In-situ electron beam characterization for electron beam powder bed fusion

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing Pub Date : 2024-09-25 DOI:10.1016/j.addma.2024.104567

Matthias Markl, Mohammad Reza Azadi Tinat, Timo Berger, Yannic Westrich, Jakob Renner, Carolin Körner

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Abstract

Electron beam powder bed fusion is an advanced additive manufacturing technology that utilizes an electron beam to fabricate complex metallic components layer by layer. It is well known, that the beam profile is one of the most important key ingredients for successful processing. Surprisingly, the beam profile during the process is almost unknown until today. The state of the art in beam characterization comprises pre-processes applying different beam measurement devices which ensure a beam profile evaluation at one or a small number of fixed locations on the build area. To the knowledge of the author, there exist no technique to measure the beam profile in-situ during manufacturing at arbitrary locations on the build area.

This study presents a groundbreaking method for an in-situ measurement technique of the beam profile for electron beam powder bed fusion. The method exploits electron optical images of a sintered powder bed after preheating. After converting the image into the frequency space by a Fourier transformation, the beam profile is reconstructed. In this work we demonstrate the feasibility on a focused electron beam with an elliptical Gaussian intensity distribution. This real-time assessment capability, completed within seconds, marks a significant advancement in the field of electron beam powder bed fusion, promising to improve manufacturing outcomes through enhanced process optimization and beam profile monitoring.

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电子束粉末床熔合的原位电子束表征

电子束粉末床熔融是一种先进的增材制造技术，利用电子束逐层制造复杂的金属部件。众所周知，光束轮廓是成功加工的最重要的关键因素之一。令人惊讶的是，直到今天，这个过程中的光束轮廓几乎是未知的。光束表征的最新技术包括应用不同光束测量设备的预处理，这些设备确保在构建区域上的一个或少数固定位置进行光束轮廓评估。据作者所知，在制造过程中，没有技术可以在建筑区域的任意位置测量梁的轮廓。本研究提出了一种具有开创性的电子束粉末床熔合束轮廓的原位测量方法。该方法利用预热后烧结粉末床的电子光学图像。通过傅里叶变换将图像转换到频率空间后，重建光束轮廓。在这项工作中，我们证明了具有椭圆高斯强度分布的聚焦电子束的可行性。这种实时评估能力在几秒钟内完成，标志着电子束粉末床熔合领域的重大进步，有望通过增强的工艺优化和光束轮廓监测来改善制造结果。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Additive manufacturing Materials Science-General Materials Science

CiteScore

19.80

自引率

12.70%

发文量

648

审稿时长

35 days

期刊介绍： Additive Manufacturing stands as a peer-reviewed journal dedicated to delivering high-quality research papers and reviews in the field of additive manufacturing, serving both academia and industry leaders. The journal's objective is to recognize the innovative essence of additive manufacturing and its diverse applications, providing a comprehensive overview of current developments and future prospects. The transformative potential of additive manufacturing technologies in product design and manufacturing is poised to disrupt traditional approaches. In response to this paradigm shift, a distinctive and comprehensive publication outlet was essential. Additive Manufacturing fulfills this need, offering a platform for engineers, materials scientists, and practitioners across academia and various industries to document and share innovations in these evolving technologies.