Electron beam melting
Electron beam melting (EBM) is a type of metal additive manufacturing (AM) process that uses an electron beam as a heat source. This process combines the principles of physics, chemistry and engineering to create a highly accurate, quick and cost efficient way of producing certain metals and alloys. The EBM process melts metal powders layer by layer in an enclosed machine to create high-strength parts that can be used in a variety of applications.
The process of EBM begins with a CAD or computer aided design file of the intended part. The design file is then translated into 3D printable code which is fed into the EBM machine. Inside the machine, the electron beam is directed and focused onto the powder bed using a set of lenses. This heat energy melts the metal particles in the powder bed to create a layer of melted metal that conforms to the 3D design. The melted layer is then re-solidified before the next layer is melted and added in the same process. This layer-by-layer process is continued until the part is built up and finished.
The EBM process has several advantages when compared with other more conventional processes, such as machining. Parts produced through EBM can have greater complexity, as the layers can be controlled in terms of shape, size, and composition with great accuracy. 3D printing also allows for greater flexibility in design and construction as parts can be built layer by layer in any orientation. This reduces the time and energy required in the production process, making it both cost efficient and environmentally friendly.
Unlike machining, the EBM process results in minimal waste as the metal powder used is recycled and new powder is added each layer; only the excess is removed and disposed of. The end product, when compared to conventionally made metal parts, can also be much lighter and stronger due to its optimized build structure.
The use of metal 3D printing in the aerospace, automotive and medical industries is increasingly popular as it directly influences the performance and cost efficiency of these products. EBM is used to produce parts for these industries in a fraction of the time it would take for them to be machined. In addition, the process can be further automated with robotic arms, making the production process even more efficient.
Electron beam melting offers a quick, high-quality and cost efficient way of producing metal parts that have highly precise geometric and physical characteristics. The process is used in many industries to produce parts that would be impossible to machine; thus, its application and use are only likely to increase in the future.
