Development and validation of a model for the EBM process and visit at the IAM@PoliTo Center
Seminar wuth Manuela Galati
The term additive manufacturing (AM) today refers to a large number of technologies that allow components to be fabricated using a layer-by-layer strategy. This approach has revolutionised the manufacturing and design world because it offers the possibility of manufacturing parts of any geometric complexity without using additional tools or machine.
The combination of AM principles and electron beam (EB) technology allows complex metal parts, featuring excellent quality material such as titanium alloys, to be produced, whenever traditional methods are expensive or difficult to apply. Although the use of an electron beam in the AM field is relatively recent, Electron Beam Melting (EBM) process has already several applications in the aerospace and medical fields.
Today, the optimization of process parameters, for a given metal powder, is generally attained through an empirical trial and error approach. Simulations may have the potential to reduce the optimisation time and the costs when compared with experimental trial and error approach. In fact, by means of numerical modelling, process stability could be reached by exploring virtually what-if scenarios. However, experimental validations of the simulated melt pool presented in literature has shown an error of more than 50%. In order to improve the effectiveness and reliability of EBM simulation, a new type of modelling for the energy source and the powder material properties have been introduced. Preliminary experimental validations by applying DOE showed a very good ability of the model to forecast the melt pool. Several process parameters have been investigated and the largest deviation was found to be around 18%.
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