M f t db A I ti S d ManufacturedbyArcamIncorporation,Sweden

Introduction to EBM Introduction to EBM

EBM is one form of high energy beam used for
l i metal processing.
Basically EBM is a thermal process.
Due to the various facilities provided with the Due to the various facilities provided with the
system, EBM becomes a versatile process for various
precision and micro manufacturing applications. The
system has system has
capability to vary the current density.
provision of energy in Pulsed form besides
Continuous mode.
very fine focusing system to a longer focal length
as compared to its competitor i.e. laser beam.
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Electron Beam Generation
1 A th d ti 1. A cathode section
generates an electron
beam. beam.
2. An anode section
accelerates the beam.
3. The magnetic lens
converges and deflects
the electron beam to
the desired position.
Scheme of Electron BeamMachining Process
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Scheme of Electron-Beam Machining Process
Electron Beam Set-upp
The rate at which electrons are
emitted from a hot surface by
thermo-ionic emission is given
by
I = C u
2
exp(-|/u)
where I is in amp/cm
2
, u is the p ,
absolute temperature, C is a
constant, and | is given by
| = e/(ku)
with e = charge of an electron,
k = Boltzmans constant and k = Boltzmans constant, and
(when measured in electron-
volts) = thermo-ionic work
f ti
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function
Electron BeamGeneration Electron Beam Generation
A tungsten wire filament in cathode is heated to
produce electron beam by thermo-ionic emission.
Electrons are accelerated to a speed of about 200,000
km/s (about 2/3 of Speed of light) with a voltage of km/s (about 2/3 of Speed of light) with a voltage of
about 150 kV.
The electron beam can be focused to 10 to 200 m to
produce an energy-density of about 3500 GW/mm
2
.
The focusing area of the electron beam can be
t ll d il b l t ti l controlled easily be electro-magnetic lenses.
The electron beam can be maneuvered precisely and
swiftly by magnets on the work-surface. swiftly by magnets on the work surface.
A high vacuum minimizes the electron collision with air
molecules and energy loss.
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Electron Beam in Ambient Air Electron Beam in Vacuum
In vacuum a clear stream of electrons bombarding the
surface of a material, allowing an easy and predictable cut.
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Effect of Vacuum Electron
Beam Propagation
Vacuum Level acuu e e
(courtesy, Leybond-Heraeus Vacuum System, Inc)
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Analysis for High Voltage y g g
and Vacuum
E f th l t it b ti th b t t Energy of the electrons, on its absorption on the substrate,
should be sufficient to cause thermal processing.
Energy means the kinetic energy of the electrons to reach its
maximum velocity. y
This may be possible under
under high accelerating electric field
under magnetic field (however it may be used for
d i ti f th l t f it i di ti ) deviation of the electrons fromits moving direction)
under high vacuum to avoid resistance to the moving
electrons
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electrons
Requirement for High Voltage Requirement for High Voltage
The electrons out of the cathode (having high potential ( g g p
energy) are accelerated under and electric field towards the
anode. As it moves, it gains kinetic energy at the cost of
potential energy. potential energy.
The sum totals energy of the electron at any point in its path:
1/2 (m U
2
) eE = C 1/2 (m
e
U
e
) eE
s
C
where, m
e
= Mass of an electron; U
e
= velocity of the electron;
e = Electron Charge; E
s
= Field strength and C = Constant.
At the cathode E
s
= 0 and U
e
= 0; so C = 0 and 1/2 (m
e
U
e
2
) = eE
s
U
e
= \(2e/ m
e
). \E
s
km/sec
As m
e
= 9.109 x 10
-31
kg, and e = 1.602 x 10
-19
coulomb
U
e
= 600\E
s
km/sec
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So at about 150 kV, V
s
= 230,000 km/sec
The electron can be deflected by Magnetic field, which
helps in focusing or deflect the beamof electrons due to helps in focusing or deflect the beam of electrons due to
Lorenz force.
So the beam can be deflected magnetically and can
also also
be focused to 10 to 200 micron and
attain an energy density of about 6500 GW/mm
2
achieve good narrow cut or hole achieve good narrow cut or hole.
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Electron Beam Processing Mechanism
The intensity of the beam is compromised by the collision
with air molecules. It is difficult to calculate the time and/or
beam intensity of the irradiated stream hitting the surface beam intensity of the irradiated stream hitting the surface,
required to cut the part or drill a hole.
=2.6 x 10
-17
(V
2
/ ), mm
V =Accelerating potential, V
=Density of material, kg/mm
3
Drilling Steel by EBM operating at 150 kV:
= 2 6 10
-17
[(150 10
3
)/ (76 10
-7
)]
2
mm = 77 m = 2.6 x 10
-17
[(150 x 10
3
)/ (76 x 10
-7
)]
2
mm = 77m
The electron beam is shot through the vacuum towards the
i l Th l f h h h l material. The electrons often pass through the outer layer
of the material and then become trapped in the material.
The dark line shows the path of the electron.
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Process parameters for electron
beammachining beam machining
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Schematic of Arcams electron
beammelting process beam melting process
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TheEBMProcess
Apowerfulelectrongun shootsout
highspeedelectrons.Thenbyusing
electromagnets,theelectronbeamis
f d d h l
Themagazineofpowderscrapesouta
thinlayerofmetalpowderinavertically
adjustablecradle.Inthiscradlethe
bj illb d focusedandyetotherelectromagnetsare
usedtosteerthebeam.Whenthebeam
hitsthemetalpowderitisheatedso
muchthatthemetalpowdermelts.
M t l d i f di t i th t
objectwillbecreated.
Thefirstlayeroftheobjectiscreated
throughmeltingthelayerofmetal
powderwithacomputercontrolled
l t b Th bj tf th Metalpowderisfedintoamagazinethat
ismountedintothemachine.
Dependingontheuseoftheobject,a
numberofdifferentmetalpowders
canbeusede g alloys
electronbeam.Theobjectfromthe
CADmodelisbuiltlayerbylayeruntila
complete,solid,metalproductis
created.
Whentheruniscompletethecradle
canbeusede.g.alloys.
Themachine,whichisusedduringthe
manufacturing,ispreparedfortherun.
Thedoorisclosedandvacuum is
induced.Hightemperature maybe
Whentheruniscompletethecradle
withtheobjectinitspowderbeddingis
beingremovedfromthemachine.Then
itislefttocooloff.
Whentheobjecthascooleddown it's
g p y
maintained.
Whentheobjecthascooleddown,it s
beingcleanedfromexcessivepowder
andtheslightlyrough metalobjectis
readyforthefinaltreatment.
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Different Modules of EBM DifferentModulesofEBM
Machine
ENCLOSURE
Themachinehasanenclosuretoprotectthesystemswithinthemachine.Theenclosure
isalsofortheoperatorssafety.Theenclosureisconstructedinpaintedsheetmetaland
h i d f h h b i d fh d d l dl d l thewindowforthevacuumchamberismadeofhardenedglassandleadglass.
VACUUMCHAMBER
Madeof20mmstainlesssteel.ContinuouslyTIGweldedontheinsideforvacuum
tightnessandintermittentlyTIGweldedontheoutsideforstrength Thechamberis tightnessandintermittentlyTIGweldedontheoutsideforstrength.Thechamberis
alsoreinforcedwithstruts.Connectionflangesofstandardtype.
VACUUMSYSTEM
Thevacuumsystemconsistsofoneturbopump260l/secandisbackedupbyone y p p p y
mechanicalpumpwithacapacityof10m3/h.Thevacuumsystemiscontrolledviaa
PLCwhichinturncommunicateswiththecontrolcomputer.
THEELECTRONGUN
Consistsofthreeroundunits Thebottomunithasawater cooledbaseandcontains Consistsofthreeroundunits.Thebottomunithasawatercooledbaseandcontains
thelenssystemforfocusingandcontrollingthebeam.Themiddleunitcontainsthe
anode.Thetopunitconsistsofhighvoltageconnection,filamentholder(cathode),
controlelectrodeandsetscrews.
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DifferentModulesofEBM
Machine
THEHIGHVOLTAGEUNIT
Thehighvoltageunitiscontrolledfromthecontrolcomputer.
CONTROLSYSTEM CONTROLSYSTEM
Consistofanindustrialcomputer(MicrosoftWindows2000Professional)whichinturn
controlsandchecksthevacuumsystem,thehighvoltageunits,theelectronbeamlens
system,thefabricationtable,powderdosageandpowderplacement.
CONTROLPANEL
Thecontrolpanelconsistsofabuiltinindustrialtype15"PCtouchscreen.Inaddition,an
industrialtypekeyboardisavailableonaslidingunitformorecomplexcommands.
THEBUILDINGTANK
Madeofstainlesssteel,joinedwithscrewjoints.Thevolumeofthebuildingtankis
250x250x200mm,WxDxH,whichgivesavolumeof12,5liter.
Thebuildingtankhasaheightadjustablebottomplatewhichiscontrolledbyalinear
device device.

DOSAGEEQUIPMENT
Consistsoftwopowdercontainers,welded,ofstainlesssteel.Twopowderdosageunits
andapowderdistributionunitwhichmoveshorizontallyacrossthefabricationtable
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andapowderdistributionunitwhichmoveshorizontallyacrossthefabricationtable.
DifferentModulesofEBM
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EBMSpecifications p
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Materials
ToolSteel
L All S l LowAlloySteel
AlloyedTitanium
CommerciallyPureTitanium
NickelAlloys
Nextclassofmaterialstobedevelopedwillbe
aluminumalloy(s)forautomotiveandaerospace
applications.
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MechanicalProperties p
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AdvantagesofEBM g
ElectronBeamWelding has
becomeavitaltechnologyin
manyindustries Someofits
ElectronBeamMelting
benefitsfromallofthesefactors
inthesameway Comparedwith manyindustries.Someofits
benefits include:
Abilitytoachieveahighenergy
levelinanarrowbeam.
inthesameway.Comparedwith
lasersintering/melting
additionalbenefits include:
Higherefficiencyingenerating levelinanarrowbeam.
Vacuummeltqualitycanyield
highstrengthpropertiesofthe
material.
Higherefficiencyingenerating
thebeamofenergyresultingin
lowerpowerconsumptionas
wellaslowermaintenanceand
i t ll ti t
Vacuumenvironmenteliminates
impuritiessuchasoxidesand
nitrides.
ld f
installationcosts
Highactualoverallpower
resultinginhighbuildspeeds
Deflectionofthebeamcan
Permitsweldinginrefractory
metalsandcombinationsof
dissimilarmetals
Deflectionofthebeamcan
achievedwithoutmovingparts
resultinginhighscanningspeed
andlowmaintenance.
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DisadvantagesofEBM g
Requiresvacuumwhichaddsanothersystemon
themachinewhichcostmoneyandmustbe themachinewhichcostmoneyandmustbe
maintained[Addedbenefit:Vacuumeliminates
impuritiesandprovideandgoodthermal p p g
environmentforfreeformfabrication]
Electronbeamtechnologyproducesgammarays gy p g y
whileinoperation[Solution:Thevacuumtank
shieldstheraysperfectlyifproperlydesigned.]
Requireselectricallyconductivematerials
[Comment:metalsareconductive]
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ApplicationsofEBM pp
PresentR&Disfocusingonpartsforhighperformanceapplications
withinautomotive andaerospace industryaswellasbiomedical
applicationssuchasimplants applicationssuchasimplants.
Typicalapplicationsarecomplexpartsmanufacturedinlowvolumes
wherecastingandmachiningwouldrequiretoomuchofleadtime,
machinetimeorscrappingofmaterial. machinetimeorscrappingofmaterial.
Thetechnologycanalsobeusedtomanufacturepartsfeaturing
geometriesthatcannotbeachievedinothermanufacturing
technologies,thusprovidingsuperiorperformanceinthepartand g p g p p p
valuetothecustomer.Examplesofsuchapplicationsare:
Complexlattice/frameworkstructuresforlightweightdesign
Internalcavitiesforlightweightdesign,weightdistribution g g g g
optimizationandflowcontrol
Optimizationofmaterialandstressdistribution
Conformalcoolingchannels g
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Titaniumandsteelplatesfabricatedfor
repair of bone fracture repairofbonefracture
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EBM Fabricated exhaust coupling flange (Volvo),
The component shown mounted for real-world
testing on the right testing on the right
Steel test piece
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Volvo camshaft sensor cover Volvo camshaft sensor cover
made of reinforced PBT by injection
molding.
The cooling cycle for this part was
The shape of the
conformal cooling
channels within the mold
g y p
reduced from 25 to 15 seconds
using conformal cooling channels,
created as Arcams EBM
channels within the mold
for the Volvo part created in
the normal course of the
structural building process
technology made the core and
cavity inserts.
gp
from CAD to metal.
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