Investigation of a novel additive manufacturing process for copper alloys based on the non-vacuum electron beam Technology.

• Applicant: Dr.-Ing. Thomas Hassel
• Subject Area: Production Automation and Assembly Technology
• Term: from 2019 to 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 410130255

Additive manufacturing (AM) is an manufacturing process that offers the potential for reductions in the use of metal to generate geometric shapes for manufactured products. AM encompasses a process family for producing components directly from a computer aided design file in a layered approach allowing the 3-d creation of a complex structure. Currently, the laser is the most commonly used energy source for powder bed fusion process or powder- or wire-fed direct energy deposition.Aim of the project is the investigation of a novel additive manufacturing process using atmospheric electron beam technology using wire fed material. To utilize the high power and power density of the non-vacuum electron beam, a wire-based process for large products is focus for this project. The efficiency of the energy transfer is largely independent of material type. Copper alloys, which are relevant materials for the use in seawater conditions, are chosen to be investigated using the NVEB-AM process. These exemplary application serves as a test-bed for the process. Other materials, process variations and later industrial applications will be derived from the results of this project.This leads to the approach chosen for this research project using wire fed material to produce large, near net-shape parts. The NVEB AM process is developed, using process observation and material scientific investigation to enhance process understanding and characterize material produced. Main goal is to achieve a high build rate for large components. Due to this, thorough theoretical modelling is used within this project to identify limitations of the process and to optimise strategies to enable high production rates.The investigations will be shared among the Institute of Materials Science (IW) in Germany and the Institute of Laser and Welding Technologies (ILWT) in Russia. IW will mostly focus on experimental investigation of the process and the governing parameters as well as on scientific characterization of the materials. ILWT will apply their successful model for powder-based deposition to create a comprehensive model of the process for enhanced process understanding. They will also provide tools to help with parameter choice depending on material properties and geometry. Together, both participants will verify the model, derive parameters and boundaries for process control and generate the base for a comprehensive assessment of the NVEB AM process and its applicability.Experimental investigations at IW will encompass the investigation of influences of machine and process parameters such as travel speed, wire speed, wire positioning, beam power and working distance to enable a phenomenological process description. As the gas atmosphere is an important influence for both, electron beam and melt pool dynamics, these investigation will be conducted using different shielding gas derivat functional dependencies of beam power, travel speed and wire speed with properties of material.

• DFG Programme: Research Grants
• International Connection: Russia
• Cooperation Partner: Professor Dr.-Ing. Gleb Turichin