104. The selected region 118 in the second layer 112b can be fused to the selected region 116 in the first layer 112a by the energy module 108. In various non-limiting embodiments, the energy module 108 can be adapted to selectively sinter and/or melt feedstock in a selected region of an exposed layer of feedstock in the material deposition region 102 to fuse the feedstock in the selected region of the layer together and to at least two underlying layers, including an immediately adjacent underlying layer and an additional layer of feedstock underlying the immediately adjacent underlying layer.

[0041] The sequence of depositing a layer or layers of feedstock and affixing a selected region or regions of the layer or layers can be repeated as needed to produce layers of the additively manufactured part, which includes feedstock bound/fused together.

[0042] As illustrated in FIG. 2A, the energy module 108 can comprise an energy source 220 and an aperture 222 in electromagnetic or electron communication with the energy source 220. The energy source 220 can be adapted to emit energy 228 comprising at least one of electromagnetic radiation (e.g., by a laser module) and an electron beam (e.g., by an electron beam module) and control at least one of a spot size, a shape, and an intensity of energy emitted by the energy module 108. The energy source 220 can comprise, for example, at least one of a laser diode, a flashlamp laser, an ion laser, an electrical discharge laser, an excimer laser, and an electron beam gun. In various embodiments, the emitted energy 228 can be collimated and coherent.

[0043] The aperture 222 comprises a body 224 and an opening 226 within the body 224. The body 224 can be adapted to absorb at least a portion of the energy 228 emitted by the energy source 220. In various non-limiting embodiments, the absorption of the energy 228 by the body 224 includes converting energy from photons/electrons within the energy 228 to internal energy of the body 224. In various non-limiting embodiments, the internal energy can heat the body 224. The body 224 can comprise a material adapted to withstand the absorbed energy without melting of the body. For example, the body 224 can comprise quartz. In various non-limiting embodiments, the body 224 can be configured to limit, and in some embodiments prevent, reflection of the energy 228.

[0044] The opening 226 can be adapted to shape the energy 228 emitted by the energy source 220 and transmit energy 230 through the opening 226. For example, a shape of a cross section of the energy 228 passing to opening 226 can be different than a shape of a cross section of energy 230 passing from opening 226. In various non-limiting embodiments, the aperture 222 can shape energy having a Gaussian beam profile into energy having a steeper intensity drop off and a more uniform maximum intensity. In various non-limiting embodiments, the amount (e.g., power) of energy absorbed by the body 224 and transmitted through the opening 226 can equal the amount (e.g., power) of the energy 228 emitted by the energy source 220.

[0045] The energy 230 can be transmitted from the opening 226 into the material deposition region 102 to selectively contact feedstock disposed in the material deposition region 102. At least a portion of the feedstock contacted by the energy 230 can be melted to form a molten pool in the material deposition region 102. After the energy 230 no longer contacts the molten pool and/or an intensity of the energy 230 is lessened sufficiently, the molten pool can re-solidify and form a portion of an additively manufactured part. The energy 230 can scan (e.g., raster) through the feedstock in the material deposition region 102. The molten pool can move concomitantly with movement of the energy 230.

[0046] The shape of the opening 226 can be configured in a variety of shapes that can affect the shape of transmitted energy 230 and thereby affect the configuration of the molten pool in the feedstock in the material deposition region 102. For example, the shape of the opening 226 can be one of an ellipse (e.g., a circle) and a rectangle (e.g., a square), and a cross section of the energy 230 can comprise a corresponding shape, such as, for example, at least one of an ellipse(e.g., circle) and a rectangle (e.g., a square). In various non-limiting embodiments, as illustrated in FIG. 2A, the opening 226 can comprise an elongated shape having a width, w, larger than a length, /, of the elongated shape. At least one of the width, w, and the length, /, of the elongated shape has a dimension smaller than a dimension of a cross section of the energy emitted by the energy source 220 (e.g., diameter, d) and/or transmitted by the aperture 222. In various non-limiting embodiments, the energy 230 can comprise an elongated shape corresponding to the elongated shape of the opening 226. [0047] In various non-limiting embodiments, the energy 226 and energy 230 may be not focused (e.g., unfocused energy).

[0048] Energy 230 can be scanned across the material deposition region 102 in a variety of directions, such as, for example, a first direction 258a and/or a second direction 258b. FIG. 2B provides a schematic representation of energy 230 being scanned across the material deposition region 102 in the first direction 258a. The first direction 258a can be substantially parallel to the length, /, of the elongated shape of the opening 226. As illustrated, the feedstock in the material deposition region 102 is being contacted by the energy 230, and a molten pool 256a is formed. Scanning in the first direction 258a can move the molten pool 256a throughout the feedstock in the material deposition region 102 in the first direction 256a.

[0049] FIG. 2C illustrates a schematic representation of energy 230 being scanned across the material deposition region 102 in the second direction 258b. The second direction 258b can be substantially perpendicular to the length, /, of the elongated shape of the opening 226. As illustrated, the feedstock in the material deposition region 102 is being contacted by the energy 230, and a molten pool 256b is formed. Scanning in the second direction 258b can move the molten pool 256b throughout the feedstock in the material deposition region 102 in the second direction 256b.

[0050] The scan configuration (e.g., substantially parallel to the length, I) shown in FIG. 2B may enable a higher scanning speed with a lower surface area scanned per pass compared to FIG. 2C. The scan configuration (e.g., substantially perpendicular to the length, I) of FIG. 2C may enable a faster rate of affixing feedstock in the material deposition region 102 than the scan configuration of FIG. 2B, which may be due to the higher surface area scanned per pass in FIG. 2C compared to FIG. 2B. The scan configurations in FIG. 2B and 2C can comprise a defined beam profile that can form a molten pool 256a, 256b, respectively, having minimal turbulence therein. In various non-limiting embodiments, the minimal turbulence can be due to uniform heating of the feedstock by the energy 230. Reducing turbulence within the molten pools 256a, 256b can decrease imperfections in an additively manufactured part produced therefrom (e.g., reduced cracking, spalling, erosion).

[0051] In various non-limiting embodiments, the energy module 108 can comprise at least one of a lens 332 and a mirror 336. For example, FIG. 3 illustrates a laser module 308 comprising a laser source 320, the aperture 222, a lens 332, and a mirror 336. The lens 332 can be intermediate the laser source 320 and the material deposition region 102 in the path of the electromagnetic radiation 328 emitted by the laser source 320. In various non-limiting embodiments, the lens 332 can be intermediate the aperture 222 and the material deposition region 102 in the path of the electromagnetic radiation 328 emitted by the laser source 320.

In various other embodiments, the lens 332 can be intermediate the aperture 222 and laser source 320 in the path of the electromagnetic radiation 328 emitted by the laser source 320.

In various other embodiments, the lens 332 can be intermediate the mirror 336 and the material deposition surface 102 in the path of the electromagnetic radiation 328 emitted by the laser source 320.

[0052] As illustrated in FIG. 3, the lens 332 can be adapted to refract electromagnetic radiation emitted by the laser source 320 and transmitted through the opening 226. The refraction of the electromagnetic radiation can form focused electromagnetic radiation 334, which can comprise a greater intensity (e.g., power concentration per unit area) than the electromagnetic radiation 330 entering the lens 332.

[0053] The lens 332 can comprise various shapes suitable to focus the electromagnetic radiation 330 to form focused electromagnetic radiation 334. For example, the lens 332 can comprise a convex shape. The lens 332 can comprise an optical system that focuses the electromagnetic radiation 330 (e.g., a condenser lens system). In various non-limiting embodiments, the shape of the lens 332 can affect the focal length,/ of the lens 332.

[0054] The lens 332 can be disposed at a distance, Di, from the material deposition surface 102 suitable to enable a desired power concentration per unit area (e.g., melt the feedstock). For example, the lens 332 can be positioned at a distance equal to Di from the material deposition region 102 according to equation 1.

[0055] Equation 1 wherein: Di is the distance electromagnetic radiation travels from the aperture 222 to the lens 332, and Di is greater than / D2 is the distance electromagnetic radiation travels from the lens 332 to material deposition region 102; and /is the focal length of the lens 332. [0056] In various non4imiting embodiments, a mirror 336 can be disposed intermediate laser source 320 and the material deposition region 102 in the path of electromagnetic radiation 328 emitted by the laser source 320. In various non-limiting embodiments, the mirror 336 can be disposed intermediate the lens 332 and the material deposition region 102 in the path of electromagnetic radiation 328 emitted by the laser source 320. In various non-limiting embodiments, the mirror 336 can be disposed intermediate the aperture 222 and the laser source 320 in the path of the electromagnetic radiation 328 emitted by the laser source 320.

In various other embodiments, the mirror 336 can be disposed intermediate the aperture 222 and the lens 332.

[0057] As illustrated in FIG. 3, the mirror 336 can be adapted to receive electromagnetic radiation 334 emitted by the laser source 320 and focused by the lens 332, if present. The mirror 336 can direct the received electromagnetic radiation to the material deposition region 102. For example, the mirror 336 can change the direction of the received focused electromagnetic radiation 334 by reflecting the received focused electromagnetic radiation 334 towards the material deposition region 102 as electromagnetic radiation 338. The angle of the mirror 336 relative to the material deposition region 102 can be changed to redirect the electromagnetic radiation 338 and contact a different area of the feedstock in the material deposition region 102. In various non-limiting embodiments, the mirror 336 can comprise a curved shape, which may be suitable to minimize projection effects that may distort the shape of the cross section of the electromagnetic energy transmitted through the opening 226 and the lens 332, if present.

[0058] FIG. 4 illustrates a schematic representation of a laser module 408 comprising the laser source 320 and an aperture 440 adapted to create an interference pattern. The aperture 440 comprises a body 442 and an opening 444. The opening 444 can be adapted to create an interference pattern from the electromagnetic radiation 328 emitted by the laser source 320. For example, as the electromagnetic radiation 328 is being transmitted through the opening 444, the electromagnetic radiation 328 begins to interfere with itself and can change direction into at least two different portions. In various non-limiting embodiments, the shape of the opening 444 can comprise one of an ellipse (e.g., a circle) and a rectangle (e.g., a square).

[0059] The aperture 440 can diffract electromagnetic radiation 328 into a zero beam 446a and a diffracted beam 446b. In certain embodiments where the shape of the opening 444 is an ellipse, as illustrated in FIG. 4, the shape of the diffracted beam 446b can be a hollow cone (e.g., a shape of a cross section of the diffracted beam can be a ring). A power concentration of the diffracted beam 446b can be lower than a power concentration of the zero beam 446a. For example, the power concentration of the zero beam 446a can be adapted to heat feedstock in the material deposition region 102 to a temperature at least as great as a liquidus temperature of the feedstock. The power concentration of the diffracted beam 446b can be adapted to heat feedstock in the material deposition region 102 to a temperature less than a liquidus temperature of the feedstock. In various non-limiting embodiments, the power concentration of the diffracted beam 446b can be adapted to heat feedstock in the material deposition region 102 to a temperature at least as great as a liquidus temperature of the feedstock.

[0060] In various non-limiting embodiments, the aperture 440 can include at least two openings, including opening 444. The openings can be positioned relative to each other to create an interference pattern. In various non-limiting embodiments, laser module 408 can comprise at least two laser sources, including the laser source 320. The electromagnetic radiation emitted by each laser source can be used to interfere with one another to create an interference pattern. In various non-limiting embodiments, the laser module 408 can comprise a beam splitter in electromagnetic communication with the laser source. The beam splitter can be suitable to create at least two beams of electromagnetic radiation from electromagnetic radiation 328 and can cause interference between the two beams of electromagnetic radiation to create an interference pattern.

[0061] In various non-limiting embodiments, the laser module 408 can comprise at least one of the lens 332 and the mirror 336.

[0062] FIG. 5 illustrates a non-limiting embodiment of a laser module 508 comprising the laser source 320, the aperture 440, and an aperture 548. The aperture 548 is in

electromagnetic communication with the laser source 320 and is disposed between the aperture 440 and the material deposition surface 102 in the path of the electromagnetic radiation 328 emitted by the laser source 320. The aperture 548 comprises a body 550 and an opening 552 within the body 550. The body 550 can be adapted to absorb at least a portion of the electromagnetic radiation 446a-b transmitted by the opening 444 in the aperture 440. The opening 552 can be adapted to transmit electromagnetic radiation 554a-c onto the material deposition surface 102. In various non-limiting embodiments, the shape of the opening 548 can comprise one of an ellipse (e.g., a circle) and a rectangle (e.g., a square)..

For example, the shape of the opening 548 can comprise an elongated shape.

[0063] The aperture 548 can shape the electromagnetic radiation transmitted by the opening 444 (e.g., zero beam 446a and diffracted beam 446b). In embodiments where the shape of the opening 548 comprises the elongated shape and the shape of the opening 444 comprises an ellipse as illustrated in FIG. 5, the diffracted beam 446b can be shaped by the aperture 548 into at least two diffracted beams 554b-c. In various non-limiting embodiments, the zero beam 446a may be transmitted through opening 552 with minimal, if any, absorption by body 550 as zero beam 554a. A power concentration of the diffracted beams 554b-c can equal to or lower than a power concentration of the zero beam 554a. For example, the power concentration of the zero beam 554a can be adapted to heat feedstock in the material deposition region 102 to a temperature at least as great as a liquidus temperature of the feedstock. The power concentration of the diffracted beams 554b-c can be adapted to heat feedstock in the material deposition region 102 to a temperature less than a liquidus temperature of the feedstock. In various non-limiting embodiments, the power concentration of the diffracted beams 554b-c can be adapted to heat feedstock in the material deposition region 102 to a temperature at least as greater as a liquidus temperature of the feedstock.

[0064] In various non-limiting embodiments, the laser module 508 can comprise at least one of the lens 332 and the mirror 336. The lens 332 can be positioned intermediate the laser source 320 and the aperture 440 in the path of the electromagnetic radiation 328 emitted by the laser source 320 and the lens 332 can be positioned intermediate the aperture 548 and the material deposition region 102 in the path of the electromagnetic radiation 328 emitted by the laser source 320. In various embodiments, the lens 332 is positioned intermediate the mirror 336 and the laser source 320 in the path of the electromagnetic radiation 328 emitted by the laser source 320.

[0065] The beams 554a-c can be scanned in various directions across the material deposition region 102, such as, for example, in a first direction 560a and a second direction 560b. FIG.

6 illustrates a schematic representation of beams 554a-c being scanned across the material deposition region 102 in the first direction 560a. The first direction 560a can be substantially parallel to the length, /, of an elongated shape of the opening 556. As illustrated, the feedstock in the material deposition region 102 can be contacted by the beams 554a-c and a molten pool 670 can be formed. Scanning in the first direction 560a can move the molten pool 670 throughout the feedstock in the material deposition region 102 in the first direction 560a.

[0066] FIG. 7 A depicts a graph illustrating the power concentration of each beam 554a-c at a first power configuration. Zero beam 554a can have a power concentration 764a greater than a power concentration 764b of diffracted beam 554b and a power concentration 764c of diffracted beam 554c. The power concentrations 764a-c of each beam 554a-c can be configured in order to achieve a desired configuration of the molten pool 570.

[0067] A first power concentration 766 can be at least the liquidus temperature of the feedstock and the zero beam 554a can melt the feedstock and the diffracted beams 554b-c may not melt the feedstock. Thus, as illustrated in FIG. 6, diffracted beam 554c may preheat and/or sinter the feedstock in the material deposition region 102. The zero beam 554a can melt the preheated and/or sintered feedstock and form the molten pool 670. The diffracted beam 554b may reduce cooling of the molten pool after melting of the feedstock with the zero beam 554a.

[0068] FIG. 7B depicts a graph illustrating the power concentration of each beam 554a-c at a second power configuration. A second power concentration 768 can be at least the liquidus temperature of the feedstock and the zero beam 554a can melt the feedstock and the diffracted beams 554b, 554c can melt the feedstock. Thus, as illustrated in FIG. 6, all beams 554a-c may melt the feedstock in the material deposition region 102. Thus, as illustrated in FIG. 6, diffracted beams 554b-c can extend the molten pool 670 if in the second power configuration compared to the molten pool 670 at the first power configuration.

[0069] FIG. 8 illustrates a schematic representation of beams 554a-c being scanned across the material deposition region 102 in the second direction 560b. As illustrated, the feedstock in the material deposition region 102 can be contacted by the beams 554a-c and a molten pool 872 can be formed. The second direction 560b can be substantially perpendicular to the length, /, of an elongated shape of the opening 556. Scanning in the second direction 560b can move the molten pool 872 throughout the feedstock in the material deposition region 102 in the second direction 560b. In various non-limiting embodiments, the beams 554a-c can scan across in the material deposition region in respective paths substantially parallel to one another. [0070] At the first power concentration 766 of FIG. 7A, the zero beam 554a can melt the feedstock and form the molten pool 872a. The diffracted beams 554b-c may preheat and/or sinter the feedstock in the material deposition region 102 in a path generally parallel to a path of the zero beam 554a while scanning in the second direction 560b as shown in FIG. 8. The diffracted beams 554b-c may reduce the cooling of the molten pool after melting of the feedstock with the zero beam 554a while scanning in the second direction 560b as shown in FIG. 8.

[0071] At the second power concentration 768 of FIG. 7B, the beams 554a-c can melt the feedstock. Thus, as illustrated in FIG. 8, diffracted beams 554b-c can extend the molten pool 872a to include side regions 872b-c.

[0072] FIG. 9 is a schematic representation of a perspective view of a cooled aperture 922. The cooled aperture 922 can comprises a first layer 974 disposed adjacent to the body 924. The first layer 974 can be disposed on a first side 924a of the body 924. The first layer 974 can comprise a material substantially transparent to electromagnetic radiation 328 emitted by the laser source 320. As used herein,“substantially transparent” means at least 90% of the electromagnetic radiation is transmitted through the material, such as, for example, at least 95% of the electromagnetic radiation or at least 99% of the electromagnetic radiation. The first layer 974 can be adapted to receive the electromagnetic radiation 328 from the laser source 320 and transmit the electromagnetic radiation to the opening 926.

[0073] In various nondimiting embodiments, the cooled aperture 922 can comprises a second layer 976 disposed adjacent to the body 924. The second layer 976 can be disposed on a second side (not shown) of the body 924 distal from the first side 924a. The second layer 976 can comprise a material substantially transparent to electromagnetic radiation transmitted by the opening 926. The second layer 976 can be adapted to receive the electromagnetic radiation transmitted by an opening 926 of the cooled aperture 922 and can be suitable to transmit the electromagnetic radiation to the material deposition region 102.

[0074] A cooling module 978 can be provided in thermal communication with the aperture 922 and can be suitable to cool (e.g., remove heat from) the aperture 922. For example, the cooling module 976 can be provided in thermal communication with at least one of the body 924, layer 974, and layer 976. The cooling module 978 can comprise at least one of a thermal radiative structure (e.g., fins), a fluid circulator (e.g., fan, pump, compressor), and a thermoelectric device (e.g., Peltier assembly).

[0075] It is understood that a laser module and an electron beam module comprise similar optical properties. Accordingly, the use of an electron beam module can be used in place of a laser module in the embodiments provided herein. In various embodiments, the electron beam module does not comprise a mirror.

[0076] As illustrated in FIGs. 10A-B, a flow chart 1000 is provided for a method for additive manufacturing. The method comprises depositing a layer of feedstock in a material deposition region of an additive manufacturing apparatus (1002). At least a selected region of the layer is affixed together in the selected region (1004). More specifically, energy is emitted from an energy source (1006). The emitted energy is shaped utilizing an aperture (1008). In various non-limiting embodiments, shaping the energy can comprise diffracting, by the aperture, energy emitted by the energy source into a zero beam and a diffracted beam (1010). A power concentration of the diffracted beams can be equal to or lower than a power concentration of the zero beam.

[0077] In various non-limiting embodiments, a lens is positioned at a distance equal to /from the selected region according to Equation 1. In various non-limiting embodiments, the energy emitted from the energy source is focused through the lens after shaping the emitted energy (1012). In various non-limiting embodiments comprising a laser source, the energy from the aperture and/or lens can be directed utilizing a mirror (1014). For example, the mirror can direct the energy towards the material deposition region.

[0078] The shaped energy is transmitted to contact feedstock in the selected region in the material deposition region (1016). In various non-limiting embodiments, the energy transmitted into the material deposition region has a cross-sectional shape of at least one of an ellipse (e.g., a circle) and a rectangle (e.g., a square).. In various non-limiting

embodiments comprising an aperture with an elongated shape, energy transmitted onto the region can be scanned in a direction substantially parallel and/or perpendicular to the length of the elongated shape.

[0079] In various non-limiting embodiments comprising diffracting the energy, the feedstock can be heated with the zero beam to a temperature at least as great as a liquidus temperature of the feedstock (1018), and the feedstock can be heated with the diffracted beams to a temperature less than a liquidus temperature of the feedstock (1020). In various non-limiting embodiments, the feedstock can be heated with the diffracted beams to a temperature at least as great as a liquidus temperature of the feedstock. In various non-limiting embodiments, the aperture can be cooled (1022).

[0080] Depositing a layer and affixing at least a selected region of the layer can be repeated as needed (1024) to produce an additively manufactured part in the material deposition region of the additive manufacturing apparatus (1026). The additively manufactured part can suffer from limited, if any, cracks, spalls, and erosion.

[0081] Additive Manufacturing

[0082] In various non-limiting embodiments, the inventions according to the present disclosure may be used with, for example, a laser additive manufacturing technique and an electron beam additive manufacturing technique as described in ASTM F2792-12a. In one embodiment, the additive manufacturing process includes depositing successive layers of powder and then selectively melting and/or sintering the powder to create, layer-by-layer, an additively manufactured part. In one non-limiting embodiment, a powder bed is used to create a part, such as, for example, a tailored alloy part and/or a unique structure

unachievable through traditional manufacturing techniques (e.g., without excessive post processing machining).

[0083] Non-limiting examples of additive manufacturing processes useful in producing additively manufactured parts from feedstocks include, for example, DMLS, SLM, and SLS, among others. In one embodiment, an additive manufacturing process uses an EOSINT M 280 Direct Metal Laser Sintering (DMLS) additive manufacturing system, or comparable system, available from EOS GmbH (Robert-Stirling-Ring 1, 82152 Krailling, Munich, Germany). Additive manufacturing techniques (e.g., when utilizing metallic feedstocks) may facilitate the selective heating of powder above the liquidus temperature of the powder, thereby forming a molten pool followed by rapid solidification of the molten pool.

[0084] Any suitable feedstocks may be used, including powder, a sheet, a wire, and combinations thereof. In various non-limiting embodiments, the feedstock may be, for example, metallic feedstocks (e.g., with additives to promote various properties, such as, for example, grain refiners and/or ceramic materials), polymeric feedstocks (e.g., plastic feedstocks), and ceramic feedstocks. In certain embodiments, the wire can comprise a ribbon and/or a tube. The metallic feedstocks can be at least one of titanium, a titanium alloy, aluminum, an aluminum alloy, nickel, a nickel alloy, iron, an iron alloy, cobalt, a cobalt alloy, copper, a copper alloy, molybdenum, a molybdenum alloy, magnesium, a magnesium alloy, tantalum, a tantalum alloy, tungsten, a tungsten alloy, zinc, a zinc alloy, silver, a silver alloy, chromium, a chromium alloy, tin, a tin alloy, gold, a gold alloy, platinum, a platinum alloy, zirconium, and a zirconium alloy.

[0085] As used herein,“aluminum alloy” means a metal alloy including aluminum as the predominant alloying element. Corresponding definitions apply to the other alloys referenced herein (e.g., titanium alloy means a metal alloy including titanium as the predominant alloying element).

[0086] In one approach, an additive manufacturing process comprises: (a) dispersing a layer of a feedstock (e.g., powder in a powder bed); (b) selectively heating a portion of the dispersed powder (e.g., via an energy source) to a temperature above the liquidus temperature of the powder; (c) forming a molten pool; and (d) cooling the molten pool at a cooling rate of at least 1000°C per second, such as, for example, at least 10,000°C per second, at least 100,000°C per second, or at least 1,000,000°C per second. Steps (a)-(d) may be repeated as necessary until the additively manufactured part is completed.

[0087] Production and Processing

[0088] In some embodiments, the additively manufactured part may be subject to any appropriate dissolving (e.g., includes homogenization), working, and/or precipitation hardening steps. If employed, the dissolving and/or the working steps may be conducted on an intermediate form of the additively manufactured part and/or may be conducted on a final form of the additively manufactured part. If employed, the precipitation hardening step is generally conducted relative to the final form of the additively manufactured part.

[0089] After or during production, an additively manufactured part may be deformed (e.g., by one or more of rolling, extruding, forging, stretching, and compressing). The final deformed product may realize, for instance, improved properties due to the tailored regions and thermo-mechanical processing of the final deformed part. Thus, in some embodiments, the final part is a wrought part. In such case, the word“wrought” refers to the working (hot working and/or cold working) of the additively manufactured part, wherein the working occurs relative to an intermediate and/or final form of the additively manufactured part. In other approaches, the final part is a non-wrought product, i.e., it is not worked during or after the additive manufacturing process. In these non-wrought product embodiments, any appropriate number of dissolving and precipitating steps may still be utilized.

[0090] Product Applications

[0091] The resulting additively manufactured parts made in accordance with the systems and methods described herein may be used in a variety of product applications, such as commercial end-uses in industrial applications, in consumer applications (e.g., consumer electronics and/or appliances), or in other areas. For example, the additively manufactured parts can be utilized in at least one of the aerospace field (e.g., an aerospace component), automotive field (e.g., an automotive component), transportation field (e.g., a transportation component), or building and construction field (e.g., a building component or a construction component). In certain embodiments, the additively manufactured parts can be configured as at least one of an aerospace component, an automotive component, a transportation component, and a building and construction component.

[0092] In one embodiment, an additively manufactured part can be utilized in an elevated temperature application, such as in an aerospace or automotive vehicle. In one embodiment, an additively manufactured part can be utilized as an engine component in an aerospace vehicle (e.g., in the form of a blade, such as a compressor blade incorporated into the engine). In another embodiment, an additively manufactured part can be used as a heat exchanger for the engine of the aerospace vehicle. The aerospace vehicle including the engine

component/heat exchanger may subsequently be operated. In one embodiment, an additively manufactured part can be an automotive engine component. The automotive vehicle including an automotive component (e.g., engine component) may subsequently be operated. For instance, the additively manufactured part may be used as a turbo charger component (e.g., a compressor wheel of a turbo charger, where elevated temperatures may be realized due to recycling engine exhaust back through the turbo charger), and the automotive vehicle including the turbo charger component may be operated. In another embodiment, an additively manufactured part may be used as a blade in a land based (stationary) turbine for electrical power generation, and the land-based turbine included the additively manufactured part may be operated to facilitate electrical power generation. In some embodiments, an additively manufactured part can be utilized in defense applications, such as in body armor and armed vehicles (e.g., armor plating). In other embodiments, the additively manufactured part can be utilized in consumer electronic applications, such as in consumer electronics, such as, laptop computer cases, battery cases, cell phones, cameras, mobile music players, handheld devices, computers, televisions, microwaves, cookware, washers/dryers, refrigerators, and sporting goods, among others.

[0093] In another aspect, an additively manufactured part can be utilized in a structural application, such as, for example, an aerospace structural application and an automotive structural application. For instance, the additively manufactured part may be formed into various aerospace structural components, including floor beams, seat rails, fuselage framing, bulkheads, spars, ribs, lingering, and brackets, among others. In another embodiment, the additively manufactured part can be utilized in an automotive structural application. For instance, the additively manufactured part can be formed into various automotive structural components, including nodes of space frames, shock towers, and subframes, among others.

In one embodiment, the additively manufactured part can be a body -in-white automotive product.

[0094] In another aspect, the additively manufactured part can be utilized in an industrial engineering application. For instance, the additively manufactured part or products may be formed into various industrial engineering products, such as tread-plate, tool boxes, bolting decks, bridge decks, and ramps, among others.

[0095] Various aspects of the invention according to the present disclosure include, but are not limited to, the aspects listed in the following numbered clauses.

1. An additive manufacturing system comprising:

a material deposition region adapted to receive a feedstock and comprising a material deposition surface;

a material deposition module adapted to dispose the feedstock in the material deposition region; and

an energy module adapted to affix at least a selected region of the feedstock disposed in the material deposition region, the energy module comprising:

an energy source adapted to emit energy comprising at least one of electromagnetic radiation and an electron beam; and a first aperture in electromagnetic communication with the energy source, the first aperture comprising:

a body adapted to absorb at least a portion of the energy emitted by the energy source; and

a first opening within the body, the first opening adapted to shape the energy emitted by the energy source and transmit energy emitted by the energy source into the material deposition region to selectively contact feedstock disposed in the material deposition region.

2. The system of clause 1, further comprising a lens intermediate the energy source and the material deposition region, the lens adapted to refract the energy emitted by the energy source.

3. The system of clause 2, wherein the lens comprises a convex shape.

4. The system of any one of clauses 2-3, wherein the lens is disposed at a distance Di from the material deposition region according to the equation: wherein Di is the distance energy travels from the first aperture to the lens and Di is greater than /;

wherein D2 is the distance energy travels from the lens to the material deposition region; and

/is the focal length of the lens.

5. The system of any one of clauses 1-4, further comprising a mirror adapted to receive energy emitted by the energy source and direct the received energy to the material deposition region.

6. The system of any one of clauses 1-5, wherein the first opening in the first aperture comprises a shape selected from one of an ellipse and a rectangle.

7. The system of any one of clauses 1-6, wherein the first opening in the first aperture comprises an elongated shape having a width larger than a length of the elongated shape. 8. The system of clause 7, wherein at least one of the width and the length of the elongated shape has a dimension smaller than a dimension of a cross section of the energy emitted by the energy source.

9. The system of clause 8, wherein the energy module is adapted to scan energy transmitted by the first opening across feedstock disposed in the material deposition region in a direction substantially parallel to the length of the elongated shape.

10. The system of any one of clauses 8-9, wherein the energy module is adapted to scan energy transmitted by the first opening in the aperture across a direction substantially perpendicular to the length of the elongated shape.

11. The system of any one of clauses 1-10, wherein the first aperture further comprises a second opening.

12. The system of any one of clauses 1-11, wherein the first aperture further comprises a first layer disposed adjacent to the body, the first layer comprises material transparent to the energy emitted by the energy source, and the first layer is adapted to receive the energy from the energy source and transmit the energy to the first opening.

13. The system of any one of clauses 1-12, wherein the body of the first aperture comprises a material adapted to withstand the absorbed energy without melting of the body.

14. The system of any one of clauses 1-13, wherein the body of the first aperture comprises quartz.

15. The system of any one of clauses 1-14, further comprising a cooling module adapted to cool the first aperture.

16. The system of any one of clauses 1-15, wherein the first opening in the first aperture is adapted to create an interference pattern from the energy emitted by the energy source.

17. The system of clause 16, wherein the first aperture is adapted to diffract energy emitted by the energy source into a zero beam and a diffracted beam, wherein a power concentration of the diffracted beam is lower than a power concentration of the zero beam. 18. The system of clause 17, wherein the power concentration of the zero beam is adapted to heat feedstock in the material deposition region to a temperature at least as great as a liquidus temperature of the feedstock.

19. The system of any one of clauses 17-18, wherein the power concentration of the diffracted beam is adapted to heat feedstock in the powder deposition region to a temperature less than a liquidus temperature of the feedstock.

20. The system of any one of clauses 1-19, further comprising a second aperture in electromagnetic communication with the energy source, the second aperture disposed between the first aperture and the material deposition surface, the second aperture

comprising:

a second body adapted to absorb at least a portion of the energy transmitted by the first opening; and

a second opening within the second body, the second opening adapted to transmit energy onto the material deposition surface.

21. The system of clause 20, wherein the first opening comprises an elliptical shape and the second opening comprises an elongated shape.

22. The system of any one of clauses 1-21, wherein the emitted energy from the energy source is not focused.

23. The system of any one of clauses 1-22, further comprising at least two energy sources, including the energy source.

24. The system of any one of clauses 1-23, further comprising a beam splitter in electromagnetic communication with the energy source.

25. The system of any one of clauses 1-24, wherein the feedstock comprises at least one of powder and a sheet.

26. A method for additive manufacturing comprising:

depositing a layer of feedstock in a material deposition region of an additive manufacturing apparatus; affixing at least a selected region of the layer together in the selected region, the affixing comprising:

emitting energy comprising at least one of electromagnetic radiation and an electron beam from an energy source;

shaping the emitted energy utilizing an aperture; and

transmitting the shaped energy to contact feedstock in the selected region in the material deposition region.

27. The method of clause 26, further comprising repeating depositing a layer and affixing at least a selected region of the layer as needed to provide an additively manufactured part in the material deposition region of the additive manufacturing apparatus.

28. The method of any one of clauses 26-27, further comprising focusing the energy emitted from the energy source through a lens after shaping the emitted energy.

29. The method of any one of clauses 26-28, further comprising positioning the lens at a distance equal to Di from the at least one selected region according to the equation: wherein Di is the distance emitted energy travels from the aperture to the lens and Di is greater than /; wherein D2 is the distance energy travels from the lens to the material deposition region; and

/is the focal length of the lens.

30. The method of any one of clauses 26-29, further comprising directing energy emitted from the energy source to the material deposition region utilizing a mirror.

31. The method of any one of clauses 26-30, wherein energy transmitted onto the material deposition region has a cross sectional shape of at least one of an ellipse and a rectangle. 32. The method of any one of clauses 26-31, wherein the aperture comprises an opening comprising an elongated shape comprising a width larger than a length of the elongated shape.

33. The method of clause 32, further comprising scanning energy transmitted onto the selected region in a direction substantially parallel to the length of the elongated shape.

34. The method of any one of clauses 32-33, further comprising scanning energy transmitted onto the selected region in a direction substantially perpendicular to the length of the elongated shape.

35. The method of any one of clauses 26-34, further comprising cooling the aperture.

36. The method of any one of clauses 26-35, wherein shaping the emitted energy further comprises diffracting, by the aperture, energy emitted by the energy source into a zero beam and a diffracted beam, wherein a power concentration of the diffracted beam is lower than a power concentration of the zero beam.

37. The method of clause 36, further comprising heating the feedstock with the zero beam to a temperature at least as great as a liquidus temperature of the feedstock.

38. The method of any one of clauses 36-37, further comprising heating the feedstock with the diffracted beam to a temperature less than a liquidus temperature of the feedstock.

39. The method of any one of clauses 26-38, wherein the feedstock comprises at least one of powder and a sheet.

40. The method of any one of clauses 26-39, wherein the emitted energy from the energy source is not focused.

[0096] One skilled in the art will recognize that the herein described methods, processes, systems, apparatus, components, devices, operations/actions, and objects, and the discussion accompanying them, are used as examples for the sake of conceptual clarity and that various configuration modifications are contemplated. Consequently, as used herein, the specific examples/embodiments set forth and the accompanying discussions are intended to be representative of their more general classes. In general, use of any specific exemplar is intended to be representative of its class, and the non-inclusion of specific components, devices, operations/actions, and objects should not be taken as limiting. While the present disclosure provides descriptions of various specific aspects for the purpose of illustrating various aspects of the present disclosure and/or its potential applications, it is understood that variations and modifications will occur to those skilled in the art. Accordingly, the invention or inventions described herein should be understood to be at least as broad as they are claimed, and not as more narrowly defined by particular illustrative aspects provided herein.