Electron-optical in-situ crack monitoring during electron beam powder bed fusion of the Ni-Base superalloy CMSX-4

Bäreis, Johannes; Semjatov, Nick; Renner, Jakob; Ye, Jihui; Fu, Zongwen; Körner, Carolin

doi:10.1007/s40964-022-00357-9

Cited by 7 publications

(1 citation statement)

References 21 publications

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“…Технология электронно-лучевого аддитивного производства (ЭЛАП, от англ. Wire-feed electron-beam additive manufacturing, EBAM) активно используется для получения изделий из никелевых жаропрочных сплавов [9][10][11][12], интерметаллидных соединений, таких как TiAl [13][14][15], магнитомягких материалов на основе железа [16], алюминиевых сплавов [17,18], магниевых сплавов [19], а также бронз [20,21].…”

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Study of the properties of silicon bronze-based alloys printed using electron beam additive manufacturing technology

Filippov¹,

Khoroshko²,

Shamarin³

et al. 2023

Metal Working and Material Science

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Introduction. Additive technologies make it possible to curb material expenses by reducing allowances for the final dimensional machining of workpieces. For such expensive materials as copper and copper alloys, this method is considerably attractive from a perspective of increasing resource efficiency in production. The operational properties of the C65500 alloy manufactured using additive technologies have not been fully studied and require additional research. The aim of the work is to study the structural and phase state, mechanical and operational properties of C65500 bronze specimens printed using electron beam additive manufacturing technology. In the work, specimens made of C65500 wire with different heat input values are studied, some of which were subjected to thermal treatment and mechanical processing, as well as specimens, manufactured using multi-wire technology. The work uses such research methods as the study of corrosion resistance of bronze specimens using a potentiostat, confocal laser scanning microscopy, friction tests and X-ray phase analysis. Results and discussion. Processing of specimens by plastic deformation (compression) and subsequent annealing leads to the most serious structural changes. Based on X-ray phase analysis, it is found that higher silicon content is observed in the case of the addition of silumins to bronze. The study of mechanical properties shows that the specimens, printed using multi-wire technology, have the highest strength properties. During tribological testing, fluctuations in the value of the friction coefficient are revealed, due to the scheme of the experiment and the combined adhesive-oxidative mechanism of specimens’ wear. The addition of 10 wt.% aluminum filament to bronze in the additive manufacturing process is an effective means for increasing the resistance of the material to electrochemical corrosion and increasing its wear resistance.

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Study of the properties of silicon bronze-based alloys printed using electron beam additive manufacturing technology

Filippov¹,

Khoroshko²,

Shamarin³

et al. 2023

Metal Working and Material Science

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Machine learning-enabled real-time anomaly detection for electron beam powder bed fusion additive manufacturing

Cannizzaro,

Antonioni,

Ponzio

et al. 2024

J Intell Manuf

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Despite the many advantages and increasing adoption of Electron Beam Powder Bed Fusion (PBF-EB) additive manufacturing by industry, current PBF-EB systems remain largely unstable and prone to unpredictable anomalous behaviours. Additionally, although featuring in-situ process monitoring, PBF-EB systems show limited capabilities in terms of timely identification of process failures, which may result into considerable wastage of production time and materials. These aspects are commonly recognized as barriers for the industrial breakthrough of PBF-EB technologies. On top of these considerations, in our research we aim at introducing real-time anomaly detection capabilities into the PBF-EB process. To do so, we build our case-study on top of a Arcam EBM A2X system, one of the most diffused PBF-EB machines in industry, and make access to the most relevant variables made available by this machine during the layering process. Thus, seeking a proficient interpretation of such data, we introduce a deep learning autoencoder-based anomaly detection framework. We demonstrate that this framework is able not only to early identify anomalous patterns from such data in real-time during the process with a F1 score around 90%, but also to anticipate the failure of the current job by 6 h, on average, and in one case by almost 20 h. This avoids waste of production time and opens the way to a more controllable PBF-EB process.

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A review of the current state-of-the-art on in situ monitoring in electron beam powder bed fusion

Grasso,

Colosimo

2024

Prog Addit Manuf

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The industrial development of electron beam powder bed fusion (PBF-EB) is relatively younger and much more limited in terms of global widespread and revenues compared to laser powder bed fusion (PBF-L). Nevertheless, PBF-EB has been adopted in some of the most successful industrial case studies of metal AM, as it provides specific benefits and capabilities that make it a key enabling technology in a variety of industrial applications. Moreover, the recent years have seen a rapid evolution with new actors and new systems entering the market, together with a considerable increase of research and innovation programs. A field of major interest is the development and continuous improvement of in situ sensing and monitoring methods to anticipate the detection of defects, to predict the final quality of the part, and to rethink product qualification procedures. The technological features of the PBF-EB process have motivated the development of solutions that differ from the ones in PBF-L. Some of them have reached a good maturity level, being recently integrated into industrial machines, while others still deserve further research. This study explores the current state-of-the-art on in situ and in-line monitoring of the PBF-EB process, aiming to provide an up-to-date overview of the major differences with respect to PBF-L, currently available methods and their performances, as well as open issues, challenges to be tackled, and perspective for future research and industrial developments.

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Electron-optical in-situ crack monitoring during electron beam powder bed fusion of the Ni-Base superalloy CMSX-4

Cited by 7 publications

References 21 publications

Study of the properties of silicon bronze-based alloys printed using electron beam additive manufacturing technology

Study of the properties of silicon bronze-based alloys printed using electron beam additive manufacturing technology

Machine learning-enabled real-time anomaly detection for electron beam powder bed fusion additive manufacturing

A review of the current state-of-the-art on in situ monitoring in electron beam powder bed fusion

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