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Optimising The Dynamic Process Parameters In Electron Beam Melting (EBM) To Achieve Internal Defect Quality Control

  • : Shuai Hou1, Emmanuel Muzangaza1, Melanie Bombardiere1, Annestacy Okioga1, Mostafizur Rahman1
  • : 1The Manufacturing Technology Centre Ltd
  • : PDF Download
  • : 2017


Electron Beam Melting (EBM) is an Additive Manufacturing (AM) process which can be used to fabricate complex 3D Ti-6Al-4V components. However, defects are often found in the as-built components, which can make a significant difference to the fatigue resistance of the parts. In this study, dynamic process parameters, including reference current, speed function, beam focus and line offset were investigated and a response surface methodology used to develop a regression model to correlate the effect of those parameters on pore characterisations. The pore size, pore morphology and volume fractions were characterised using X-ray Computed Tomography (XCT). The as-built component porosity were found reduced from ~0.2% (based on the default melting theme) to ~0.06% through parameter optimisation, where all the resolved pores under the new melting theme were found as spherical gas pores (<300 μm). This work will enable EBM users to manufacture components of better quality.


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