Electron Beam Free from fabrication process

1. ELECTRON BEAM FREEFORM
FABRICATION PROCESS:-
A RAPID METAL DEPOSITION PROCESS
Guided by : Presented by :
Mohammed Swalih N U Arshad Arif N P
Asst. Professor CEANEME016
Dept of Mechanical Engineering

2. INTRODUCTION
• Is a cross-cutting rapid manufacturing technology for producing
structural metal parts
• Used to built a complex, unitized part in a layer-additive fashion
• builds a near-net-shape metal part directly from a Computer Aided
Design (CAD) file.
• EBF3 process is scalable for components from fractions of an inch to
tens of feet in size

3. SOLID FREEFORM FABRICATION
• consist of processes that can be used to design and construct parts
using a layer additive approach.
• processes are an outgrowth of rapid prototyping processes such as
steriolithography for plastics and welding repair techniques ,
employing laser ,electron beam etc.
• current developments efforts are resulting in the product of new
SFF layer additive processes to build structural parts directly from
CAD data.

4. DIFFERENT SFF PROCESSES
Selective laser sintering(SLS)
Electron beam melting(EBM)
a.
b.
c.
d.
e.
f.
g.
Precision metal deposition(PMD)
Ultrasonic consolidation(UC)
Direct metal deposition(DMP)
Laser additive manufacturing(LAM)
Electron beam free form
fabrication(EBF3)
Operating in a powder bed and
requires secondary process
Focus on low heat inputs
Direct laser deposition
Focused electron beam and
feedstock

5. WHO NEEDS EBF3?
(ELECTRON BEAM FREEFORM FABRICATION)
• When you need a metal part and you need it now
– Not in stock off-the-shelf
– Inaccessible locations
• When you need something that nobody makes
– Prototypes / custom fabrication
– Component-level repairs

6. ELECTRON BEAM FREEFORM FABRICATION
• EBF3 is an emerging cross cutting edge technology for producing
structural metal parts.
• The process can be used to build complex unitized parts in a layer
additive fashion
• Used as a manufacturing process for adding details to components
resulting from simplified castings and forging or plate products,

8. ELECTRON BEAM FREEFORM FABRICATION
• EBF3 employs a high power electron beam in a vacuum
environment(1x10-4 torr or lower).
• Operations in vacuum ensures clean process environment and
eliminates the need for a consumable shield gas.
• Wire feedstock is used due to difficulties in feeding powder in
vacuum, since the carrier used to assist the powder delivery will be
ionized in electron beam.

9. ELECTRON BEAM FREEFORM FABRICATION
• makes use of commercially available “welding wire” as its feedstock
material.
• Deposition rates for EBF3 are 330 to 2500 cm3/hr with lower
resolutions in the ability to build fine details
• The EBF3 processes are almost 100% efficient in feedstock
consumption and 95% efficient in power usage.

10. ELECTRON BEAM FREEFORM FABRICATION
• Recentwork has focused on characterizing the resulting
microstructures and mechanical properties to optimize the process
for 2219 Al and Ti 6-4
• Al alloy 2219 has a nominal composition of Al-6 & % Cu, has
excellent weldability, good strength and toughness.
• Ti-6Al-4V has high temperature applications and where excellent
strength and corrosion resistance are required.

13. ELECTRON BEAM FREEFORM FABRICATION
• The parts made using EBF3 process were finished using conventional milling, wire
electric discharge machining, bead blasting and electron beam glazing.
• EBF3 parts had good localized surface finishing but larger long range surface
irregularity and mild tensile residual stress.
• The machinability of EBF3 process was comparable to standard wrought product
for both milling and wire EDM process.

15. EBF3 DEPOSITION SCHEMES
• 2219 Al shapes built using EBF3 demonstrate different deposition
schemes: a) high deposition rate
b) Varied wire feed angle

16. EBF3 DEPOSITION SCHEMES
c) complex curvature
d) unsupported overhangs
e) transmission from one geometry to another

19. NEW GENERATION EBF3 SYSTEM

20. ADVANTAGES
• reduced production and material cost
• reduced development and lead time
• improved performance
• reduced design time
However factors such as efficiency ,deposition rates, material compatibility
and process quality must be considered to assess the feasibility of such
processes.

21. EBF3 POTENTIAL APPLICATIONS
• Aerospace
• Automotive
• Medical implants
• Tool & dies for casting/molding industries
• Sporting goods
• Repairs and fabrication in remote locations

22. CONCLUSION
• leading candidate for generating large nearnet-shaped performs.
• significant cost savings can be realized when compared to
conventional processes due to the reduction in raw material usage
and minimized lead times.
• suitable for fabricating a wide range of structures using a number of
engineering alloys.

23. Thank you …