A modeling study of stress and strain formation induced during melting process in powder-bed electron beam melting for Ni superalloy

2018 ◽  
Vol 257 ◽  
pp. 163-169 ◽  
Author(s):  
Satoshi Tadano ◽  
Takehisa Hino ◽  
Yuujiro Nakatani
Keyword(s):  
Electron Beam ◽  
Electron Beam Melting ◽  
Melting Process ◽  
Stress And Strain ◽  
Powder Bed ◽  
Modeling Study

scholarly journals The Effect of Post-Processing on the Mechanical Behavior of Ti6Al4V Manufactured by Electron Beam Powder Bed Fusion for General Aviation Primary Structural Applications

Aerospace ◽  
2020 ◽  
Vol 7 (6) ◽  
pp. 75
Author(s):  
Carmine Pirozzi ◽  
Stefania Franchitti ◽  
Rosario Borrelli ◽  
Antonio Chiariello ◽  
Luigi Di Palma
Keyword(s):  
Electron Beam ◽  
Mechanical Behavior ◽  
Electron Beam Melting ◽  
Melting Process ◽  
General Aviation ◽  
Powder Bed Fusion ◽  
Structural Elements ◽  
Post Processing ◽  
Powder Bed ◽  
Structural Applications

In this work a mechanical characterization of Ti6Al4V processed by electron beam powder bed fusion additive manufacturing was carried out to investigate the viability of this technology for the manufacturing of flyable parts for general aviation aircraft. Tests were performed on different manufacturing conditions in order to investigate the effect of post processing as machining on the mechanical behavior. The study provides useful information to airframe designers and manufacturing specialists that work with this technology. The investigation confirms the low process variability and provides data to be used in the design loop of general aviation primary structural elements. The test results show a high level of repeatability indicating that the process is well controlled and reliable enough to match the airworthiness requirements. In addition, the so-called “as-built specimens”, i.e., specimens produced by the electron beam melting machine without any major post-processing, have lower mechanical performances than specimens subjected to a machining phase after the electron beam melting process. Specific primary structural elements will be designed and flight cleared, resulting from the findings presented herein.

scholarly journals In Situ Monitoring of Powder Bed Fusion Homogeneity in Electron Beam Melting

Materials ◽  
2021 ◽  
Vol 14 (22) ◽  
pp. 7015
Author(s):  
Marco Grasso
Keyword(s):  
Electron Beam ◽  
Electron Beam Melting ◽  
Infrared Imaging ◽  
Melting Process ◽  
In Situ Monitoring ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
In Situ Sensing ◽  
In Situ Detection

Increasing attention has been devoted in recent years to in situ sensing and monitoring of the electron beam melting process, ranging from seminal methods based on infrared imaging to novel methods based on backscattered electron detection. However, the range of available in situ monitoring capabilities and solutions is still quite limited compared to the wide number of studies and industrial toolkits in laser-based additive manufacturing processes. Some methods that are already industrially available in laser powder bed fusion systems, such as in situ detection of recoating errors, have not yet been investigated and tested in electron beam melting. Motivated by the attempt to fill this gap, we present a novel in situ monitoring methodology that can be easily implemented in industrial electron beam melting machines. The method is aimed at identifying local inhomogeneity and irregularities in the powder bed by means of layerwise image acquisition and processing, with no external illumination source apart from the light emitted by the hot material underneath the currently recoated layer. The results show that the proposed approach is suitable to detect powder bed anomalies, while also highlighting the link between the severity of in situ detected errors and the severity of resulting defects in the additively manufactured part.

scholarly journals Residual stress investigation on Ti-48Al-2Cr-2Nb samples produced by Electron Beam Melting process

Procedia CIRP ◽  
2021 ◽  
Vol 99 ◽  
pp. 336-341
Author(s):  
Manuela Galati ◽  
Giovanni Rizza ◽  
Alessandro Salmi ◽  
Sara Biamino ◽  
Cristian Ghibaudo ◽  
...  
Keyword(s):  
Residual Stress ◽  
Electron Beam ◽  
Electron Beam Melting ◽  
Melting Process ◽  
Electron Beam Melting Process

Realizing a full volume component by in-situ welding during electron beam melting process

2018 ◽  
Vol 22 ◽  
pp. 375-380 ◽  
Author(s):  
Pan Wang ◽  
Mui Ling Sharon Nai ◽  
Wai Jack Sin ◽  
Shenglu Lu ◽  
Baicheng Zhang ◽  
...  
Keyword(s):  
Electron Beam ◽  
Electron Beam Melting ◽  
Melting Process ◽  
Electron Beam Melting Process ◽  
Full Volume

Developing New Materials for Electron Beam Melting: Experiences and Challenges

2018 ◽  
Vol 941 ◽  
pp. 2190-2195 ◽  
Author(s):  
Andrey Koptyug ◽  
Mikael Bäckström ◽  
Carlos Alberto Botero Vega ◽  
Vladimir Popov ◽  
Ekaterina Chudinova
Keyword(s):  
Electron Beam ◽  
Electron Beam Melting ◽  
Basic Knowledge ◽  
Metallic Materials ◽  
New Materials ◽  
Powder Bed ◽  
New Process ◽  
Machine Manufacturer ◽  
Small Test ◽  
Process Material

Lack of industrially available materials for additive manufacturing (AM) of metallic materials along with the promises of materials with improved or unique properties provides a strong drive for developing new process/material combinations. As powder bed technologies for metallic materials are relatively new to the market, and to some extent are only maturing, developers of new process/material combinations have certain challenges to overcome. Firstly, basic knowledge on the behavior of materials (even those well established for other applications) under extreme conditions of melting/solidification with beam-based AM methods is far from being adequate. Secondly, manufacturing of the equipment is up to date driven by industrial application, thus optimization of the AM machines for small test batches of powders is still belongs to research and development projects. Also, majority of the powder manufacturers are primarily driven by the market development, and even they are well aware of the demands imposed by the powder bed AM machines, availability of small test batches of adequate powders may be problematic or at least quite costly for the R&D oriented users. Present paper describes the experiences in developing new materials for EBM A2 machine by Arcam EBM, modified for operating with powder batches of 100-200 ml and less. In particular it discusses achievements and challenges of working with powders from different materials with specifications far beyond the range suggested by machine manufacturer. Also it discusses the possibility of using blended rather than pre-alloyed powders for achieving both composite-like and alloyed materials in the same part by steering electron beam energy deposition strategy.

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