Electron Beam Powder Bed Fusion Research Articles

Corrosion fatigue behavior of nanoparticle modified iron processed by electron powder bed fusion

Due to its excellent biocompatibility, pure iron is a very promising implant material, but often features corrosion rates that are too low. Using additive manufacturing and modified powders the microstructure and, thus, the material properties, e.g., the corrosion properties, can be tailored for specific applications. Within the scope of this study, pure iron powder was modified with different amounts of CeO2 or Fe2O3 nanoparticles and subsequently processed by Electron Beam Powder Bed Fusion (PBF-EB/M). The corrosion-fatigue behavior of CeO2 and Fe2O3 modified iron was investigated using rotation bending tests under the influence of simulated body fluid (m-SBF). While the modification using Fe2O3 showed reduced fatigue and corrosion-fatigue strengths, it could be demonstrated that the modification with CeO2 is characterized by improved fatigue properties. The superior fatigue properties in air are attributed to the positive impact of dispersion strengthening. Additionally, an increased degradation rate compared to pure iron could be observed, eventually promoting an earlier failure of the specimens in the corrosion fatigue tests.

In situ build surface topography determination in electron beam powder bed fusion

AbstractElectron optical imaging is the most promising process monitoring method in electron beam powder bed fusion. State of the art in modern machines is the installation of a single detector in the top center of the build chamber. Exemplary applications are the reconstruction of digital twins of manufactured parts to compare their dimensional accuracy or analysing the top surface of each layer to identify surface features like pores or material transport. Multi-detector systems are currently under research and have shown great potential in reconstructing the surface topography in situ. A recently developed ray tracing model, describing the image formation process, allows to formulate design guide lines for multi-detector systems and provides a method for the computation of the normal vector field of the build surface. This work utilizes the recent progress and presents a newly developed four-detector system and an updated computation chain, which enable build surface topography reconstruction in situ in every layer of a build process. The computation chain contains a normal integration algorithm, which employs Tikhonov regularization to cope with measurement irregularities. The integration method is validated with ex situ measured as-built surfaces. Additionally, first applications are demonstrated and connections to process parameter changes illustrated.

Extracting powder bed features via electron optical images during electron beam powder bed fusion

Electron beam powder bed fusion offers the unique opportunity to observe the process by measuring scattered electrons on a metal detector. This technique is the state of the art in generating electron optical images of the build area after melting using single- or multi-detector setups. The images enable the detection of surface defects like porosity or material transport by reconstructing the surface topography. Internal defects such as layer-bonding defects cannot be identified. Many of these defects, particularly layer-bonding defects, often originate from an irregular distribution of the powder bed.This work introduces an additional process step by recording an electron optical image after the distribution of the powder bed. Combining this with an electron optical image after melting the previous layer enables extraction of powder bed features such as the current powder bed height. The underlying method bases on the correlation of experimental measurements and numerical simulations of the intensity of the electron optical signal for different powder bed heights. With this approach, it is possible to identify irregular powder distributions, such as uncovered areas of previously molten material or locally varying powder bed heights. This information is crucial for online monitoring and real time process control. Exemplary, this opens the opportunity of healing the powder bed by an additional raking step.

Vapor chemical composition in electron beam powder bed fusion using Ti–6Al–4V powder

Vapor chemical composition in electron beam powder bed fusion using Ti–6Al–4V powder

Electron beam powder bed fusion additive manufacturing of Ti6Al4V alloy lattice structures: orientation-dependent compressive strength and fracture behavior

High porosity level lattice structures made using electron beam powder bed fusion additive manufacturing (EBPBF) need to be sufficiently strong and the understanding of the mechanical anisotropy of the structures is important for the design of orthopedic implants. In this work, the combined effects of loading direction (LD), cell orientation, and strut irregularity associated with EBPBF of Ti6Al4V alloy lattices on the mechanical behavior of the lattices under compressive loading have been studied. Three groups of simple cubic unit cell lattices were EBPBF made, compressively tested, and examined. The three groups were [001]//LD lattices, [011]//LD lattices, and [111]//LD lattices. Simulation has also been conducted. Yield strength (σy-L) values of all lattices determined experimentally have been found to be comparable to the values predicted by simulation; thus, EBPBF surface defects do not affect σy-L. σy-L of [001]//LD lattices is 1.8–2.0 times higher than those of [011]//LD and [111]//LD lattices. The reason for this is shown to be due to the high stress concentrations in non-[001]//LD samples, causing yielding at low loading levels. Furthermore, plastic strain (εp) at ultimate compression strength of [001]//LD samples has been determined to be 4–6 times higher than the values of non-[001]//LD samples. Examining the tested samples has shown cracks more readily propagating from EBPBF micro-notches in non-[001]//LD samples, resulting in low εp.

Additive Manufacturing of TiC/Steel Composites Using Electron Beam Melting and In Situ Infiltration

Cemented carbides containing titanium carbide (TiC), characterized by low specific weight, superior hardness, and excellent high‐temperature resistance, are widely used as wear‐resistant cutting tools and brake discs. Instead of using conventional powder metallurgical approaches, composites comprising TiC and stainless steel are fabricated in this study by means of an innovative method combining electron beam powder bed fusion (PBF‐EB) and in situ liquid metal infiltration. For PBF‐EB, a pure TiC powder as feedstock and a stainless steel plate as substrate are used, respectively. Owing to the high processing temperature in the hatching area, the TiC particles are inhomogeneously sintered. Simultaneously, an in situ infiltration of liquid steel into the pores between TiC particles takes place during PBF‐EB, forming a dense and crack‐free composite material containing ≈68% TiC. The electrical properties of the raw TiC powder are investigated at different temperatures to optimize the process parameters ensuring high process stability during PBF‐EB. The microstructure and mechanical properties (compression strength, hardness, and fracture toughness) of the PBF‐EB‐produced TiC/steel composite are analyzed.

Melting ceramic Al2O3 powder by electron beam powder bed fusion

AbstractElectron beam powder bed fusion (PBF-EB) is a known metal additive manufacturing (AM) technology. Processing non-conducting powders such as ceramics has so far been considered as not feasible because of the inherent problems with Coulomb repulsion due to insufficient electrical conductivity. In this study, a method for functionalizing ceramic powder is proposed where particles are electroless coated by a ~ 1 µm Ni layer to decrease the surface resistivity. The feasibility of the suggested approach is tested on Al2O3 powder, and the results show that the coated ceramic powder has a decreased surface resistivity, which enables processing by PBF-EB. Heating and melting parameters were investigated and samples were manufactured at ~ 1600 °C. Sintered and melted powders were analyzed by microscopy and micromechanically tested by nanoindentation. Calculations, visual observation and SEM–EDX suggest that the Ni coating is evaporated during the process, which suggests that the process could be feasible for the manufacturing of pure ceramic parts.

A Systematic Approach to Optimize Parameters in Manufacturing Complex Lattice Structures of NiTi Using Electron Beam Powder Bed Fusion Process

Herein, the quality and accuracy to manufacture delicate parts from NiTi powder using electron beam powder bed fusion (EB‐PBF) technology is investigated. Therefore, benchmarks with thin cylinders and thin walls are designed and fabricated using two distinct scan strategies of EB‐PBF manufacturing (i.e., continuous melting and spot melting) with different process parameter sets. After these optimizations, four different lattice structures (i.e., octahedron, cell gyroid, sheet gyroid, and channel) are manufactured and characterized. It is shown both continuous melting and spot melting modes are able to manufacture lattices with relative densities over 97%. And as‐built lattice structures exhibit an excellent pseudoelasticity up to 8% depending on the design of the structure, e.g., the channel structure shows more deformation recoverability than the cell gyroid. This is attributed to the integrity of geometry as well as compressive mode of the mechanical loading. Of course, the compressive strength and ultimate compressive strength also increase with the increasing volume fraction. Moreover, the spot melting can be used as an engineering tool to customize a delicate beam‐shaped structure with a superior pseudoelasticity.

Machine learning-enabled real-time anomaly detection for electron beam powder bed fusion additive manufacturing

AbstractDespite the many advantages and increasing adoption of Electron Beam Powder Bed Fusion (PBF-EB) additive manufacturing by industry, current PBF-EB systems remain largely unstable and prone to unpredictable anomalous behaviours. Additionally, although featuring in-situ process monitoring, PBF-EB systems show limited capabilities in terms of timely identification of process failures, which may result into considerable wastage of production time and materials. These aspects are commonly recognized as barriers for the industrial breakthrough of PBF-EB technologies. On top of these considerations, in our research we aim at introducing real-time anomaly detection capabilities into the PBF-EB process. To do so, we build our case-study on top of a Arcam EBM A2X system, one of the most diffused PBF-EB machines in industry, and make access to the most relevant variables made available by this machine during the layering process. Thus, seeking a proficient interpretation of such data, we introduce a deep learning autoencoder-based anomaly detection framework. We demonstrate that this framework is able not only to early identify anomalous patterns from such data in real-time during the process with a F1 score around 90%, but also to anticipate the failure of the current job by 6 h, on average, and in one case by almost 20 h. This avoids waste of production time and opens the way to a more controllable PBF-EB process.

Comparison of in-plane compression of additively manufactured Ti6Al4V 2D auxetic structures: Lattice design, manufacturing speed, and failure mode

The metal-based 2D auxetic lattice structures hold the potential for multifunctional tasks in aerospace applications. However, the compression response of those manufactured by powder bed fusion process is underexplored. This study proposes a comprehensive comparison of in-plane quasi-static compression performance of 2D auxetic lattice structures, utilizing three designs (anti-tetrachiral (ATC), double arrow-headed (DAH), and tree-like re-entrant (TLR)), manufactured with stiff Ti6Al4V by the electron beam powder bed fusion process (PBF-EB) with various manufacturing speeds. The results revealed unique failure patterns and superior energy absorptions among 2D lattice structures in the literature. TLR design enhanced energy absorption by overcoming failures between DAH columns and exhibited the lowest standard deviations in specific energy absorption (SEA) values (9.75 %–12.62 %). Besides, Kernel average misorientation (KAM) values followed the order of DAH, TLR, and ATC, and inversely correlated with SEA values. ATC structures with the lowest KAM outperformed DAH and TLR by 47.5 % and 6.44 %, respectively. Scan speed variations affected SEA and porosity values differently for each lattice design while exhibiting similar microstructure characteristics. The findings in this study propose a significant contribution to the development of aerospace sandwich structures where harsh environments exist and employment of 2D topologies are required.

On the fatigue behavior of a tool steel manufactured by powder bed based additive manufacturing—a comparison between electron- and laserbeam processed AISI H13

AbstractIn recent years, additive manufacturing (AM) techniques have gained increased attention. The most common AM technologies to realize complex parts are powder bed-based fusion processes, especially electron beam powder bed fusion of metals (PBF-EB/M) and laser-based powder bed fusion of metals (PBF-LB/M). Focusing on industrial applications, cyclic loading scenarios and fatigue properties of components produced by such techniques came into focus of research. The present work deals with a comparison between microstructure, hardness, density and fatigue properties of a high-alloy tool steel AISI H13 (1.2344, X40CrMoV5-1) manufactured by PBF-EB/M and PBF-LB/M. The investigated specimens are characterized by a complex phase composition containing ferrite, perlite, bainite and martensite, eventually resulting in different hardness values depending on the used AM technology. Fatigue data for PBF-EB/M AISI H13 are reported for the first time in open literature. It is shown that the fatigue behavior is significantly influenced by the specimen density. Accordingly, parts with a high density are characterized by superior fatigue strength.

A review of the current state-of-the-art on in situ monitoring in electron beam powder bed fusion

AbstractThe industrial development of electron beam powder bed fusion (PBF-EB) is relatively younger and much more limited in terms of global widespread and revenues compared to laser powder bed fusion (PBF-L). Nevertheless, PBF-EB has been adopted in some of the most successful industrial case studies of metal AM, as it provides specific benefits and capabilities that make it a key enabling technology in a variety of industrial applications. Moreover, the recent years have seen a rapid evolution with new actors and new systems entering the market, together with a considerable increase of research and innovation programs. A field of major interest is the development and continuous improvement of in situ sensing and monitoring methods to anticipate the detection of defects, to predict the final quality of the part, and to rethink product qualification procedures. The technological features of the PBF-EB process have motivated the development of solutions that differ from the ones in PBF-L. Some of them have reached a good maturity level, being recently integrated into industrial machines, while others still deserve further research. This study explores the current state-of-the-art on in situ and in-line monitoring of the PBF-EB process, aiming to provide an up-to-date overview of the major differences with respect to PBF-L, currently available methods and their performances, as well as open issues, challenges to be tackled, and perspective for future research and industrial developments.

A CALPHAD-Informed Enthalpy Method for Multicomponent Alloy Systems with Phase Transitions

Solid–liquid phase transitions of metals and alloys play an important role in many technical processes. Therefore, corresponding numerical process simulations need adequate models. The enthalpy method is the current state-of-the-art approach for this task. However, this method has some limitations regarding multicomponent alloys as it does not consider the enthalpy of mixing, for example. In this work, we present a novel CALPHAD-informed version of the enthalpy method that removes these drawbacks. In addition, special attention is given to the handling of polymorphic as well as solid–liquid phase transitions. Efficient and robust algorithms for the conversion between enthalpy and temperature were developed. We demonstrate the capabilities of the presented method using two different implementations: a lattice Boltzmann and a finite difference solver. We proof the correct behaviour of the developed method by different validation scenarios. Finally, the model is applied to electron beam powder bed fusion—a modern additive manufacturing process for metals and alloys that allows for different powder mixtures to be alloyed in situ to produce complex engineering parts. We reveal that the enthalpy of mixing has a significant effect on the temperature and lifetime of the melt pool and thus on the part properties.

Preprocessing method for robust topography reconstruction of surfaces of metal additive manufactured parts based on focus variation microscopy

Abstract When using an areal measuring optical instrument to measure rough surfaces, especially surfaces generated by metal additive manufacturing (e.g. laser and electron beam powder bed fusion), topographical artifacts such as spikes on a reconstructed surface are nearly unavoidable. These artifacts may affect the determination of surface roughness parameters and lead to erroneous surface features. This paper proposes a new preprocessing method to eliminate most artifacts before extracting surface heights of rough surfaces measured by focus variation microscopy. In this method, the axial region where a surface height value is located with the highest probability is estimated, based on datasets of planes parallel to the axial scanning direction. Results regarding height measurements with and without the preprocessing method are compared by measuring a Rubert Microsurf 329 comparator test panel for reference and workpieces produced by metal additive manufacturing.

D retention in e-beam powder-bed fused (3-D printed) tungsten exposed to high-flux deuterium plasma in Pisces-RF

Tungsten targets produced by the additive manufacturing (AM) method of electron-beam powder-bed fusion, or 3-D metal printing, are exposed to high flux D plasma in the Pisces-RF linear plasma device with the plasma-exposed surface normal to the AM build direction. D retention was measured by thermal desorption mass spectrometry following exposure to D plasma with an associated ∼50eV D+ ion flux. D+ fluence, and operational temperature, in the ranges 5×1024–5×1026 m−2 and 400–1000 K, are explored. D retention values for the AM W are compared to identically plasma exposed ’conventional’ sintered W and it is found that total D retention is similar. However, the D thermal release is notably different. Desorption from the AM W shows reduced D retention in traps typical of sintered W, and moderately increased trapping in defect types of higher trap release energy. The dependence of D retention on fluence is also different for the AM W, revealing an uptake slower than expected from Fickian diffusion, while that for sintered W is consistent and in agreement with previous poly-crystalline W results from Pisces-B. Hydrogen transport modeling of the fluence dependence suggests that interconnected pathways for D release back to the surface during plasma-exposure can account for the slower D uptake in the AM W.

Feasibility of Melting NbC Using Electron Beam Powder Bed Fusion

High melting point materials such as ceramics and metal carbides are in general difficult to manufacture due to their physical properties, which imposes the need for new manufacturing methods where electron beam powder bed fusion (EB‐PBF) seems promising. Most materials that have been successfully printed with EB‐PBF are metals and metal alloys with good electrical conductivity, whereas dielectric materials such as ceramics are generally difficult to print. Catastrophic problems such as smoking and spattering can occur during the EB‐PBF processing owing to inappropriate physical properties such as lack of electrical, and thermal conductivity and high melting point, which are challenging to overcome by process optimization. Due to these difficulties, a limited level of understanding has been achieved regarding melting ceramics and refractory alloys. Herein, three different substrates of niobium carbide (NbC) are melted using EB‐PBF. The established process parameter window shows a good correlation between EB‐PBF process parameters, surface, and melt characteristics, which can be used as a baseline for a printing process. Melting NbC is proven feasible using EB‐PBF; the work also points out challenges related to arc trips and spattering, as well as future investigations necessary to create a stable printing process.

A new variant of the inherent strain method for the prediction of distortion in powder bed fusion additive manufacturing processes

A new variant of the inherent strain (IS) method is proposed to predict component distortion in powder bed fusion additive manufacturing (AM) that addresses some of the shortcomings of the previous work by accounting for both the compressive plastic strain formed adjacent to the melt pool and the thermal strain associated with the changing macroscale thermal field in the component during fabrication. A 3D thermomechanical finite element (FE) model using the new approach is presented and applied to predict the distortion of a component fabricated in an electron beam powder bed fusion (EB-PBF) machine. To improve computational efficiency, each computational layer is comprised of six powder layers. A time-averaged volumetric heat input based on beam voltage and current data obtained from the EB-PBF system was calculated and applied to each computational layer, consistent with the process timing. The inherent strains were applied per computational layer as an initial anisotropic contribution to the thermal strain at the time of activation of each computational layer, resulting in the sequential establishment of static equilibrium during component fabrication, which accounts for the variation in the local macroscale thermal field. The thermal field and distortion predicted by the thermomechanical model were verified using experimentally derived data. The model predicts in-plane compressive strains in the order of 10−3. Differences in the inherent strain were found at different locations in the component, consistent with differences in the macroscale thermal field. The proposed method is general and may also be applied to the laser powder bed fusion (L-PBF) process.

The impact of Ti6Al4V powder reuse on the quality of electron beam powder bed fusion parts

The impact of Ti6Al4V powder reuse on the quality of electron beam powder bed fusion parts

A multiscale framework for the evaluation of thermal conductivity of sintered powder at the powder bed fusion with electron beam conditions

AbstractThe thermal conductivity of the powder bed during the electron beam powder bed fusion (PBF-EB) process strongly influences the process conduction and the quality of the components produced. The evaluation of this property is challenging. The models currently available in the literature cannot provide values of the thermal conductivity that consider the temperature evolution typical of the preheating step. This work presents a novel computational framework to evaluate the thermal conductivity of a powder bed for the PBF-EB process. The framework combines the thermal conditions of the PBF-EB process with information on the geometrical features of the powder bed and an analytic method to calculate the thermal conductivity and its variation with temperature and time. The proposed numerical framework is applied to the body centred structure (BCC), a typical arrangement that can emulate the PBF-EB conditions. The numerical framework is multiscale by nature, providing information about the whole powder bed starting from geometrical information about the neck among the powder particles.

Mechanical and microstructural characterization of Ti6Al4V lattice structures with and without solid shell manufactured via electron beam powder bed fusion

The topological optimization of components by means of lattice structures allows to reduce their weight avoiding a loss in the mechanical performance. Often the lattice parts are integrated in a more complex geometry, and they present an interface with a solid part.In the present paper, the mechanical and microstructural characterization of Ti6Al4V lattice structures with body-centered cubic unit cell was carried out. Samples with and without an external solid shell were designed and produced with electron beam powder bed fusion in order to investigate the behavior of these complex structures, especially at the interface between the solid and lattice parts. The microstructure and defects were analyzed, and compression tests were performed on the samples with and without solid shell to understand the influence of the solid part and its interaction with the lattice structure. After the fracture and detachment of the shell, the same behavior for both set of samples was observed.Finally, a finite element model was defined to better understand the mechanical behavior of the investigated structures. The nominal sample stiffness was significantly higher than the experimental one. This discrepancy can be attributed to local defects, both in terms of porosities and deviations from ideal geometry.