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Abstract
Electron beam melting (EBM) technology is a novel additive manufacturing (AM) technique, which uses computer controlled electron beams to create fully dense three-dimensional objects from metal powder. It gives the ability to produce any complex parts directly from a computer aided design (CAD) model without tools and dies, and with variety of materials. However, it is reported that EBM has limitations in building overhang structures, due to the poor thermal conductivity for the sintered powder particles under overhang surfaces. In the current study, 2D thermo-mechanical finite element models (FEM) are developed to predict the stresses and deformation associated with fabrication of overhang structures by EBM for Ti-6Al-4V alloy. Different support structure geometries are modeled and evaluated. Finally, the numerical results are validated by experimental work.
Highlights
Introduction and Literature ReviewAdditive manufacturing (AM) is one of the latest approaches used for manufacturing products in advanced applications
2D finite element (FE) models with plane strain formulations showed promising results to predict the effects of different overhang structures on deformation and warping associated with the predict the effects of different overhang structures on deformation and warping associated with the Electron beam melting (EBM) build of Ti-6Al-4V parts
Analysis of showed that deformation and warping associated with the EBM parts were influenced by the choice of experimental results showed that deformation and warping associated with the EBM parts were support structure
Summary
Introduction and Literature ReviewAdditive manufacturing (AM) is one of the latest approaches used for manufacturing products in advanced applications. In AM, parts are fabricated by adding material as layers. Electron beam melting (EBM) is relatively new AM technology; it works under the powder bed fusion process. It was developed in 1997 by Arcam AB Company (Sweden). EBM is used to produce parts for high performance applications within the biomedical, aerospace, and automotive industries. This technology is more effective with complex parts manufactured in low volumes where machining and casting would require too much lead-time and wastage of material
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