Powder-based Electron Beam Additive Mfg - Process Modeling with Applications to Novel Overhang Support Designs - (PPT)

摘要

Powder-based electron beam additive manufacturing (EBAM) is one of a few additive manufacturing (AM) technologies that are capable of making full-density, functional metallic components for numerous engineering applications. EBAM is particularly of advantage for high-value, low-volume, custom-design productions in a variety of industries such as medical, transportation, and military, etc. Different metal powders and different structures, unattainable by traditional means, have been commonly studied for general and niche applications. However, process modeling, a basis to technology advancements, has not been systematically investigated to enhance the EBAM process performance. This presentation will discuss the powder-based EBAM technology. In particular, modeling of the EBAM process physics, by finite element (FE) analysis, will be addressed. The key points of the model will be elucidated using different examples, and process improvements derived from FE simulations/analyses will be demonstrated. One improvement is novel overhang support structure designs, which will eliminate the need of mechanical ways for support removals, and thus, simplify post-processing and enhance EBAM performance. The study demonstrates the powerful potential of FE modeling in studying the EBAM fundamentals and in capturing the complexity of the process, which in turn helps understand and advance metal-based rapid manufacturing technologies.