| Abstract: |
Additive manufacturing (AM) producesparts from wire or powder very close to their final dimensions while minimising material costs. One technique, electron beam powder bed melting (EBM), is used to produce successive layers of a part and offers the ability to produce components closest to their final dimensions, with good surface finish. At this time the process is faster than other techniques of comparable quality. However,parts cannot be produced at a sufficient rate to make the method economically viable for any but very high value, bespoke or prototype applications.
Developmentof electron beam additive layer manufacturing equipment and processing methods is underway to increase productivity by at least 5 times and produce parts up to 400mm square. A high intensity, high power electron gun and low aberration beam deflection system have been designed and optimised. In addition, a 3-dimensional model addressing beam interaction with the powder bed is being developed that will allow simulation and optimisation of the process for high productivity. Airframe component manufacture is the main focus but results will be applicable to other markets including turbine components and orthopaedic implants.
This paper details the limitations of existing technology, objectives of the project and the initial findings.
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