Innovative Process Models for Additive Manufacturing of 4340 Steel Components via Wire-Fed Electron Beam

Despite recent advances in Ebeam additive manufacturing, the parts produces by such processes often are inferior to those produced by traditional machining methods. Due to the complexity of the process and the multiple physical phenomena that interact, it is difficult to predict and control the properties and underlying microstructure of the resulting component. In addition, the rapid and repeated thermal cycling can induce multiple solid state phase transformations within certain layers, leading to possible inhomogeneity. Mainstream has already developed custom software to model electron beam processes using multi-physics finite element models. In the Phase I, Mainstream will continue to develop this technology to allow for prediction and control of the underlying microstructure and physical properties. Mainstream and the University of Alabama will validate the software models using experimental data obtained from an Ebeam facility owned by NASA as well as Mainstreams new on-site superconducting Ebeam facility. In the Phase I Option, Mainstream will design the control system and wire feed system to prepare the facility for component fabrication in Phase II.