Electron beam freeform fabrication (EBF3) is a process that uses an electron beam and wire feedstock to fabricate metallic parts inside a vacuum chamber. In this study, single and multiple layer linear deposits of AISI 316L stainless steel were produced with the EBF3 machine at NASA Langley Research Center (LaRC). EBF3 process parameters, including beam current, translation speed, and wire feed rate, were investigated in order to consider their effects on the resulting steel deposit geometry, microstructure and mechanical properties. Results indicate that the EBF3 process can produce pore-free, fully dense material within the range of process parameters used in this study. The electron beam deposited stainless steel has a solidification microstructure with fine columnar grains within most parts of the deposit due to the high cooling rate during the deposition, with some small homogeneous equiaxed grains at the top of the deposit. The mechanical properties of the deposits are comparable to those of wrought metal, which is attributed to the homogeneous fine-grained microstructure.
