Electron beam melting:

• Process description : A thin layer of metal powder is selectively melted

by an electron beam. The parts are built up layer by layer the in the
powder bed.
• Electron beam melting is similar to laser melting, but working with an
electron beam instead of a laser.
• The machine distributes a layer of metal powder onto a build platform,
which is melted by the electron beam. The build platform is then lowered
and the next layer of metal powder will be coated on top.
• The process of coating powder and melting where needed is repeated and
the parts are built up layer by layer in the powder bed.
• Electron beam melting requires support structures, which anchor parts and
overhanging structures to the build platform.
• This enables the heat transfer away from where the powder is melted.
• Therefore, it reduces thermal stresses and prevents wrapping.
• The build envelope can be filled by several parts which are built in parallel
as long as they are all attached to the build platform.
• Parts are built under vacuum.
 EBM- AM process- fully dense parts with properties equal to
those of wrought materials
material: titanium metal powder Application: aircraft industry
 Process chain

• When planning an EBM build, critical tolerances, surface finishes and

overhangs need to be taken into consideration.
• After the build, parts often need to be thermally processed and support
structure needs to be mechanically removed.
• Electron beam melting parts can be further post-processed as any welding
part.
Pre-build planning
• The production of parts is planned in a build preparation software. One or
several parts are placed in the build using the digital 3D files (typically in the STL
file format). Important decision during the set-up phase is the orientation of the
part in the build envelope and what support structures are required.

This depends on:

• Geometry, overhangs and inclination
• Location of most critical tolerances and surface finishes
• Areas where post-processing is required and additional material needs to be
added
 Post-processing

• Removal of build envelope: The build cylinder is removed from the machine
• Remove powder: Build platform with the parts attached is taken out of the
loose powder. Excess loose powder is removed by sand balsting. This is
usually straight forward, however might require some extra effort for parts
with complex geometric features (e.g. trapped powder)
• Thermal processing: After the build parts, are often thermally processed to
release residual stresses and improve part characteristics and metallurgical
structure. Which regime is best depends on the application, desired part
characteristics and the material used. Typical processes include vacuum heat
treatment, heat treatment under inert gas or hot isostatic pressing (HIP).
• Removal of supports and post-machining: Afterwards, parts are taken off the
build platform, typically through wire cutting EDM or machining. Further,
support structures are mechanically removed. Parts might be partially post-
machined in order to fulfil critical tolerances.
• Surface finish: Often parts need to be further processed to improve surface
finish – either mechanically (e.g. polishing, grinding, peening) or chemically
(e.g. plating, electro polishing).
• After melting and solidifying one layer of titanium powder, the process is
repeated for subsequent layers until the part is complete.
• For industries such as aerospace, this creates new opportunities for both
prototyping and low volume production of titanium parts.
• The time, cost, and challenges of machining or investment casting are
eliminated, which makes titanium parts readily available for functional
testing or installation on the aircraft.
• Additionally, the additive process opens the door to new design
configurations and weight-reduction alternatives.
How it works :
• When the high-speed electrons strike the metal powder, the kinetic energy
is instantly converted into thermal energy.
• Raising the temperature above the melting point, the electron beam rapidly
liquefies the titanium powder Within the electron beam gun, a tungsten
filament incandesces and “boils off” a cloud of electrons
• These electrons stream through the gun at approximately half the speed of
light.
• Two magnetic fields organize and direct the fast moving electrons.
• The first acts as a magnetic lens, which focuses the beam to the correct
diameter.
• The second magnetic field deflects the focused beam to the target point on
the powder bed
• The electron beam gun is stationary, and no moving mechanical parts are
needed to deflect the beam.
• This delivers very high scanning speeds, up to 1000 m/sec. (3280 ft/sec)
and fast build rates, up to 60 cm3/hour (3.7 in3/hour).
• The process is three to five times faster than other additive technologies.
• The EBM parts are built in a vacuum to prevent a loss of energy that would
be caused by the fast moving electrons colliding with air or gas molecules.
The vacuum has two advantages:
1. The process is 95% energy-efficient, which is five to ten times greater than
laser technology
2. The vacuum supports processing of reactive metal alloys such as titanium.
Fully dense titanium The EBM machine produces components from Ti6Al4V
and Ti6Al4V ELI, two alloys common in ELECTRON BEAM MELTING
• The Ti64 parts exhibit properties that match those of wrought materials and
exceed those of investment castings.
• Directly from the EBM machine, the parts are 100% dense, eliminating the
need for a secondary infiltration processes. However, the Ti-64 parts can be
hot isostatically pressed.
 Advantages / Limitations
• Parts can be manufactured in some standard metals with high density
by electron beam melting. However, the availability of materials is
limited and the process is rather slow and expensive.
•The technology manufactures parts in standard metals with high density
(above 99%) and good mechanical properties (comparable to traditional
production technologies).
• Compared to laser melting, EBM produces less thermal stress in parts
and therefore requires less support structure. Further, it builds parts faster.
•Electron beam melting is still a slow and expensive process that only
works with a limited set of metals. Parts usually require quite a lot of post-
processing. Compared to laser melting, the technology does not achieve
equally good surface finishes.
• Parts produced via EBM are near-net shape, like those made via casting
processes.
• Since the electron beam fully melts the titanium, the liquefied metal conforms
to the surrounding metal powder, which yields a surface finish similar to a
precision sand casting. As a result, some light secondary machining or
grinding of the surface may be required.
• With material properties that match or exceed those of conventional
processes, EBM allows aerospace companies to produce titanium
prototypes and production parts without the inherent cost and
challenges of machining, casting, and welding.
• The ease and speed of producing titanium parts with the EBM machine
makes functional prototypes readily accessible to the design and
manufacturing team.
• This means that functional evaluations can be completed earlier and more
frequently in the design cycle. Complex designs Inherent to additive
fabrication processes is the ability to produce complex designs that are
difficult or impossible to make when machining or casting.
• This freedom of design can be exploited to achieve exceptional
strength-to-weight ratios, reduce manufacturing costs, and minimize
assembly time. Because EBM produces true titanium parts, these
advantages can be applied to components for commercial and military
aircraft
• EBM creates an opportunity to rapidly manufacture flight-ready titanium structures.
Although titanium is often the best material for certain aircraft components, its high cost
and manufacturing challenges often prevent its application.
• In these instances, machined or investment cast aluminum is chosen for weight reduction.
When aluminum is not satisfactory, steel may be selected in spite of its weight.
• With EBM, manufacturers have an effective alternative that combines the advantages of
aluminum and steel, while overcoming the obstacles of making titanium parts.
• Other advantages: • Multi-piece assemblies: The additive process can make a multi-
piece assembly as one component.
• In those cases where the limits of machining and casting force a designer to create an
assembly, EBM can reduce production costs.
• By combining two or more individual components into a single piece, assembly is
eliminated, and the cost of manufacturing may be reduced.
• Buy-to-fly ratios: EBM creates an opportunity to design and manufacture aircraft
components with unprecedented strength-to-weight and buy-to-fly ratios.
• Hollow parts: The EBM process can also produce hollow parts with an internal
strengthening scaffold.
• Impossible with any other method, EBM can deliver the required mechanical
strength with much less mass. This reduces the cost of raw materials and the weight of
the component.
• Aerospace companies such as Boeing Phantom Works have recognized the benefits of
EBM for prototyping and manufacturing.
• Directly from CAD, it is producing metal parts for functional testing, and creating new
designs that capitalize on the design freedom that the additive process offers
• Advantages of EBM_- Additive Manufacturing
• Extremely complex geometries not possible with traditional
methods (geometric lattice structures, conformal channels )
• Structurally optimized components-unique properties
(thermal, electrical, biological etc.)
• Material is only used where it is needed
• Significant reductions in buy-to-fly ratio
• Significant savings in fuel
• No tooling or dies needed to fabricate a part = short runs,
small batches, legacy parts
• Point of use process - reduced inventory -reduced carrying
and transport costs
• Combine assemblies into single parts
• 4kW Electron beam is generated within the electron beam gun
• The tungsten filament is heated at extremely high temperatures which
releases electrons
• Electrons accelerate with an electrical field and are focused by
electromagnetic coils
• The electron beam melts each layer of metal powder to the desired geometry
• Vacuum/melt process eliminates impurities and yields high strength
properties of the material
• Vacuum also facilitates the use of highly reactive metals
• High build temperature provides good form stability and low residual stress
in the part
• 20-200 micron layer thickness
• 20-300 micron powder
• Energy Balance –Maintain constant build temperature
Preheat 1: Lightly sinter the powder “Jump Safe”
Preheat 2: Increased local sintering “Melt Safe”
 Top Ten Industrial AM
Applications
1. Product Development of Functional Metal Parts
2.Hybrid Manufacturing Additive/Subtractive in One Machine Tool
3. Manufacturing Rework of New Metal Parts
4. Turbine Engine Component Repair
5. Remanufacturing of Obsolete Metal Components
6. Mass Production of 3D Conformal Antennas for Consumer
Electronics
7. 3D Printed Electronics for Molded Interconnect Devices (MIDs)
8. 3D Printed Sensors for Internet of Things Applications
9. Printed Electronics for Semiconductor Packaging
10. 3D Printed Heater Circuits for Auto/Aero Applications
 THE BENEFITS OF ADDITIVE MANUFACTURING

• Lowers overall production costs by reducing costs of materials and

assembly
• Reduces time to market with a digital process – no hard tooling
required
• Enables more materials and feature size options
• Can Produce lighter weight structures with internal hidden cavities
• Increases design and manufacturing flexibility, reduces the number
of processing steps
• Supports a full range of use models, from prototyping to
repair/replacement to full production
• Integrates within traditional production environments
• Reduces environmental impacts
• 3D printing can use almost any material to fabricate any complex
part, in any quantity and in any location, for any industrial field.
These five “any”s are the main advantages of 3D printing.
Interdisciplinary research will tremendously accelerate the
development of this technology.