Interstitial control during additive manufacturing

A non-transitory machine-readable storage device comprising instructions, which when executed by a one or more processors, cause a system to perform operations to operate an additive manufacturing system, the operations comprising operations to fabricate a target end product in an additive manufacturing process including operations to:

• access, via a communication network, one or more databases having thermodynamic data associated with composition of the target end product and thermodynamic data of candidates to react with a gaseous species in an environment in which the target end product is fabricated;
• determine a sacrificial element, from among the candidates, to react with and remove the gaseous species away from molten material formed in the additive manufacturing process to fabricate the target end product;
• execute a finite element model of a thermal process incorporating a Langmuir equation, using the thermodynamic data associated with the composition of the target end product and the sacrificial element;
• generate results from execution of the finite element model in which the results specify composition of starting materials for an additive manufacturing build, the starting materials including the sacrificial element with the sacrificial element to combine with the gaseous species in the processing environment to prevent the gaseous species from entering into the molten material such that one or more components of the gaseous species are included in the target end product at a level below a threshold for acceptable levels of the one or more components of the gaseous species in the target end product;
• and
• transmit the results to control instruments associated with preforming the additive manufacturing process to fabricate the target end product.

A method comprising:

• introducing a first wire of an alloy for processing into a processing chamber at a first feed rate, the processing chamber having a processing environment;
• introducing a second wire into the processing chamber at a second feed rate, the second wire including sacrificial material for modification of the alloy by an additive manufacturing process;
• monitoring temperature of a molten state formed by the additive manufacturing processing of the first wire and/or or monitoring a location within a simulation corresponding to position of the wires being processed within an additive manufacturing build in the processing chamber;
• and
• adjusting, based on data from the monitoring, the first feed rate and/or the second feed rate using on output from a model tied to a Langmuir equation and thermodynamic data of the sacrificial material and a target composition of the additive manufacturing build, the model including the composition of the sacrificial material during the additive manufacturing build to produce a target composition with the sacrificial material combining with one or more elements in the processing environment to prevent the one or more elements from entering into the molten state such that the one or more elements are included in the target composition at a level below one or more thresholds for acceptable levels of the one or more elements in the target composition.

A non-transitory machine-readable storage device comprising instructions, which when executed by a one or more processors, cause a system to perform operations, the operations comprising operations to:

• introduce a first wire of an alloy for processing into a processing chamber at a first feed rate, the processing chamber having a processing environment;
• introduce a second wire into the processing chamber at a second feed rate, the second wire including sacrificial material for modification of the alloy by an additive manufacturing process;
• monitor temperature of a molten state formed by the additive manufacturing processing of the first wire and/or or monitor a location of a stored simulation corresponding to position of the wires being processed within an additive manufacturing build in the processing chamber;
• and
• adjust, based on data from the monitoring, the first feed rate and/or the second feed rate by use of output from a model tied to a Langmuir equation and thermodynamic data of the sacrificial material and a target composition of the additive manufacturing build, the model including the composition of the sacrificial material during the additive manufacturing build to produce a target composition with the sacrificial material combining with one or more elements in the processing environment to prevent the one or more elements from entering into the molten state such that the one or more elements are included in the target composition at a level below one or more thresholds for acceptable levels of the one or more elements in the target composition.