Abstract
This paper reports the technology and equipment designed for manufacturing parts and components with predefined properties by 3D printing methods. Underlying the technology is the use of a beam of high-power electrons to smelt metal powder in a vacuum chamber with the formation of successive layers that repeat the contours of the digital model of the article. The object of research is the process of surfacing articles from the Ti6Al4Vtitanium alloy powder. The purpose is to determine the optimal surfacing modes based on identifying the effect of process parameters on the quality indicators of articles. The result of the study is the analyzed influence of technological parameters on the properties of articles. The optimum energy density of the beam of 44.5 J/mm3has been determined. Based on the research results, 25 experimental samples were printed. Three beam speed modes were used: 270, 540, and 780 mm/s. For each mode, the dynamic focusing current varied from −1.2 to 1.27 A in increments of about 0.3 A. The articles were carefully examined. A method of raster electron microscopy was used to study the morphology of the samples' surfaces in several zones, namely in the central zone and along the contour; the roughness parameters of the surface micro relief, as well as the presence of defects (pores, non-melting, micro irregularities, inclusions), were established. It has been found that the articles are characterized mainly by a homogeneous micro relief of the profile. The structure of surfaces, formed in different zones depending on technological modes, differs in its morphology. Surfacing modes have been established that have the practical application: beam speed, 780 mm/s; power, 675 W; dynamic focus current, from –1.2 to 0 A. This provides for the minimal parameters of the surface micro relief and the absence of defects such as shrinkage pores, non-melting, as well as a minimum number of inclusions.
Highlights
Determining the technological parameters of surfacing by additive electron beam technology is a necessary component for making articles with the desired properties [1]
Paper [2] reports the results of studying the influence of modes of electron beam surfacing on the roughness of surfaces of articles made of Ti6Al4V
That gives grounds to assert that it is advisable to investigate the process of electron beam surfacing and determine the optimal technological parameters
Summary
Innovative technologies of layer-by-layer manufacturing of articles by the rapid prototyping method open up new opportunities for fabricating parts of the predefined shape with predicted properties. The process of making articles using this method involving an electronic beam is relatively new but has already shown great prospects for the manufacture of a wide range of industrial and medical articles. Underlying it is the operation of layer-by-layer smelting of metals in a vacuum with an electron beam. Manufacturers of additive equipment supply turnkey technology, that is, technological equipment, the range of materials, and modes of their processing This provides for only some of the possible characteristics of the strength and quality properties of the resulting articles, which does not allow the full introduction of additive technology methods into the industry. It is important to tackle the issue related to fabricating high-quality articles in terms of their defect-free structure in the absence of non-melting, pores, inclusions, etc., including the formation of surfaces with homogeneous relief
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