Electronic Prototype and Electron Beam Melting (EBM) and Prototyping
Electronic Prototype and Electron Beam Melting (EBM) and Prototyping
Electron Beam Melting or EBM is a great new alternative method, that
can be used instead of both rapid prototyping and manufacturing of
metal products. The method is especially useful to the aerospace
industry.
The technology is becoming very popular because it has the ability to
build dense parts that are similar to any wrought material. Besides,
the cost for manufacturing parts through this process is substantially
less as compared to the other additive fabrication or metal based
methods that are common employed. EBM has also opened the doors to
configurations for several new designs.
The technology is very useful as it can help produce parts using
titanium within hours as opposed to days. The technology also creates
low volume products, which are essential for the aerospace industry.
The time and the cost factors involved in creating titanium products
are major obstacles for the aerospace industry. However, with the help
of EBM, ready to install titanium parts can be created in an efficient
manner.
Working of Electron Beam Melting: Like the name suggests, the Electron
Beam Melting device consists of an electron beam that has the ability
to melt metal powder. The machine lays down layers of the powder metal
successively, after reading data from 3 - D CAD model. The parts of the
machines are computer controlled, and it builds the finished model by
laying one layer over another, of the metal.
The system consists of beam gun that emits the electrons. There is a
tungsten filament that releases a cloud of electron when it
incandesces. The electrons that are emitted pass through the gun at
around ½ the speed of light. The electron movement is organized and
directed with the help of a magnetic field within the system. The
magnetic field also acts like a lens and directs the beam in the
direction that is desired so that the powder can melt to create an
appropriate design. The second magnetic field deflects the beam at the
desired point on the target powder.
When the electrons hit the metal powder, the kinetic energy of the
electrons gets converted into thermal energy. As a result of which, the
temperature is raised above the melting point of the metal powder and
the powder liquefies.
In the Electron Beam Melting system, the electron gun remains
stationary while there are mechanical parts that move and thus deflect
the electron beam so that the metal can be build into a desired shape.
The complete process is carried out in a vacuum so as to avoid any kind
of energy loss, which may occur, if the electrons are allowed to
collide with gas or air molecules. The system is 95 % efficient when it
comes to energy consumption.
Besides, the melted product that is formed is in the pure form and thus
there is thermal treatment is not required on the product formed.
Another major advantage of using the machine is that it is capable of
creating strength to weight components. Besides, with the help of the
machine only one component can be created instead of the multi piece
components that need to be assembled later.
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