Process Modeling for Additive Manufacturing of Alloys by Electron Beam

ABSTRACT: UES proposes to develop a thermal model for additive manufacturing by electron beam melting that will enable selection of machine process parameters to maximize first part yield for arbitrarily shaped parts, and provide documentation to support rapid part qualification. The research will address manufacturing with Ti 6Al 4V and with Ti 6Al 2Sn 4Zr 2Mo using powder sources from different vendors. An experimental program has been designed to correlate change process parameter changes with microstructure while building shape elements that are representative of typical features within parts. The data obtained will be used to anchor the physics-based thermal model that will be developed as a commercial product. Aerospace partners have been identified that support such technology development for both engine and airframe parts. BENEFIT: The program is aimed at increasing the first part yield of additively manufactured parts manufactured by electron beam melting, and providing part metadata for part validation documentation. A successfully developed thermal model will be commercialized or licensed to users of EBM machines.