Electron beam fusion (EBM) is a rapid manufacturing method that uses an electron beam in a vacuum to fuse layers of powder to create complex parts with high density and desirable physical characteristics. EBM is suitable for use with metals, ceramics, and metal-ceramic composites and is often used to produce high-performance parts such as turbine blades and medical implants. The process allows for high melting capacity, high productivity, and avoids additional heat treatment operations.
Electron beam fusion (EBM) is a technique in which a machine part is manufactured by fusing layer upon layer of powder to form the desired shape. This rapid manufacturing method uses an electron beam in a vacuum to produce the temperature needed to melt the powder. Parts built this way are typically known to have more desirable physical characteristics than parts built by other methods.
To build a component via electron beam fusion, the material to be machined is placed in a vacuum chamber. The size of this chamber determines the maximum possible size of the finished part. The electrons are then emitted from a filament and accelerated to about half the speed of light. Magnetic fields focus and direct the beam to the necessary locations. When electrons collide with dust particles, their kinetic energy is transformed into thermal energy thus heating the dust.
Because the beam affects only a very shallow area on the material surface, the part is built layer by layer. Computers are typically used to control the position and dwell time of the beam, although an operator supervising the process sometimes regulates this. Three-dimensional computer aided design schemes provide the dimensional information needed to direct the beam.
EBM is often referred to as a type of rapid manufacturing method known as additive manufacturing. Such processes deliver precise amounts of energy and material in precise locations to develop the desired structure. Rather than using a mold to define the shape of the part, additive manufacturing techniques use a three-dimensional digital blueprint to specify its shape.
Metals are the most typical materials used to build components with electron beam fusion. Other materials, however, are sometimes used, such as ceramics and metal-ceramic composites. Electron beam fusion is particularly suitable for use with materials that react with oxygen as the fabrication takes place in a vacuum chamber.
There are a number of benefits associated with electron beam fusion. Due to the high energy involved, this technology allows for high melting capacity and high productivity. EBM is able to produce components of extremely complex geometries. The resulting parts are generally noted for their extremely high density and lack of voids in the structure.
The extremely high temperatures typically involved in the process often produce metal parts with metallurgical characteristics similar to heat treated components. For example, products from this method generally have higher strength and little or no residual stress than products from other manufacturing methods. This often reduces production time by avoiding additional heat treatment operations once the part has been built.
Components fabricated with electron beam fusion are found in a wide variety of applications. Its suitability for use with reactive titanium alloys means that electron beam melting is often used to construct lightweight titanium components such as medical implants. Known for producing parts with high strength and good metallurgical quality, it is also often used to produce high performance parts. For example, it is used to manufacture items such as turbine blades for aerospace applications and vehicle frames used in motorsports.
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