Properties and microstructure of elements made by electron beam rapid prototyping process with wire

Marek Stanisław Węglowski,Łukasz Rogal,Jan Pilarczyk,Jan Dutkiewicz,Sylwester Błacha,Robert Jachym

doi:10.26628/wtr.v90i9.950

Abstract

In the paper the results of research on rapid prototyping using electron beam and deposit-ed material in the form of wire are presented. Electron beam rapid prototyping with wire is an efficient method for manufacturing complex shapes from metal alloys such as alloy steels, nickel alloys or titanium. This technology is used primarily in the aviation industry, especially in the military as it is designed rather for a unit production or small series production. As part of the work, technological conditions of the process for which it is possible to deposit test pieces in the form of rectangular prism were determined. Test elements were made using a stainless steel wire grade G 18 8 Mn. Metallographic examinations and selected mechanical properties were investigated. The deposited material is characterized by austenitic with ferrite delta, cell-dendritic microstructure. There are large dendritic grains which are extended towards the heat dissipation – towards the substrate. The hardness in the deposited material is in the range of 192 to 273 HV0.05 depending on the number of layers. In the area of mixing with the substrate, the hardness reaches the value of 355 HV0.05.

Highlights

Rapid prototyping using electron beam (EBAM – Electron Beam Additive Manufacturing) and deposited material in the form of wire is a modern technology that allows the creation of an element with a given geometry from metal alloys
The purpose of this work was to determine the technological parameters of the process of rapid prototyping with an electron beam using wire as deposited material, enabling the performance of test pieces
The following conclusions can be drawn on the basis of the research: – the process of rapid prototyping using a beam of electrons with deposited material in the form of wire enables the fabrication of test elements with strictly defined technological parameters; – deposited material is characterized by cell-dendritic microstructure

Summary

Introduction

Rapid prototyping using electron beam (EBAM – Electron Beam Additive Manufacturing) and deposited material in the form of wire is a modern technology that allows the creation of an element with a given geometry from metal alloys. The depositing process is usually carried out in a vacuum [1], there are devices enabling the manufacture of elements at atmospheric pressure [2]. The technology has its limitations, such as: a narrower assortment of deposited alloys, difficulties in the production of elements with a complex shape, higher minimum thickness of the manufactured element, limitations in the production of gradient materials. In the case of manufacturing thin-walled elements, it is important to control the deformations, which in the case of the use of additional material in the form of wire are greater [8]

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