Electron Beam Melting of Thermally Sprayed Layers – Overview

Biuletyn Instytutu Spawalnictwa ◽

10.17729/ebis.2021.3/1 ◽

2021 ◽

pp. 7-19

Author(s):

Marek St. Węglowski ◽

Robert Jachym ◽

Krzysztof Krasnowski ◽

Krzysztof Kwieciński ◽

Janusz Pikuła ◽

...

Keyword(s):

Electron Beam ◽

Electron Beam Melting ◽

Thermal Spraying ◽

Structural Elements ◽

Protective Layers ◽

The Stability ◽

Thermally Sprayed

Thermal spraying is one of the most common methods enabling the deposition of variously-purposed layers on surfaces of structural elements. However, in certain cases, the process of spraying itself is ineffective in terms of the stability and properties of protective layers. One of the possible solutions making it possible to reduce the porosity and improve the adhesion of surfaced layers involves their melting using the concentrated electron beam. The article contains an overview of reference publications concerning electron beam melting technologies.

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The Effect of Post-Processing on the Mechanical Behavior of Ti6Al4V Manufactured by Electron Beam Powder Bed Fusion for General Aviation Primary Structural Applications

Aerospace ◽

10.3390/aerospace7060075 ◽

2020 ◽

Vol 7 (6) ◽

pp. 75

Author(s):

Carmine Pirozzi ◽

Stefania Franchitti ◽

Rosario Borrelli ◽

Antonio Chiariello ◽

Luigi Di Palma

Keyword(s):

Electron Beam ◽

Mechanical Behavior ◽

Electron Beam Melting ◽

Melting Process ◽

General Aviation ◽

Powder Bed Fusion ◽

Structural Elements ◽

Post Processing ◽

Powder Bed ◽

Structural Applications

In this work a mechanical characterization of Ti6Al4V processed by electron beam powder bed fusion additive manufacturing was carried out to investigate the viability of this technology for the manufacturing of flyable parts for general aviation aircraft. Tests were performed on different manufacturing conditions in order to investigate the effect of post processing as machining on the mechanical behavior. The study provides useful information to airframe designers and manufacturing specialists that work with this technology. The investigation confirms the low process variability and provides data to be used in the design loop of general aviation primary structural elements. The test results show a high level of repeatability indicating that the process is well controlled and reliable enough to match the airworthiness requirements. In addition, the so-called “as-built specimens”, i.e., specimens produced by the electron beam melting machine without any major post-processing, have lower mechanical performances than specimens subjected to a machining phase after the electron beam melting process. Specific primary structural elements will be designed and flight cleared, resulting from the findings presented herein.

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