Wisconsin Alumni Research Foundation

Dan J Thoma

Frank Ewald Pfefferkorn

Salman Jahani

Adrien Couet

Michael Joseph Moorehead

Seyyed Behzad Hosseini Rankouhi

As may be implemented in accordance with one or more approaches herein, a plurality of metal alloy samples are formed on a surface, in which each sample has a different metal alloy composition relative to the others. Elemental metal powders are provided from hoppers at respective delivery rates and mixed, such that the mixture for each sample is set via the respective delivery rates and is different than the mixture for the other samples. Multiple layers of each mixture are deposited by dispensing and melting the mixture to form the respective samples, and one or more layer of each of the samples is remelted

In situ alloying

A system and method for controlling an additive manufacturing system to form a multi-material component. Operating parameter values may be determined for the additive manufacturing system based on a first material and a second material used to form the multi-material component to ensure a requisite level of bonding between particles of a gradient between the first and second materials. Data or models for the first and second materials, along with observed data from a plurality of sample multi-material components formed from the first and second materials may be utilized to determine the operating parameter values. In some cases, the operating parameter values may be tuned to form a multi-material component having predetermined values for parameter objectives along the gradient of the multi-material component. The additive manufacturing system may be a selective laser melting system.

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Madison, WI, United States of America

Dan J Thoma