Numerical Modeling of Heat Distribution in the Electron Beam Melting® of Ti-6Al-4V

2013 ◽  
Vol 135 (6) ◽  
Author(s):  
Mahdi Jamshidinia ◽  
Fanrong Kong ◽  
Radovan Kovacevic
Keyword(s):  
Numerical Modeling ◽  
Electron Beam ◽  
Process Parameters ◽  
Molten Pool ◽  
Electron Beam Melting ◽  
Flow Model ◽  
Numerical Models ◽  
Heat Distribution ◽  
Powder Bed ◽  
Thermal Fluid Flow

Electron beam melting® (EBM) is one of the fastest growing additive manufacturing processes capable of building parts with complex geometries, made predominantly of Ti-alloys. Providing an understanding of the effects of process parameters on the heat distribution in a specimen built by EBM®, could be the preliminary step toward the microstructural and consequently mechanical properties control. Numerical modeling is a useful tool for the optimization of processing parameters, because it decreases the level of required experimentation and significantly saves on time and cost. So far, a few numerical models are developed to investigate the effects of EBM® process parameters on the heat distribution and molten pool geometry. All of the numerical models have ignored the material convection inside the molten pool that affects the real presentation of the temperature distribution and the geometry of molten pool. In this study, a moving electron beam heat source and temperature dependent properties of Ti-6Al-4V were used in order to provide a 3D thermal-fluid flow model of EBM®. The influence of process parameters including electron beam scanning speed, electron beam current, and the powder bed density were studied. Also, the effects of flow convection in temperature distribution and molten pool geometry were investigated by comparing a pure-thermal with the developed thermal-fluid flow model. According to the results, the negative temperature coefficient of surface tension in Ti-6Al-4V was responsible for the formation of an outward flow in the molten pool. Also, results showed that ignoring the material convection inside the molten pool resulted in the formation of a molten pool with narrower width and shorter length, while it had a deeper penetration and higher maximum temperature in the molten pool. Increasing the powder bed density was accompanied with an increase in the thermal conductivity of the powder bed that resulted in a reduction in the molten pool width on the powder bed top surface. Experimental measurements of molten pool width and depth are performed to validate the numerical model.

scholarly journals Surface Roughness Characterisation and Analysis of the Electron Beam Melting (EBM) Process

Materials ◽  
2019 ◽  
Vol 12 (13) ◽  
pp. 2211 ◽  
Author(s):  
Manuela Galati ◽  
Paolo Minetola ◽  
Giovanni Rizza
Keyword(s):  
Surface Roughness ◽  
Electron Beam ◽  
Cross Section ◽  
Mass Production ◽  
Electron Beam Melting ◽  
Heat Distribution ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Key Factor ◽  
Process Factors

Electron Beam Melting (EBM) is a metal powder bed fusion (PBF) process in which the heat source is an electron beam. Differently from other metal PBF processes, today, EBM is used for mass production. As-built EBM parts are clearly recognisable by their surface roughness, which is, in some cases, one of the major limitations of the EBM process. The aim of this work is to investigate the effects of the orientation and the slope of the EBM surfaces on the surface roughness. Additionally, the machine repeatability is studied by measuring the roughness of surfaces built at different positions on the start plate. To these aims, a specific artefact was designed. Replicas of the artefact were produced using an Arcam A2X machine and Ti6Al4V powder. Descriptive and inferential statistical methods were applied to investigate whether the surface morphology was affected by process factors. The results show significant differences between the upward and downward surfaces. The upward surfaces appear less rough than the downward ones, for which a lower standard deviation was obtained in the results. The roughness of the upward surfaces is linearly influenced by the sloping angle, while the heat distribution on the cross-section was found to be a key factor in explaining the roughness of the downward surfaces.

scholarly journals Comparison of Phase Characteristics and Residual Stresses in Ti-6Al-4V Alloy Manufactured by Laser Powder Bed Fusion (L-PBF) and Electron Beam Powder Bed Fusion (EB-PBF) Techniques

Crystals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 796
Author(s):  
Aya Takase ◽  
Takuya Ishimoto ◽  
Naotaka Morita ◽  
Naoko Ikeo ◽  
Takayoshi Nakano
Keyword(s):  
Electron Beam ◽  
Residual Stresses ◽  
Cooling Rate ◽  
Process Parameters ◽  
Phase Evolution ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Solidification Temperature ◽  
Powder Bed ◽  
Β Phase

Ti-6Al-4V alloy fabricated by laser powder bed fusion (L-PBF) and electron beam powder bed fusion (EB-PBF) techniques have been studied for applications ranging from medicine to aviation. The fabrication technique is often selected based on the part size and fabrication speed, while less attention is paid to the differences in the physicochemical properties. Especially, the relationship between the evolution of α, α’, and β phases in as-grown parts and the fabrication techniques is unclear. This work systematically and quantitatively investigates how L-PBF and EB-PBF and their process parameters affect the phase evolution of Ti-6Al-4V and residual stresses in the final parts. This is the first report demonstrating the correlations among measured parameters, indicating the lattice strain reduces, and c/a increases, shifting from an α’ to α+β or α structure as the crystallite size of the α or α’ phase increases. The experimental results combined with heat-transfer simulation indicate the cooling rate near the β transus temperature dictates the resulting phase characteristics, whereas the residual stress depends on the cooling rate immediately below the solidification temperature. This study provides new insights into the previously unknown differences in the α, α’, and β phase evolution between L-PBF and EB-PBF and their process parameters.

Temperature Distribution and Fluid Flow Modeling of Electron Beam Melting® (EBM)

2012 ◽  
Author(s):  
M. Jamshidinia ◽  
F. Kong ◽  
R. Kovacevic
Keyword(s):  
Electron Beam ◽  
Fluid Flow ◽  
Temperature Distribution ◽  
Molten Pool ◽  
Electron Beam Melting ◽  
Control Volume ◽  
Thermal Analyses ◽  
Scanning Speed ◽  
Flow Modeling ◽  
Fluid Flow Modeling

A three-dimensional (3D) numerical model is developed by using control volume method to analyze the effects of the electron beam scanning speed on the temperature distribution and fluid flow of the liquid phase in the electron beam melting® (EBM) of Ti-6Al-4V powder. The numerical calculations are performed by Fluent codes, in which thermal analyses with and without considering fluid flow in the molten pool are compared. A series of experiments are performed with an Electron Beam Melting® machine to verify the numerical accuracy. Compared to thermal analysis without considering convection in the molten pool, a closer numerical prediction of geometrical size of molten pool to the experimental data can be achieved by using thermal and fluid flow modeling. The difference between the melt pool geometry in the two models is due to the consideration of the effects of the outward flow in the fluid flow model caused by surface tension.

Molten pool behavior and effect of fluid flow on solidification conditions in selective electron beam melting (SEBM) of a biomedical Co-Cr-Mo alloy

2019 ◽  
Vol 26 ◽  
pp. 202-214 ◽  
Author(s):  
Yufan Zhao ◽  
Yuichiro Koizumi ◽  
Kenta Aoyagi ◽  
Daixiu Wei ◽  
Kenta Yamanaka ◽  
...  
Keyword(s):  
Electron Beam ◽  
Fluid Flow ◽  
Molten Pool ◽  
Electron Beam Melting ◽  
Selective Electron Beam Melting

Developing New Materials for Electron Beam Melting: Experiences and Challenges

2018 ◽  
Vol 941 ◽  
pp. 2190-2195 ◽  
Author(s):  
Andrey Koptyug ◽  
Mikael Bäckström ◽  
Carlos Alberto Botero Vega ◽  
Vladimir Popov ◽  
Ekaterina Chudinova
Keyword(s):  
Electron Beam ◽  
Electron Beam Melting ◽  
Basic Knowledge ◽  
Metallic Materials ◽  
New Materials ◽  
Powder Bed ◽  
New Process ◽  
Machine Manufacturer ◽  
Small Test ◽  
Process Material

Lack of industrially available materials for additive manufacturing (AM) of metallic materials along with the promises of materials with improved or unique properties provides a strong drive for developing new process/material combinations. As powder bed technologies for metallic materials are relatively new to the market, and to some extent are only maturing, developers of new process/material combinations have certain challenges to overcome. Firstly, basic knowledge on the behavior of materials (even those well established for other applications) under extreme conditions of melting/solidification with beam-based AM methods is far from being adequate. Secondly, manufacturing of the equipment is up to date driven by industrial application, thus optimization of the AM machines for small test batches of powders is still belongs to research and development projects. Also, majority of the powder manufacturers are primarily driven by the market development, and even they are well aware of the demands imposed by the powder bed AM machines, availability of small test batches of adequate powders may be problematic or at least quite costly for the R&D oriented users. Present paper describes the experiences in developing new materials for EBM A2 machine by Arcam EBM, modified for operating with powder batches of 100-200 ml and less. In particular it discusses achievements and challenges of working with powders from different materials with specifications far beyond the range suggested by machine manufacturer. Also it discusses the possibility of using blended rather than pre-alloyed powders for achieving both composite-like and alloyed materials in the same part by steering electron beam energy deposition strategy.

The effect of EBM process parameters upon surface roughness

2016 ◽  
Vol 22 (3) ◽  
pp. 495-503 ◽  
Author(s):  
Rebecca Klingvall Ek ◽  
Lars-Erik Rännar ◽  
Mikael Bäckstöm ◽  
Peter Carlsson
Keyword(s):  
Surface Roughness ◽  
Electron Beam ◽  
Surface Properties ◽  
Process Parameters ◽  
Electron Beam Melting ◽  
Design Methodology ◽  
New Materials ◽  
Content Type ◽  
Melt Pool ◽  
Practical Implications

Purpose The surface roughness of products manufactured using the additive manufacturing (AM) technology of electron beam melting (EBM) has a special characteristic. Different product applications can demand rougher or finer surface structure, so the purpose of this study is to investigate the process parameters of EBM to find out how they affect surface roughness. Design/methodology/approach EBM uses metal powder to manufacture metal parts. A design of experiment plan was used to describe the effects of the process parameters on the average surface roughness of vertical surfaces. Findings The most important electron beam setting for surface roughness, according to this study, is a combination of “speed and current” in the contours. The second most important parameter is “contour offset”. The interaction between the “number of contours” and “contour offset” also appears to be important, as it shows a much higher probability of being active than any other interaction. The results show that the “line offset” is not important when using contours. Research limitations/implications This study examined “contour offset”, “number of contours”, “speed in combination with current” and “line offset”, which are process parameters controlling the electron beam. Practical implications The surface properties could have an impact on the product’s performance. A reduction in surface processing will not only save time and money but also reduce the environmental impact. Originality/value Surface properties are important for many products. New themes containing process parameters have to be developed when introducing new materials to EBM manufacturing. During this process, it is very important to understand how the electron beam affects the melt pool.

Refining Tungsten Purification by Electron Beam Melting Based on the Thermal Equilibrium Calculation and Tungsten Loss Control

2015 ◽  
Vol 34 (6) ◽  
Author(s):  
Luping Long ◽  
Wensheng Liu ◽  
Yunzhu Ma ◽  
Ye Liu ◽  
Shuhua Liu
Keyword(s):  
Electron Beam ◽  
Melting Temperature ◽  
Process Parameters ◽  
Thermal Equilibrium ◽  
Electron Beam Melting ◽  
Melting Rate ◽  
Optimum Process ◽  
Equilibrium Calculation ◽  
Evaporation Loss ◽  
Loss Control

AbstractElectron beam melting (EBM) technology has been considered as one of the key steps for preparing high purity tungsten, and reasonable setting of process parameters is the premise. In this paper, the optimum process parameters obtained from thermal equilibrium calculation and evaporation loss control of tungsten are presented. Effective power is closely related to melting temperature, and the required power for maintaining the superheating melt linearly increases with the increase of melt superheat temperature. The evaporation loss behavior of tungsten is significantly influenced by melting rate and melting temperature. Analysis of experiments show that the best results are realized at melting rate of 1.82 g/s, melting temperature of 4200 K, and the corresponding melting power of 130 kW, in which the main impurity elements in tungsten, such as As, Cd, Mg and Sn, present high removal ratio of 90%, 95%, 85.7% and 90%, respectively.

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