Adaptive deposition for initial layer of additive manufacturing process

1 . An additive manufacturing system, comprising:

an energy delivery device configured 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 configured to direct a powder stream toward the melt pool; and

a computing device configured 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, wherein the third set of deposition parameters is different from the first and second sets of deposition parameters; and

control the energy delivery device and the powder delivery device to:

deposit the innermost layer on the substrate based on the first set of deposition parameters, wherein, when operating based on the first set of deposition parameters, the energy delivery device delivers a first amount of energy to the build surface;

deposit the inner plurality of layers on the innermost layer based on the second set of deposition parameters, wherein, when operating based on the second set of deposition parameters, the energy delivery device delivers a second amount of energy to the build surface; and

deposit the outer plurality of layers on the inner plurality of layers based on third set of deposition parameters, wherein, when operating based on the third set of deposition parameters, the energy delivery device delivers a third amount of energy to the build surface, and wherein the third amount of energy is different than each of the first and second amounts of energy.

2 . The additive manufacturing system of claim 1 , wherein a melting point of the deposit is greater than a melting point of the substrate.

3 . The additive manufacturing system of claim 1 , wherein the first set of deposition parameters is configured to maintain a size of the melt pool at or below a threshold that corresponds to thermal damage of the substrate.

4 . The additive manufacturing system of claim 1 , wherein the second set of deposition parameters is configured to maintain a size of the melt pool at or below a threshold that corresponds to melt back of the substrate.

5 . The additive manufacturing system of claim 1 , wherein deposition parameters of the third set of deposition parameters that are different from the first and second sets of deposition parameters include at least one of move pause, a power or duty cycle of the energy delivery device, a thickness of the corresponding layer, a size of the melt pool, or a toolpath of the melt pool.

6 . The additive manufacturing system of claim 1 , further comprising at least one thermal sensor configured to detect thermal data indicative of a temperature of the melt pool, and

wherein the computing device if further configured to:

receive the thermal data from the at least one thermal sensor; and

determine at least the first set of deposition parameters and the second set of deposition parameters based on the thermal data.

7 . The additive manufacturing system of claim 1 , wherein a depth of the inner plurality of layers is less than 1 centimeter.

8 . The additive manufacturing system of claim 1 ,

wherein the first set of deposition parameters is different from the second set of deposition parameters, and

wherein the first amount of energy is greater than the second amount of energy.

9 . The additive manufacturing system of claim 1 , wherein the third amount of energy is greater than 10 percent and less than 50 percent of each of the first amount of energy and the second amount of energy.

10 . A method for additive manufacturing, comprising:

determining, by a computing device, a first set of deposition parameters for an innermost layer of a deposit overlying a substrate;

determining, by the computing device, a second set of deposition parameters for an inner plurality of layers of the deposit overlying the innermost layer;

determining, by the computing device, a third set of deposition parameters for an outer plurality of layers of the deposit overlying the inner plurality of layers, wherein the third set of deposition parameters is different from the first and second sets of deposition parameters; and

controlling, by the computing device, an energy delivery device to deliver energy to a build surface of the deposit to form a melt pool and a powder delivery device to direct a powder stream toward the melt pool to:

deposit the innermost layer on the substrate based on the first set of deposition parameters, wherein, when operating based on the first set of deposition parameters, the energy delivery device delivers a first amount of energy to the build surface;

deposit the inner plurality of layers on the innermost layer based on the second set of deposition parameters, wherein, when operating based on the second set of deposition parameters, the energy delivery device delivers a second amount of energy to the build surface; and

deposit the outer plurality of layers on the inner plurality of layers based on third set of deposition parameters, wherein, when operating based on the third set of deposition parameters, the energy delivery device delivers a third amount of energy to the build surface, and wherein the third amount of energy is different than each of the first and second amounts of energy.

11 . The method of claim 10 , wherein a melting point of the deposit is greater than a melting point of the substrate.

12 . The method of claim 10 , wherein the first set of deposition parameters is configured to maintain a size of the melt pool at or below a threshold that corresponds to thermal damage of the substrate.

13 . The method of claim 10 , wherein the second set of deposition parameters is configured to maintain a size of the melt pool at or below a threshold that corresponds to melt back of the substrate.

14 . The method of claim 10 , wherein deposition parameters of the third set of deposition parameters that are different from the first and second sets of deposition parameters include at least one of move pause, a power or duty cycle of the energy delivery device, a thickness of the corresponding layer, a size of the melt pool, or a toolpath of the melt pool.

15 . The method of claim 10 , further comprising:

receiving, by the computing device, thermal data from at least one thermal sensor, wherein the thermal data is indicative of a temperature of the melt pool; and

determining, by the computing device, at least the first set of deposition parameters and the second set of thermal conditions based on the thermal data.

16 . The method of claim 10 , wherein a depth of the inner plurality of layers is less than 1 centimeter.

17 . The method of claim 10 ,

wherein the first set of deposition parameters is different from the second set of deposition parameters, and

wherein the first amount of energy is greater than the second amount of energy.

18 . The method of claim 10 , wherein the third amount of energy is greater than 10 percent and less than 50 percent of each of the first amount of energy and the second amount of energy.