scholarly journals Evaluation of Support Structure Removability for Additively Manufactured Ti6Al4V Overhangs via Electron Beam Melting

Metals ◽  
2019 ◽  
Vol 9 (11) ◽  
pp. 1211 ◽  
Author(s):  
Wadea Ameen ◽  
Muneer Khan Mohammed ◽  
Abdulrahman Al-Ahmari
Keyword(s):  
Electron Beam ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Electron Beam Melting ◽  
Beam Current ◽  
Design Parameters ◽  
Support Structures ◽  
Support Design ◽  
Removal Time ◽  
Scan Speed

The addition of support structures is essential for the successful fabrication of overhang structures through additive manufacturing (AM). The support structures protect the overhang portion from distortions. They are fabricated with the functional parts and are removed later after the fabrication of the AM part. While structures bearing insufficient support result in defective overhangs, structures with excessive support result in higher material consumption, time and higher post-processing costs. The objective of this study is to investigate the effects of design and process parameters of support structures on support removability during the electron beam melting (EBM)-based additive manufacturing of the Ti6Al4V overhang part. The support design parameters include tooth parameters, no support offset, fragmentation parameters and perforation parameters. The EBM process parameters consist of beam current, beam scan speed and beam focus offset. The results show that both support design and process parameters have a significant effect on support removability. In addition, with the appropriate selection of design and process parameters, it is possible to significantly reduce the support removal time and protect the surface quality of the part.

Investigation of support structure parameters and their affects during additive manufacturing of Ti6Al4V alloy via electron beam melting

2020 ◽  
pp. 146442072098166
Author(s):  
Wadea Ameen ◽  
Muneer Khan Mohammed ◽  
Abdulrahman Al-Ahmari ◽  
Naveed Ahmed ◽  
Syed Hammad Mian
Keyword(s):  
Electron Beam ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Electron Beam Melting ◽  
High Energy ◽  
Ti6al4v Alloy ◽  
High Energy Density ◽  
Support Structures ◽  
Support Structure ◽  
Support Design

Electron beam melting technology offers various benefits like the reduced product cycle time, customization, flexibility, high energy density and less material wastage. However, electron beam melting still suffers from redundant usage of support structure material while fabricating overhang structures. The support structures not only consume additional material, but also require additional time for their design and removal. The optimized support structures have to be designed in such a way that they consume minimum material, are easy to remove and are free from defects. The aim of the current study is to study the effect of support design and process parameters on the performance of the support structures (cost and quality) during additive manufacturing of Ti6Al4V alloy via electron beam melting. The results show that the support structures parameters play a significant role in the cost of the applied support and the accuracy of the fabricated object. It was found that with appropriate selection of support design and process parameters, it is possible to reduce the support volume and hence the fabrication cost in metal additive manufacturing (AM). A tooth height of 3 mm, no support offset of 2 mm, and fragmentation separation width of 0.8 mm resulted in lower support volumes without having any effect on the quality of the overhang. This study systematically investigated the support structure design and their outcomes on overhang fabrication. Its conclusions could add value to the researchers working on additive manufacturing of Ti6Al4V alloy by electron beam melting.

Effect of processing parameters of electron beam melting machine on properties of Ti-6Al-4V parts

2016 ◽  
Vol 22 (3) ◽  
pp. 609-620 ◽  
Author(s):  
Dana H. Abdeen ◽  
Bruce R. Palmer
Keyword(s):  
Surface Roughness ◽  
Electron Beam ◽  
Process Parameters ◽  
Electron Beam Melting ◽  
Processing Parameters ◽  
Beam Current ◽  
Exterior Surface ◽  
Content Type ◽  
Critical Pitting Temperature ◽  
Model Equations

Purpose This paper aims to study the effect of processing parameters of an electron beam melting (EBM) machine on the surface roughness, critical pitting temperature and density of Ti-6Al-4V parts produced from the EBM machine. Design/methodology/approach In this study, statistically designed experiments were used to manufacture Ti-6Al-4V samples in the EBM machine under different process parameters of beam current, beam speed and offset focus. Surface roughness was measured for as-built samples using a 3D profilometer. Then, a potentiostatic test was conducted under 2.40 V vs saturated calomel electrode to determine the critical pitting temperature (CPT) in 3.5 per cent mass NaCl solution for the samples of different processing parameters. Next, density was measured for these samples. Finally, model equations were established to relate EBM’s process parameters to measured properties of surface roughness, CPT and density. Findings Results showed that offset focus had the main influence on surface roughness more than the beam current and the beam speed. Changing processing parameters did not affect corrosion behavior of EBM Ti-6Al-4V as CPT did not vary widely, although a slight effect on CPT values obtained from the beam current and the beam speed. Density was greatly affected by the offset focus more than the other parameters. It can be concluded that uniform and precise measurements of roughness and density are not achievable through this machine; only a range of these properties can be attained. Originality/value EBM machine produces 3D parts in a layer-based building process under high temperature and vacuum atmosphere. Due to the manufacturing technique and conditions, the resulting object has irregularities on the exterior surface and voids that are formed within the part, both of which affect samples’ properties like surface roughness, CPT and density. This study established model equations that can relate parts’ properties to processing parameters so that parts of specific properties are obtained to fit the application they are used for. For each property, ANOVA fits vs linear energy were also obtained.

scholarly journals Multi-Objective Optimization of Support Structures for Metal Additive Manufacturing

2021 ◽  
Author(s):  
Wadea Ameen Qaid ◽  
Abdulrahman Al-Ahmari ◽  
Muneer Khan Mohammed ◽  
Husam Kaid
Keyword(s):  
Additive Manufacturing ◽  
Optimal Solution ◽  
Beam Current ◽  
Support Structures ◽  
Multi Objective Optimization ◽  
Metal Additive Manufacturing ◽  
Multi Objective ◽  
Removal Time ◽  
Tooth Base ◽  
Metal Additive

Abstract Electron-beam melting (EBM) is a rapidly developing metal additive manufacturing (AM) method. It is more effective with complex and customized parts manufactured in low volumes. In contrast to traditional manufacturing it offers reduced lead time and efficient material management. However, this technology has difficulties with regard to the construction of overhang structures. Production of overhangs using EBM without support structures results in distorted objects, and the addition of a support structure increases the material consumption and necessitates post-processing. The objective of this study was to design support structures for metal AM that are easy to remove and consume lower support material without affecting the quality of the part. The design of experiment methodology was incorporated to evaluate the support parameters. The multi-objective optimization minimizing support volume, support removal time along with constrained deformation was performed using multi objective genetic algorithm (MOGA-II). The optimal solution was characterized by a large tooth height (4 mm), large tooth base interval (4 mm), large fragmented separation width (2.5 mm), high beam current (6 mm), and low beam scan speed (1200 mm/s).

scholarly journals Directionally-Dependent Mechanical Properties of Ti6Al4V Manufactured by Electron Beam Melting (EBM) and Selective Laser Melting (SLM)

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3603
Author(s):  
Tim Pasang ◽  
Benny Tavlovich ◽  
Omry Yannay ◽  
Ben Jakson ◽  
Mike Fry ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Tensile Strength ◽  
Electron Beam ◽  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Electron Beam Melting ◽  
Rolling Direction ◽  
Laser Melting ◽  
Plate Rolling

An investigation of mechanical properties of Ti6Al4V produced by additive manufacturing (AM) in the as-printed condition have been conducted and compared with wrought alloys. The AM samples were built by Selective Laser Melting (SLM) and Electron Beam Melting (EBM) in 0°, 45° and 90°—relative to horizontal direction. Similarly, the wrought samples were also cut and tested in the same directions relative to the plate rolling direction. The microstructures of the samples were significantly different on all samples. α′ martensite was observed on the SLM, acicular α on EBM and combination of both on the wrought alloy. EBM samples had higher surface roughness (Ra) compared with both SLM and wrought alloy. SLM samples were comparatively harder than wrought alloy and EBM. Tensile strength of the wrought alloy was higher in all directions except for 45°, where SLM samples showed higher strength than both EBM and wrought alloy on that direction. The ductility of the wrought alloy was consistently higher than both SLM and EBM indicated by clear necking feature on the wrought alloy samples. Dimples were observed on all fracture surfaces.

Microgeometry of the surface of electron beam additive manufacturing products. Selective electron beam melting

2021 ◽  
pp. 408-418
Author(s):  
E.V. Krasnova ◽  
Yu.A. Morgunov ◽  
B.P. Saushkin
Keyword(s):  
Electron Beam ◽  
Additive Manufacturing ◽  
Physical Model ◽  
Electron Beam Melting ◽  
Metallurgical Process ◽  
Additive Technology ◽  
Selective Electron Beam Melting ◽  
Surface Microgeometry ◽  
Microstructure Of The Material

The results of the analysis of works related to the formation of surface microgeometry in the process of selective electron-beam melting are presented, and the physical model of this process is refined. The developing additive technology of selective electron-beam alloying and the directions in which its research is carried out, in particular, the analysis of the metallurgical process, the formation of the microstructure of the material, the formation of microstructure defects, are described. The roughness of the surface of products obtained by the SEBM technology, as well as the microgeometry of surfaces and the mechanisms of its formation, depending on various parameters of the process, are considered.

scholarly journals The Corrosion Studies of Electron Beam Welded Nickel Alloy

2019 ◽  
Vol 253 ◽  
pp. 03005 ◽  
Author(s):  
M. Sroka ◽  
E. Jonda ◽  
M. Węglowski ◽  
S. Błacha
Keyword(s):  
Electron Beam ◽  
Process Parameters ◽  
Microstructural Analysis ◽  
Solidification Process ◽  
Beam Current ◽  
Surface Oxide Layer ◽  
Electron Beam Current ◽  
Corrosion Properties ◽  
Inconel 617 ◽  
Potentiodynamic Anodic Polarization

The paper presents the influence of electron - beam (EB) remelting effect on the surface layer electrochemical parameters obtained from potentiodynamic anodic polarization studies and impedance spectroscopy measurements for a set of Inconel 617 electron beam remelted obtained for different process parameters. The correlation between EBW process parameters and characteristic of surface oxide layer properties and resistance to the acidic environment were discussed. The electrochemical studies were supported by microstructural analysis of the remelted zone (RZ), heat affected zone (HAZ), native metal and observed precipitates formed under rapid solidification process. Both electrochemical technics applied to evaluate corrosion properties of remelted Inconel 617 evidenced a strong influence of the electron beam current on the corrosion resistance.

Ti6Al4V Parts Produced by Electron Beam Melting: Analysis of Dimensional Accuracy and Surface Roughness

2020 ◽  
Vol 19 (01) ◽  
pp. 107-130 ◽  
Author(s):  
R. Borrelli ◽  
S. Franchitti ◽  
C. Pirozzi ◽  
L. Carrino ◽  
L. Nele ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electron Beam ◽  
Additive Manufacturing ◽  
Electron Beam Melting ◽  
Complex Shape ◽  
Electron Beam Welding ◽  
Raw Materials ◽  
Dimensional Accuracy ◽  
High Energy ◽  
Quality Certification

Additive manufacturing (AM), applied to metal industry, is a family of processes that allows complex shape components to be realized from raw materials in the form of powders. Electron beam melting (EBM) is a relatively new additive manufacturing (AM) technology. Similar to electron-beam welding, EBM utilizes a high-energy electron beam as a moving heat source to melt metal powder, and 3D parts are produced in a layer-building fashion by rapid self-cooling. By EBM, it is possible to realize metallic complex shape components, e.g. fine network structures, internal cavities and channels, which are difficult to make by conventional manufacturing means. This feature is of particular interest in titanium industry in which numerous efforts are done to develop near net shape processes. In the field of mechanical engineering and, in particular, in the aerospace industry, it is crucial for quality certification purpose that components are produced through qualified and robust manufacturing processes ensuring high product repeatability. The contribution of the present work is to experimentally identify the EBM job parameters (sample orientation, location of the sample in the layer and height in the build chamber) that influence the dimensional accuracy and the surface roughness of the manufactured parts in Ti6Al4V. The repeatability of EBM is investigated too.

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