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Electron beam melting (EBM) is a direct‐metal freeform fabrication technique in which a 4 kW electron beam is used to melt metal powder in a layer‐wise fashion. As this process is relatively new, there have not yet been any independently published studies on the H13 steel microstructural properties. This paper describes the EBM process and presents results of microstructural analyses on H13 tool steel processed via EBM.

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Titanium aluminide (TiAl) is an intermetallic compound possessing excellent high-temperature performance while having significantly lower density than nickel-based superalloys. This paper presents preliminary results of experiments aimed at processing TiAl via the electron beam melting (EBM) process. Two processing routes are explored. The first uses prealloyed powder, whereas the second explores controlled reaction synthesis. Issues such as processing parameters, vaporization of alloying elements, microstructure, and properties are discussed.