Electron Beam Melting Research Articles

Numerical analysis and process optimization of electron beam melting for superalloys

This study aims to determine the optimal parameters for the electron beam melting process by employing a modified transient three-dimensional thermal model. The validity of the thermal model is confirmed through experimental results. Moreover, the proposed method establishes mathematical relationships between the resulting molten pool temperature and process parameters. A broader range of process parameters for a new Ni–Co-based superalloy was achieved by investigating the effects of scanning velocities (10–100 mm/s), scanning radius (20–60 mm), and melting mass (1500–3100 g) on temperature at various electron beam power levels (10–30 kW). Regression models were established between scanning velocities-temperature, and scanning radius-temperature under different electron beam power levels. These models laid the foundation for real-time automatic control of molten pool temperature. Significantly, orthogonal experimental design and response surface method are employed to conduct a multi-objective optimization based on sixteen experiments and three parameters. The results of multi-objective optimization indicate that with a smelting mass of 1.5 kg, an electron beam power of 11 kW, a scanning radius of 60 mm, and a scanning velocity of 75 mm/s, the energy consumption is 34.95 kW h, and the theoretical mass loss of Ni element is 0.002 kg. The desirability is 91.2 %.

Electrochemical processing of parts from Ti—6Al—4V alloy by additive manufacturing

The process of alignment of the initial microgeometry of samples obtained by the method of selective electron beam melting (EBM) by electrochemical etching in aqueous solutions of NaCl under current density 20, 30 and 40 A/cm2 was studied. The possibility of reducing the parameters Ra and Rz from the values of 35 and 180 µm, respectively, to the values of 7.2 and 33 µm during the electrolysis time of 40 s under galvanostatic conditions with the removal of the allowance of 210 µm is shown. Keywords:selective electron beam melting, surface roughness, high speed electrochemical dissolution katusha0112@yandex.ru, morgunov56@mail.ru, sbp47@mail.ru, iliaslusar42@yandex.ru, smsergei1@yandex.ru

Research on the microstructure and properties of antimicrobial stainless steel coatings on Q345R alloy steel by electron beam surface coating

In this study, 304 antimicrobial stainless steel coatings were prepared by the electron beam melting of antimicrobial stainless steel powder, in an attempt to enhance the surface properties of Q345R steel. Besides, the effect of Cu-containing 304 powder coatings on the microstructure, mechanical properties, and electrochemical properties of the Q345R surface was investigated. The results indicated that the coating grain was refined, the dislocation density was increased, and both the plasticity and toughness were enhanced after the electron beam surface coating (EBSC) treatment. Additionally, the hardness of coatings was also enhanced under the three beam currents due to grain refinement and dislocation strengthening. At a beam current of 28 mA, the coating hardness reached a maximum of 384.078 HV, representing a two-fold increase compared with the base material (BM) hardness of 131.048 HV. Moreover, the abrasion resistance of the coating was superior to that of the BM. At a beam current of 28 mA, the wear volume and wear rate were minimized to only 10 % of the wear volume of substrates. In galvanic corrosion measurements, the coatings displayed better corrosion resistance than the substrates, and these samples at a beam current of 28 mA exhibited the best corrosion resistance. Overall, the E-beam surface melting 304 stainless steel coating can effectively improve the properties of Q345R carbon steel.

Mechanical and Electrochemical Properties Comparison of Additively Manufactured Ti-6Al-4V Alloys by Electron Beam Melting and Selective Laser Melting

This work involves additively manufactured Ti-6Al-4V alloys, which are widely used in automobile, biomedical, and aircraft components for a comparison of the microstructure–properties relationship between electron beam melted (EBM) and selective laser melted (SLM) alloys after hot isostatic pressing treatment. We carried out microstructural, mechanical, and electrochemical measurements on both alloys. They showed comparable α and β phase contents with slightly higher lattice parameters in the EBM sample compared to the SLM. The EBM sample showed higher yield strength and uniform elongation due to the activation of multistage defects-driven strengthening and strain hardening mechanisms. Cracking during the tensile test nucleated mainly at the α phase near high-mechanical mismatch α/β interfaces. This mechanism was consistent with the reported generation of hetero-deformation-induced strengthening and strain hardening. Both alloys showed similar electrochemical behavior, but the SLM sample was more susceptible to corrosion than the EBM alloy.

Progress and Challenges of Additive Manufacturing of Tungsten and Alloys as Plasma-Facing Materials.

Tungsten (W) and W alloys are considered as primary candidates for plasma-facing components (PFCs) that must perform in severe environments in terms of temperature, neutron fluxes, plasma effects, and irradiation bombardment. These materials are notoriously difficult to produce using additive manufacturing (AM) methods due to issues inherent to these techniques. The progress on applying AM techniques to W-based PFC applications is reviewed and the technical issues in selected manufacturing methods are discussed in this review. Specifically, we focus on the recent development and applications of laser powder bed fusion (LPBF), electron beam melting (EBM), and direct energy deposition (DED) in W materials due to their abilities to preserve the properties of W as potential PFCs. Additionally, the existing literature on irradiation effects on W and W alloys is surveyed, with possible solutions to those issues therein addressed. Finally, the gaps in possible future research on additively manufactured W are identified and outlined.

Additive Manufacturing of Electrically Conductive Multi-Layered Nanocopper in an Air Environment.

The additive manufacturing (AM) of functional copper (Cu) parts is a major goal for many industries, from aerospace to automotive to electronics, because Cu has a high thermal and electrical conductivity as well as being ~10× cheaper than silver. Previous studies on AM of Cu have concentrated mainly on high-energy manufacturing processes such as Laser Powder Bed Fusion, Electron Beam Melting, and Binder Jetting. These processes all require high-temperature heat treatment in an oxygen-free environment. This paper shows an AM route to multi-layered microparts from novel nanoparticle (NP) Cu feedstocks, performed in an air environment, employing a low-power (<10 W) laser sintering process. Cu NP ink was deposited using two mechanisms, inkjet printing, and bar coating, followed by low-power laser exposure to induce particle consolidation. Initial parts were manufactured to a height of approximately 100 µm, which was achieved by multi-layer printing of 15 (bar-coated) to 300 (inkjetted) layers. There was no evidence of oxidised copper in the sintered material, but they were found to be low-density, porous structures. Nonetheless, electrical resistivity of ~28 × 10-8 Ω m was achieved. Overall, the aim of this study is to offer foundational knowledge for upscaling the process to additively manufacture Cu 3D parts of significant size via sequential nanometal ink deposition and low-power laser processing.

Surface characteristics of additively manufactured γ-TiAl intermetallic alloys post-processed by electrochemical machining

Electron beam melting (EBM) process is the most preferable powder bed fusion process for high melting point alloys. γ-TiAl alloys are intermetallic chemical compounds, which are lightweight and resistant to oxidation and heat, and have low ductility as well. EBM is the best manufacturing process for such alloys to produce aerospace parts, but poor surface quality is the main drawback of this process. Thus, surface post-processing is needed after the EBM process. This study presents the surface characteristics of EBM γ-TiAl alloy surfaces post-processed by electrochemical machining (ECM). The surfaces were ECM and the surface roughness values (Sa, Sq and Sz) have been reduced significantly. The mean reduction values of the experiments are 98.6 %, 98.5 % and 95.3 % for Sa, Sq and Sz, respectively. Additionally, it is observed that the surface roughness is inversely proportional to the electrolyte conductivity up to a limit value (115 mS/cm), and after that the roughness increases via the stray current transition. Sq values decrease with the increased feed rate via the increased current density. However, an increase in feed rate negatively affects the Sku values, which statistically describe the sharpness or spread of surface roughness. Also, XRD results showed that Ti2AlN layer is formed on the surface via the HIP operation. This layer inhibits the electrochemical dissolution of γ-TiAl alloy and caused surface defects.

Additive Manufacturing: A Comprehensive Review.

Additive manufacturing has revolutionized manufacturing across a spectrum of industries by enabling the production of complex geometries with unparalleled customization and reduced waste. Beginning as a rapid prototyping tool, additive manufacturing has matured into a comprehensive manufacturing solution, embracing a wide range of materials, such as polymers, metals, ceramics, and composites. This paper delves into the workflow of additive manufacturing, encompassing design, modeling, slicing, printing, and post-processing. Various additive manufacturing technologies are explored, including material extrusion, VAT polymerization, material jetting, binder jetting, selective laser sintering, selective laser melting, direct metal laser sintering, electron beam melting, multi-jet fusion, direct energy deposition, carbon fiber reinforced, laminated object manufacturing, and more, discussing their principles, advantages, disadvantages, material compatibilities, applications, and developing trends. Additionally, the future of additive manufacturing is projected, highlighting potential advancements in 3D bioprinting, 3D food printing, large-scale 3D printing, 4D printing, and AI-based additive manufacturing. This comprehensive survey aims to underscore the transformative impact of additive manufacturing on global manufacturing, emphasizing ongoing challenges and the promising horizon of innovations that could further elevate its role in the manufacturing revolution.

Evaluation of layer-by-layer assembly systems for drug delivery and antimicrobial properties in orthopaedic application

Layer-by-layer self-assembly systems were developed using monolayer and multilayer carriers to prevent infections and improve bone regeneration of porous Ti-6Al-4V scaffolds. These polymeric carriers incorporated (Gel/Alg-IGF-1 + Chi-Cef) and (4Gel/Alg-IGF-1 + Chi-Cef) on the surface of porous implants produced via electron beam melting (EBM). The results showed that the drug release from multilayer carriers was higher than that of monolayers after 14 days. However, the carrier containing Gel/Alg-IGF-1 + Chi-Cef exhibited more sustained behavior. Cell morphology was characterized, revealing that multilayer carriers had higher cell adhesion than monolayers. Additionally, cell differentiation was significantly greater for (Gel/Alg-IGF-1) + Chi-Cef, and (4Gel/Alg-IGF-1) + Chi-Cef multilayer carriers than for the monolayer groups after 7 days. Notably, the drug dosage was effective and did not interfere, and the cell viability assay showed safe results. Antibacterial evaluations demonstrated that both multilayer carriers had a greater effect on Staphylococcus aureus during treatment. The carriers containing lower alginate had notably less effect than the other studied carriers. This study aimed to test systems for controlling drug release, which will be applied to improve MG63 cell behavior and prevent bacterial accumulation during orthopaedic applications.

Wire-based electron beam additive manufacturing of NiTiNb shape memory alloy: Microstructure, phase-transformation behavior and mechanical properties

NiTiNb shape memory alloy (SMA) is considered to have great potential in aerospace due to its wide phase-transformation hysteresis. Here, we innovatively used electron-beam additive manufacturing (EBAM) to fabricate a NiTiNb SMA thin-walled structure. The phase-transformation temperature, microstructure evolution, and mechanical properties were investigated in detail. The as-built NiTiNb SMA comprised a NiTi matrix and different morphologies of β-Nb phase at room temperature. The microstructure homogeneity and mechanical properties of NiTiNb prepared by EBAM significantly improved compared with those of NiTiNb powder-based AM technology. Our work provided a promising method for the preparation of defect-free and microstructure homogeneous NiTiNb SMA by AM. This method further stimulated the potential of additively manufactured SMA components for industrial applications.

Microstructure Evolution Through Cryogenic Rolling of Ultra-High Purity Titanium Produced by Electron Beam Melting

In this study, crystal grain refinement of pure titanium manufactured by electron beam melting through cryogenic rolling was performed. The effect of rolling in a cryogenic atmosphere on average grain size was investigated. Cryogenic atmosphere rolling was confirmed to be smaller than normal temperature rolling. Electron back scatter diffraction (EBSD) confirmed the presence of oriented crystal grains in the material. The deformation, temperature, and stress generated during rolling were calculated using 3D simulation. Finite element analysis (FEM) modeling was used to analyze the trend of average grain size change during the heat treatment of the rolled samples.

Production of Experimental Samples of Nickel-Based Alloy and Copper Nozzles by Electron Beam Additive Manufacturing

Production of Experimental Samples of Nickel-Based Alloy and Copper Nozzles by Electron Beam Additive Manufacturing

Effect of Heat Treatment on the Structure and Properties of Titanium Aluminide Alloy Ti–Al–V–Nb–Cr–Gd Produced by Selective Electron Beam Melting

Effect of Heat Treatment on the Structure and Properties of Titanium Aluminide Alloy Ti–Al–V–Nb–Cr–Gd Produced by Selective Electron Beam Melting

A Prediction Model of Evaporation Behavior of Nickel-Based Superalloy in Electron Beam Melting

The electron beam melting technique has emerged as a novel refining technology extensively employed for alloy purification due to its advantages of effectively eliminating volatile impurities and non-metallic inclusions. However, a drawback associated with the melting process is the evaporation of alloy elements, which results in an uncontrollable alloy composition. In this paper, Wagner model is used to calculate and study the evaporation behavior. of nickel-based superalloy, and the database of infinite dilution activity coefficient and interaction coefficient of nickelbased superalloy has been established. The results show that the model can well predict the composition of electron beam melting superalloy, establish the relationship between electron beam melting power and temperature, and predict the composition of several groups of DZ125 alloys after melting with different power, which is in consistent with the experimental results. This model is of guiding significance for electron beam melting of nickel-based superalloy.

Functionalized chitosan hydrogel promotes osseointegration at the interface of3D printed titanium alloy scaffolds

Autogenous bone transplantation is a prevalent clinical method for addressing bone defects. However, the limited availability of donor bone and the morbidity associated with bone harvesting have propelled the search for suitable bone substitutes. Bio-inspired scaffolds, particularly those fabricated using electron beam melting (EBM) deposition technology, have emerged as a significant advancement in this field. These 3D-printed titanium alloy scaffolds are celebrated for their outstanding biocompatibility and favorable elastic modulus. Thermosensitive chitosan hydrogel, which transitions from liquid to solid at body temperature, serves as a popular carrier in bone tissue engineering. Icariin (ICA), known for its efficacy in promoting osteoblast differentiation from bone marrow mesenchymal stem cells (BMSCs), plays a crucial role in this context. We developed a system combining a 3D-printed titanium alloy with a thermosensitive chitosan hydrogel, capable of local bone regeneration and integration through ICA delivery. Our in vitro findings reveal that this system can gradually release ICA, demonstrating excellent biocompatibility while fostering BMSC proliferation and osteogenic differentiation. Immunohistochemistry and Micro-CT analyses further confirm the effectiveness of the system in accelerating in vivo bone regeneration and enhancing osseointegration. This composite system lays a significant theoretical foundation for advancing local bone regeneration and integration.

Creep behavior and creep-oxidation interaction of selective electron beam melted Ti–48Al–2Cr–2Nb alloy at different temperatures

In this work, creep behavior and creep-oxidation interaction behavior of Ti–48Al–2Cr–2Nb alloy fabricated by selective electron beam melting at different temperatures were investigated in detail. This alloy exhibits a near-γ microstructure composed of coarse/fine mixed equiaxed grains. Creep test results show that creep behavior of this alloy is sensitive to temperature. This is mainly manifested in that creep life reduces significantly by 84.8 % as temperature increases from 800 °C to 850 °C. During creep, discontinuous dynamic recrystallization characterized by grain nucleation and growth and continuous dynamic recrystallization characterized by strain gradient and orientation accumulation occur simultaneously. The formation of mechanical twins plays an important role in stimulating dynamic recrystallization. Meanwhile, creep deformation and fracture mechanisms of this alloy at different temperatures were also discussed. On the other hand, oxidation test results reveal that the applied tensile stress has a positive effect on the oxidation behavior of this alloy: the growth of TiO2 oxide is inhibited and the oxidation rate is slowed down. However, under creep-oxidation interaction, the intergranular cracking of the oxide film occurs along with the necking of the alloy matrix during creep.

Hot isostatic pressing as an alternative thermo-mechanical treatment for metallic full-arch implant-supported frameworks obtained by additive and subtractive manufacturing technology: Vertical and horizontal fit, screw removal torque, and stress analysis.

To assess vertical and horizontal fit, screw removal torque, and stress analysis (considered biomechanical aspects) of full-arch implant frameworks manufactured in Ti-6Al-4V through milling, and additive manufacturing Direct Metal Laser Sintering (DMLS) and Electron Beam Melting (EBM), and the effect of the thermo-mechanical treatment Hot Isostatic Pressing (HIP) as a post-treatment after manufacturing. Maxillary full-arch implant frameworks were made by milling, DMLS, and EBM. The biomechanical assessments were screw removal torque, strain-gauge analyses, and vertical and horizontal marginal fits. The vertical fit was assessed by the single-screw test and with all screws tightened. All frameworks were submitted to a standardized HIP cycle (920°C, 1000bar pressure, 2h), and the tests were repeated (α = 0.05). At the initial time, milled frameworks presented higher screw removal torque values, and DMLS and EBM frameworks presented lower levels of strain. Using the single-screw test, milled and DMLS frameworks presented higher vertical fit values, and with all screws tightened and horizontally, higher fit values were found for milled frameworks, followed by DMLS and EBM. After HIP, milling and EBM frameworks presented higher screw removal torque values; the lowest strain values were found for EBM. Using the single-screw test, milled and DMLS frameworks presented higher vertical fit values, and with all screws tightened and horizontally no differences were found. DMLS and EBM full-arch frameworks presented adequate values of screw removal torque, strain, and marginal fit, although the worst values of marginal fit were found for EBM frameworks. The HIP cycle enhanced the screw removal torque of milled and EBM frameworks and reduced the strain values of milled frameworks. The HIP represents a reliable post-treatment for Ti-6Al-4V dental prostheses produced by milling and EBM technologies.

Microstructure and mechanical properties of Cu-Cr-Zr alloy prepared by electron beam additive manufacturing and laser-MIG hybrid welding

Cu-Cr-Zr alloys are widely used as medium-strength and high-conductivity copper alloys in aerospace, transportation and electronic information fields. The application of additive manufacturing technology is expected to realize the preparation of Cu-Cr-Zr alloy parts with complex structure and superior property. However, the commonly used laser additive manufacturing technology is not applicable to the preparation of copper alloys due to its intrinsic high reflection to laser. In this study, we adopted two technologies, i.e., electron beam additive manufacturing (EBAM) and laser-metal inert gas hybrid welding (laser-MIG), for the preparation of Cu-Cr-Zr alloys. Finite element simulation was employed to simulate the temperature field and residual stress field of the material during solidification. The microstructure, relative density, microhardness, tensile properties and electrical conductivity of the as-fabricated samples were characterized. The results showed that samples with better moldability were obtained by both methods at a line energy density of 600 J/mm. In the top area, both methods exhibit medium-sized equiaxed grains with more precipitated phases, showing the best comprehensive properties. The EBAM method demonstrates superior formability, better relative density and electrical conductivity due to more stable temperature field changes. On the other hand, the laser-MIG method obtains finer grains and higher mechanical properties because of a faster cooling rate, but leads to a decrease in relative density and electrical conductivity. This study presents new experimental data for Cu-Cr-Zr alloys prepared by EBAM and laser-MIG methods, contributing to extend the application of additive manufacturing in the preparation of Cu alloys.

Machining of a functional hip prosthesis cone in TI-6AL-4V ELI titanium alloy produced by electron beam melting

Digital manufacturing using 3D models and innovative fabrication methods present challenges for functional areas of medical devices. The advantages arising from 3D manufacturing processes like electron beam melting (EBM) play a major role in producing medical devices as, for example, orthopaedic implants. However, surfaces with functional demands for surface roughness and dimensional accuracy require machining operations to achieve the necessary standards. This study aimed to manufacture a functional cone of the modular component of the hip prosthesis through turning and to assess if an EBM-obtained component could offer better machinability as compared to wrought titanium and ensure functionality. To achieve this, the variances in cutting forces and surface roughness of the resulting surface were analysed during the turning tests. The results show that the EBM test samples had higher roughness (Ra) values, yet it was possible to achieve Ra = 0.4 μm for f = 0.1 mm/rev. and approximately 20% lower resulting cutting forces, for example, for f = 0.1 mm/rev, 122N compared to 101N. Using the Kienzle-Victor model, the specific cutting force of titanium EBM was determined to be 1775 N/mm2. The impact of the shell geometry of the EBM test samples had no significant effect on the results. This allows for the exploration of its potential in component design, as it provides an economic advantage in manufacturing. In conclusion, the cutting forces and surface roughness showed similar or superior machinability compared to that of wrought titanium. The EBM technology enables the production of intricate forms and facilitates finishing operations in functional zones.

Powder characterisation and the impact on part performance in electron beam melted Ti6Al4V

Metallic powder for Additive Manufacturing (AM) typically varies between different batches, while being supplied to achieve the same customer specification. In order to reduce this variation and minimise waste, batches are often mixed together in both their virgin and used form. However, the properties of bulk components must have limited variance in order to be reliably used in an industrial setting. This manuscript is focused on the analysis of Grade 5 Ti6Al4V powders (3 virgin, plus 2 blends) and the associated mechanical properties of Electron Beam Melted (EBM) AM specimens. Measurements were performed in accordance with the principles defined in the MMPDS Handbook, ESDU database, and ASTM F2924. The tensile, and fatigue properties of the EBM specimens were found to be superior when compared with Ti6Al4V properties within these standards. This demonstrated that these powders are suitable for a wide range of commercial applications, and that these blended powders (including used powders) are able to achieve these requirements. Additionally, the results provide a systematic route for powder verification and highlight the importance of adhering to standardised principles and specifications to ensure quality and reliability in metallic AM materials.