Electron Beam Melting Research Articles

Powder bed fusion with electron beam: The interplay of sintering, porosity, and coordination number in modelling the powder thermal conductivity through a novel tortuosity formulation

For the powder bed fusion with electron beam (PBF-EB) additive manufacturing, properties such as the thermal conductivity of the material surrounding the melting area are critical. Thermal conductivity is influenced by the extremely high temperature reached in a short time and distributed in the building area. This fast temperature growth produces sintering phenomena and the creation of a neck between the particles. Because of this sintering, measuring the thermal conductivity at the process conditions is challenging.This paper proposes an analytical formulation for estimating the effective powder bed thermal conductivity at the PBF-EB conditions, introducing a novel modelling strategy for the tortuosity factor. In a changing net of sintered powder particles, the proposed model for the tortuosity factor considers the neck evolution and the complexity of the heat transfer due to the several heat paths possible through the particle net. To show the effectiveness of the proposed model, the thermal conductivity is evaluated for three 3D structures characterised by an increasing number of powder particles and heat path complexity: a simple cubic, a body centred cubic and a portion of a powder bed. It is shown that thermal conductivity strongly depends on the arrangement of the particles in 3D space, the structure density and the complexity of the heat diffusion path (tortuosity). Also, the numerical results from the proposed model show good agreement when compared with finite element analysis and experimental literature data.

Investigation of Effects of Spreading Parameters on Powder Bed Quality in Additive Manufacturing

Powder bed-based additive manufacturing processes such as laser powder bed fusion, binder jetting, and electron beam melting are commonly utilized in various critical areas such as medical, aviation, and energy. Common to all these operations, the powders are first spread onto the built platform in a layer-by-layer fashion and selectively fused or bound with a suitable method. The quality of the process depends on several process parameters, including how the powders are spread onto the built platform. Powder spreading is an important step in these operations and can affect various process outputs. In this study, the powder spreading is numerically investigated using the discrete element method to determine the effects of the layer thickness, rotation, and transition velocities selected as parameters with a powder spreader roller. The relationship between powder spreading parameters and powder volume packing fraction was investigated using the 'Hertz-Mindlin and Johnson-Kendall-Robert’s (JKR) contact model considering the interactions between particle-particle and particle-built plate, has been added to the numerical model. A Design of Experiment combined with analysis of variance (ANOVA) was utilized to gain a broader understanding on the relationship between process parameters and green density and dynamic angle of repose.

Determination of Cast-Metal Structures and Welded Joints After Electron-Beam Welding of the Intermetallic Titanium Alloys Ti−28Al−7Nb−2Mo−2Cr Obtained by Electron-Beam Melting Method

Determination of Cast-Metal Structures and Welded Joints After Electron-Beam Welding of the Intermetallic Titanium Alloys Ti−28Al−7Nb−2Mo−2Cr Obtained by Electron-Beam Melting Method

Investigations of particle-process-part quality relationships in electron beam melting

Electron beam melting is a powder bed fusion process capable of manufacturing parts from a variety of high-temperature alloys. Given that the process relies on feedstock recycling for process economics, understanding process-part quality relationships is critical. This work investigates process-part quality relationships in terms of the internal and external defects and component microstructure relative to a feedstock subjected to 33 build cycles without replacement. To accomplish this, a volume of fluid mesoscale model consisting of three different powder distributions were considered: (1) Monomodal; (2) As-measured; and (3) Irregular. Particle morphology was characterized using shape factors examined via optical microscopy. To approximate the particle shapes in three-dimensions, a method is presented that utilizes a binarized domain to define low frequency, macroscale particle “base” shapes implicitly and is thus not restricted to starlike particles. The discrete element method was also used to investigate velocity distributions and packing densities of the as-measured and irregular particles with respect to deviations in the nominal layer thickness of 50 μm. In general, beam power and scan speed were found to have an appreciable effect on microstructure formation and surface roughness. Finally, correlations were found between specific classifications of irregular particles and lack of fusion defect formation.Graphical abstractOverview of the discrete element method simulation domain for the electron beam melting powder bed fusion process

Progress in Additive Manufacturing of Magnesium Alloys: A Review.

Magnesium alloys, renowned for their lightweight yet high-strength characteristics, with exceptional mechanical properties, are highly coveted for numerous applications. The emergence of magnesium alloy additive manufacturing (Mg AM) has further propelled their popularity, offering advantages such as unparalleled precision, swift production rates, enhanced design freedom, and optimized material utilization. This technology holds immense potential in fabricating intricate geometries, complex internal structures, and performance-tailored microstructures, enabling groundbreaking applications. In this paper, we delve into the core processes and pivotal influencing factors of the current techniques employed in Mg AM, including selective laser melting (SLM), electron beam melting (EBM), wire arc additive manufacturing (WAAM), binder jetting (BJ), friction stir additive manufacturing (FSAM), and indirect additive manufacturing (I-AM). Laser powder bed fusion (LPBF) excels in precision but is limited by a low deposition rate and chamber size; WAAM offers cost-effectiveness, high efficiency, and scalability for large components; BJ enables precise material deposition for customized parts with environmental benefits; FSAM achieves fine grain sizes, low defect rates, and potential for precision products; and I-AM boasts a high build rate and industrial adaptability but is less studied recently. This paper attempts to explore the possibilities and challenges for future research in AM. Among them, two issues are how to mix different AM applications and how to use the integration of Internet technologies, machine learning, and process modeling with AM, which are innovative breakthroughs in AM.

The Challenges and Advances in Recycling/Re-Using Powder for Metal 3D Printing: A Comprehensive Review

This review explores the critical role of powder quality in metal 3D printing and the importance of effective powder recycling strategies. It covers various metal 3D printing technologies, in particular Selective Laser Melting, Electron Beam Melting, Direct Energy Deposition, and Binder Jetting, and analyzes the impact of powder characteristics on the final part properties. This review highlights key challenges associated with powder recycling, including maintaining consistent particle size and shape, managing contamination, and mitigating degradation effects from repeated use, such as wear, fragmentation, and oxidation. Furthermore, it explores various recycling techniques, such as sieving, blending, plasma spheroidization, and powder conditioning, emphasizing their role in restoring powder quality and enabling reuse.

Advances in Nickel-Containing High-Entropy Alloys: From Fundamentals to Additive Manufacturing.

High-entropy alloys (HEAs) are recognized as a class of advanced materials with outstanding mechanical properties and corrosion resistance. Among these, nickel-based HEAs stand out for their impressive strength, ductility, and oxidation resistance. This review delves into the latest advancements in nickel-containing HEAs, covering their fundamental principles, alloy design strategies, and additive manufacturing techniques. We start by introducing HEAs and their unique properties, emphasizing the crucial role of nickel. This review examines the complex relationships between alloy composition, valence electron concentration (VEC), and the resulting crystal structures. This provides insights into design principles for achieving desired microstructures and mechanical properties. Additive manufacturing (AM) techniques like selective laser melting (SLM), electron beam melting (EBM), and laser metal deposition (LMD) are highlighted as powerful methods for fabricating intricate HEA components. The review addresses the challenges of AM processes, such as porosity, fusion defects, and anisotropic mechanical properties, and discusses strategies to mitigate these issues through process optimization and improved powder quality. The mechanical behavior of AM-processed nickel-based HEAs is thoroughly analyzed, focusing on compressive strength, hardness, and ductility. This review underscores the importance of microstructural features, including grain size, phase composition, and deformation mechanisms, in determining the mechanical performance of these alloys. Additionally, the influence of post-processing techniques, such as heat treatment and hot isostatic pressing (HIP) on enhancing mechanical properties is explored. This review also examines the oxidation behavior of nickel-containing HEAs, particularly the formation of protective oxide scales and their dependence on aluminum content. The interplay between composition, VEC, and oxidation resistance is discussed, offering valuable insights for designing corrosion resistant HEAs. Finally, this review outlines the potential applications of nickel-based HEAs in industries such as aerospace, automotive, and energy, and identifies future research directions to address challenges and fully realize the potential of these advanced materials.

The Optimization of the Synthesis of Antibacterial Coatings on Ti6Al4V Coupons Obtained by Electron Beam Melting

Prosthetic joint infection represents a problem that worsens the patient’s quality of life and produces an economic impact on health systems. We report the anodization of Ti6Al4V coupons obtained by electron beam melting to produce a nanostructured surface. Anodization at 10 V produced TiO2 nanopores with a diameter in the range of 15–20 nm. Thereafter, Ag nanoparticles (AgNPs) were deposited in three different ways to provide antibacterial functionality to the coatings: electrochemically, thermally, and chemically. The electrochemical method did not provide good coverage of AgNPs. At 0.1 V of synthesis potential, cubic, octahedral, and truncated octahedral Ag crystals were obtained. The thermal method provided a good distribution of AgNPs but it damaged the TiO2 nanostructure. The chemical method showed the best distribution of AgNPs over the anodized surface and preserved the anodized nanostructure. For this reason, the chemical method was selected to perform further studies. Ag+ release was monitored in simulated body fluid at 37 °C, reaching 1.86 mg Ag+/L after 42 days. The antibacterial coating showed excellent antibacterial activity and inhibited biofilm formation for Staphylococcus epidermidis RP62A and Staphylococcus aureus V329 strains (lethality > 99.9% for both bacteria and assays).

Investigation of the Mechanical Strength of Artificial Metallic Mandibles with Lattice Structure for Mandibular Reconstruction.

Mandibular reconstructive surgery is necessary for large bone defects. Although various reconstruction methods have been performed clinically, there is no mandibular reconstruction method that meets both sufficient strength criteria and the patient's specific morphology. In this study, the material strength of the cylindrical lattice structures formed by electron-beam melting additive manufacturing using titanium alloy powder was investigated for mandibular reconstruction. The virtual strengths of 28 lattice structures were compared using numerical material tests with finite element method software. Subsequently, to compare the material properties of the selected structures from the preliminary tests, compression test, static bending test and fatigue test were conducted. The results showed that there were correlations with relative density and significant differences among the various structures when comparing internal stress with deformation, although there was a possibility of localized stress concentration and non-uniform stress distribution based on the lattice structure characteristics. These results suggest that the lattice structure of body diagonals with nodes and a cell size of 3.0 mm is a potential candidate for metallic artificial mandibles in mandibular reconstruction surgery.

Selective electron beam additive manufacturing of a nanoparticle-strengthened medium-entropy alloy for cryogenic applications

A strong, ductile medium-entropy alloy, MEA, (CoCrNi)94Al3Ti3 with few defects was fabricated using the selective electron beam additive manufacturing technique. Due to preheating the substrate at 1173 K, the as-printed MEA showed coherent L12 nanoparticles (dia.∼112 nm, volume fractioñ8.9 %) in 68 μm grains with a dual {100}<011> + {100}<001> texture. The as-built alloy exhibited a yield strength (YS) of 612 MPa, an ultimate tensile strength (UTS) of 1020 MPa, and an elongation to failure (ε) of 37 % at 298K. These values increased when testing was at 77 K, i.e. YS of 811 MPa, UTS of 1339 MPa, and an ε of 39 %. After tensile failure, the LAGBs and GND densities sharply increased at both temperatures to accommodate strain gradient along with <111> fiber texture. The lack of annealing twin boundaries led to a relatively low strain hardening rate (SHR) of 2500 MPa at 298 K and 3890 MPa at 77 K (at 5 % strain) as compared to values of thermo-mechanically processed (CoCrNi)94Al3Ti3. The SHR curves exhibited three distinct stages, where an abrupt upturn at an intermediate strain level can be attributed to the occurrence of DTs and SFs at 77 K, and the appearance of SFs at 298 K.

Measuring and predicting the thermal properties of powder beds for electron beam additive manufacturing

Measuring and predicting the thermal properties of powder beds for electron beam additive manufacturing

Electron Beam Impact on Microstructure and Microhardness of Ti–6Al–4V Titanium Alloy Produced by Wire Electron-Beam Additive Manufacturing Technology and Selective Laser Alloying at Simulation of Electronic-Beam Welding

Electron Beam Impact on Microstructure and Microhardness of Ti–6Al–4V Titanium Alloy Produced by Wire Electron-Beam Additive Manufacturing Technology and Selective Laser Alloying at Simulation of Electronic-Beam Welding

Recent Trends and Technologies in rapid prototyping and its Inclination towards Industry 4.0

Prototyping technology is becoming vital in the business as a means of cutting costs and manufacturing time. At present, reverse engineering and rapid prototyping are important technologies that enhance prototype development. The traditional approaches require various intricate processes, such as selective heat sintering (SHS), digital-light-processing printer (DLP), remote distributed rapid prototyping model (RDRP), Stereo Lithography (STL) models, and reconstructing computer-aided design (CAD) models from scanned point data and these approaches has limitations in terms of time-consuming and expert knowledge required for automation. This study aims to explore the significance of Industry 4.0 and its impact on rapid prototyping. The study also addresses rapid prototyping in computer network architecture; digital-light-processing printers (DLP) in rapid prototyping, and software-defined network (SDN) networks in the context of rapid prototyping. Along with this powder bed fusion (PBF) method and electron beam melting (EBM) are included in the manuscript. Based on our exploration, the study suggested vital recommendations for the advancement in rapid prototyping using Industry 4.0

Effect of Heat Treatment and Hot Isostatic Pressing on the Corrosion Behavior of Ti6Al4 V Parts Produced by Electron Beam Melting Additive Manufacturing Technology.

In this study, we investigated the effect of heat treatment (HT) and hot isostatic press (HIP) on the corrosion behavior of Ti6Al4 V, manufactured by electron beam melting (EBM) additive manufacturing. The preliminary results showed that the thermal process makes the columnar structure more pronounced and the α-lathe coarser compared to EBM. The β phase disappeared with the aging treatment and when increasing the HIP temperature treatment. According the open circuit potential (E ocp) behavior of samples, the HIP3 sample had performed more positive corrosion potential than rivals after 2 h of immersion probably due to equiaxed grain with coarser α-late and the absence of the β phase. In adverse, inferior corrosion behavior was observed for HIP1 because of a higher quantity of the β phase causing probably galvanic corrosion. The HIP process leads to a lower corrosion potential than EBM. At least one protective oxide layer formation was observed for all samples at the anodic branch, and the current density was lower for the HT3 sample. The microstructure analysis revealed the presence of the β-phase in the form of needle-like for the HT1 sample and HIP1 in the corroded area. Furthermore, the EDS line analysis showed the presence of aluminum with oxygen at the edge of the corrosion area for HIP1 suggesting aluminum plays a barrier against degradation. On the other hand, the HT1 showed higher impedance resistance due to the coarser α-lathe microstructure and well-defined β phase.

Determining technological parameters for obtaining ta15 titanium alloy blanks with improved mechanical characteristics using the electron-beam 3D printing method

The object of this study is the process of electron beam 3D printing of articles made of TA15 titanium alloy powder. Peculiarities of the structure and properties formation of alloy blanks, obtained by this method have been described. Influence of process parameters (electron beam power and geometric scanning parameters) on the characteristics of the material were considered. Step of displacement of the beam trajectory changed from 0.1 to 0.25 mm with an interval of 0.05 mm. Specific energy of the electron beam varied from 20 to 70 J/mm3 for every trajectory displacement step. The macrostructure was examined visually while the microstructure was studied by optical microscopy. Mechanical properties were determined by uniaxial tension and impact bending tests. It was established that depending on the 3D printing parameters the macrostructure of most samples is dense but with unfavorable parameters non-fusions or shrinkage porosity defects may form. The microstructure of the dendritic type has an α´+β lamellar-acicular morphology, its dispersity and shape of α´–phase areas vary depending on the process parameters. A scanning step of 0.2 mm and a beam energy of 40 J/mm3 allows obtaining a dispersed microstructure in which there are no non-fusions and shrinkage micropores. The value of the Rm is 27 %, and the R0.2 is 24 % higher than that of the alloy obtained by the conventional technology of electron beam melting. The A5 is 3.2 times higher. However, impact toughness of the sample with dendrite unfavorable orientation to the direction of load applying may be lower compared to conventional technology. The results could be used for devising commercial technology of high strength titanium alloys parts produced by 3D printing

Assessing the factors underlying the high yield strength of laser powder bed fusion processed niobium

The present study focuses on the factors underlying the substantially higher yield strength (YS) and ultimate tensile strength (UTS) in laser powder bed fusion (LPBF) processed niobium, as compared to electron beam additive manufacturing (EBAM) or conventionally processed Nb. LPBF builds of pure Nb, with a relative density of 98 %, exhibited an YS of 490 MPa, UTS of 609 MPa, and ductility of 9 % with appreciable strain hardenability. Detailed electron backscatter diffraction analysis revealed a high density of sub-boundaries within the BCC Nb grains. Additionally, the LPBF Nb sample contained ∼1200 ppm of oxygen and ∼380 ppm of nitrogen, part of which segregated to the grain boundaries, as revealed by atom probe tomography (APT). The individual strengthening contributions from grain boundaries, dislocations, and oxygen and nitrogen interstitials have been quantitatively estimated, giving an overall computed YS of 506 MPa, in close agreement with the experimentally measured value of 490 MPa. This quantitative assessment also revealed that solid solution strengthening from oxygen and nitrogen can be of the same order of magnitude as strengthening from dislocations and sub-boundaries in LPBF processed Nb.

Understanding the fatigue behaviour of Ti–6Al–4V manufactured via various additive processes

Additive Manufacturing (AM) is receiving widespread attention from both industry and academia who are looking to benefit from the numerous advantageous possibilities that AM processes have to offer, such as the potential to design and produce highly complex bespoke geometries with minimal material wastage. Yet, despite this, AM also has some drawbacks. Some of the most significant include the presence of process-induced defects and the inherent surface roughness of an AM built component, both of which can have a considerable influence on the mechanical properties of the final product. This research will investigate the role of an as-built surface on the fatigue properties of AM Ti–6Al–4V manufactured by electron beam melting (EBM), laser powder bed fusion (L-PBF) and laser metal deposition with wire (LMD-w). Fatigue results have been generated alongside advanced surface profilometry, microstructural, defect and fractographic analyses that have revealed that whilst the surface roughness in the majority of instances is the primary factor impacting the fatigue performance on AM material, it cannot be considered alone. It was found that the inherent as-built (AB) surface finish was significantly different across the various AM processes, inducing a range of effective stress concentrations and thus, a contrasting impact on the resulting fatigue performance. Results from each variant have been compared against a machined and polished equivalent, to provide a further consideration as to whether the as-built surface would be suffice from a time and economical viewpoint. Statistical analysis of the generated results also allowed for an extrapolation of predicted fatigue lives in the very high cycle regime for the alternative AM Ti–6Al–4V variants.

Pathways to exploit the multi-spot scanning strategy in electron beam additive manufacturing for control of microstructure and defect density

The goal of this study is to investigate the impact of beam deflection pattern characteristics on microstructure and porosity formation during Powder Bed Fusion Electron Beam Melting (PBF-EB/M) processing of Inconel 718. Specifically, the complex interplay between “beam return time” and “beam jump distance” and their influence on heat accumulation, porosity, and grain formation is explored. The findings reveal that beam jump distance plays a critical role in the transition from columnar to equiaxed solidification, while beam return time is essential for achieving optimal heat accumulation and minimizing porosity. By controlling these two universal beam deflection pattern characteristics, a novel multi-spot scanning strategy was developed, enabling the formation of a fine-grained equiaxed microstructure. It is demonstrated that sufficient heat accumulation is essential for a pore-free bulk material and can be achieved by short beam return times or small beam jump distances. However, for equiaxed grain formation, a large beam jump distance, i.e., a wide distribution of melt pools, is required. Therefore, heat accumulation must be controlled by means of the beam return time if equiaxed grains are aimed for. Additionally, it is found that higher beam currents are beneficial for equiaxed grain formation, but the strongest impact on the columnar to equiaxed transition is attributed to the beam movement pattern itself. This approach offers insights into microstructure control and process reliability, regardless of the specific PBF technique employed, and enables application-specific microstructure design of Inconel 718.

Effect of surface topography on the fatigue behavior of additively manufactured Ti6Al4V and CoCr alloys

Powder bed fusion (PBF), including selective laser melting and electron beam melting, fabricates complex, porous, osseointegrative implants for widespread clinical use. Fatigue testing is imperative for predicting long-term strength and durability of rough and surface porous implants while bone remodels around and grows into the implant. This study analyzes different materials (Ti6Al4V and Co28Cr6Mo) with varying topographies including as-printed surface roughness and the addition of a surface porous layer common to implants. The results are compared to wrought and PBF controls that are polished and machined. Moreover, different PBF techniques for titanium result in different as-printed surface roughness (∼0.07–17 μm) and microstructure. The fatigue data demonstrates that the surface finish impact was stronger in Ti6Al4V versus CoCr and SLM Ti6Al4V HIP + surface porous gyroid samples didn't perform worse than the roughest solid sample without surface porosity (EBM Ti6Al4V). With the same mechanical surface finishes, the SLM and wrought Ti6Al4V samples display similar fatigue resistance (800 and 850 MPa respectively), while EBM samples remain inferior (350 MPa). This study provides a foundation to compare fatigue resistance across materials and surface topographies through different fabrication techniques to optimize the lifespan of orthopedic implants while incorporating rough as printed surfaces and added surface porosity, both of which are essential for osseointegration.

The Effects of Hot Isostatic Pressing (HIP) and Heat Treatment on the Microstructure and Mechanical Behavior of Electron Beam-Melted (EBM) Ti-6Al-4V Alloy and Its Susceptibility to Hydrogen.

The effects of the secondary processes of Hot Isostatic Pressing (HIP) at 920 °C and Heat Treatment (HT) at 1000 °C of Electron Beam-Melted (EBM) Ti-6Al-4V alloy on the microstructure and hydrogen embrittlement (HE) after electrochemical hydrogen charging (EC) were investigated. Comprehensive characterization, including microstructural analysis, X-ray diffraction (XRD), thermal desorption analysis, and mechanical testing, was conducted. After HIP, the β-phase morphology changed from discontinuous Widmanstätten to a more continuous structure, 10 times and ~1.5 times larger in length and width, respectively. Following HT, the β-phase morphology changed to a continuous "web-like" structure, ~4.5 times larger in width. Despite similar mechanical behavior in their non-hydrogenated state, the post-treated alloys exhibit increased susceptibility to HE due to enhanced hydrogen penetration into the bulk. It is shown that hydrogen content in the samples' bulk is inversely dependent on surface hydride content. It is therefore concluded that the formed hydride surface layer is crucial for inhibiting further hydrogen penetration and adsorption into the bulk and thus for reducing HE susceptibility. The lack of a hydride surface layer in the samples subject to HIP and HT highlights the importance of choosing secondary treatment process parameters that will not increase the continuous β-phase morphology of EBM Ti-6Al-4V alloys in applications that involve electrochemical hydrogen environments.