Wire-Feed Electron Beam Additive Manufacturing: A Review

Osipovich, K. S.; Калашников, К. Н.; Чумаевский, А. В.; Gurianov, D. A.; Калашникова, Т. А.; Vorontsov, A. V.; Zykova, Anna; Utyaganova, V. R.; Panfilov, A. D.; Nikolaeva, Aleksandra; Dobrovolskii, Artem; Рубцов, В. Е.; Колубаев, Е. А.

doi:10.3390/met13020279

Cited by 21 publications

(17 citation statements)

References 169 publications

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“…Metal materials have lower reflectivities to electron beams than lasers, giving significant advantages of high energy density and high energy utilization. Electron beam additive manufacturing has the characteristics of high power and high radiation and needs to be carried out in a vacuum environment [ 51 , 52 ]. Thus, the equipment cost is high.…”

Section: Metal Additive Manufacturing Formation Processmentioning

confidence: 99%

Advances in Fatigue Performance of Metal Materials with Additive Manufacturing Based on Crystal Plasticity: A Comprehensive Review

Zhang,

Wang,

Wang

et al. 2024

Materials

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Using metal additive manufacturing processes can make up for traditional forging technologies when forming complex-shaped parts. At the same time, metal additive manufacturing has a fast forming speed and excellent manufacturing flexibility, so it is widely used in the aerospace industry and other fields. The fatigue strength of metal additive manufacturing is related to the microstructure of the epitaxially grown columnar grains and crystallographic texture. The crystal plasticity finite element method is widely used in the numerical simulation of the microstructure and macro-mechanical response of materials, which provides a strengthening and toughening treatment and can reveal the inner rules of material deformation. This paper briefly introduces common metal additive manufacturing processes. In terms of additive manufacturing fatigue, crystal plasticity simulations are summarized and discussed with regard to several important influencing factors, such as the microstructure, defects, surface quality, and residual stress.

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Section: Metal Additive Manufacturing Formation Processmentioning

confidence: 99%

Advances in Fatigue Performance of Metal Materials with Additive Manufacturing Based on Crystal Plasticity: A Comprehensive Review

Zhang,

Wang,

Wang

et al. 2024

Materials

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“…При решении задач повышения экономической эффективности аддитивного производства, например, повышение производительности процесса печати за счет применения проволоки сопряжено со сложностями управления термическими режимами. Это значит, что и сплав формируется с особым структурно-фазовым состоянием [28,29]. Как показывает анализ литературы, посвященной титановым сплавам, сформировавшимся в условиях АТ, данные о модуле упругости получались при обработке кривых деформации при растяжении или сжатии либо методами наноиндентирования [29] и в меньшей степени -с применением ультразвука [30].…”

Section: Introductionunclassified

“…Это значит, что и сплав формируется с особым структурно-фазовым состоянием [28,29]. Как показывает анализ литературы, посвященной титановым сплавам, сформировавшимся в условиях АТ, данные о модуле упругости получались при обработке кривых деформации при растяжении или сжатии либо методами наноиндентирования [29] и в меньшей степени -с применением ультразвука [30]. В то же время в случае исследования сплавов сложного фазового и структурного состояния предлагается использовать одновременно несколько методов для измерения модуля упругости [31].…”

Section: Introductionunclassified

Elastic modulus and hardness of Ti alloy obtained by wire-feed electron-beam additive manufacturing

Klimenov,

Kolubaev,

Han

et al. 2023

Metal Working and Material Science

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Introduction. The development and application of additive manufacturing depends on many factors, including the printing process performance and buy-to-fly ratio. Wire-feed electron-beam additive manufacturing (EBAM) is attracting more and more attention from research teams. Moreover, the use of electron beams is the most effective and competitive for additive manufacturing of parts from alloys possessing high oxidation characteristics, e.g., titanium, stainless steels, since selective laser melting occurs in vacuum. Welding titanium wire VT6sv is the most preferable choice due to its availability and a wide range of thickness. This alloy, however, has fewer alloying elements than VT6 (Ti–6Al–4V) alloys. The high performance of wire-feed 3D printing and the VT6sv alloy composition affect the structure, phase composition, and properties of the fabricated alloy. As is known, the elastic modulus and hardness of alloys are important parameters, which can be measured rapidly also using non-destructive testing. The purpose of this work is to study the application of different approaches to measuring the elastic modulus and hardness of products obtained by wire-feed EBAM using the equipment of the Institute of Strength Physics and Materials Science SB RAS. Research methods. The structure of VT6sv titanium alloys fabricated by 3D printing and VT1-0 (Grade 2), VT6 (Ti–6Al–4V) alloys, was investigated by different methods such as metallography, ultrasonic gauging, instrumented indentation technique, macro- and micro-indentation, indentation hardness testing. Results and Discussion. Titanium alloy fabricated from VT6sv titanium wire under different thermal conditions has a typical columnar structure throughout the forging height. The structure formation determines the elastic modulus and hardness at various points of the forging. It is found that the elastic modulus is higher than that of as-delivered Ti–6Al–4V alloys, while the hardness is lower. Micro-indentation shows lower values of the elastic modulus than macro-indentation, which approach to values obtained by ultrasonic gauging and in other works. Different values of the elastic modulus at different points of the 3D printed forging indicate its sensitivity to the structure and phase composition of the material and demonstrate capabilities of measuring techniques used in this work.

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“…The essence of the method is the sequential deposition of wire material layer by layer on a cooled substrate. The filament deposition is performed by electron beam melting in a vacuum chamber, while the filament is fed into the melting zone by wire feeders [37][38][39][40][41]. A feature of the process is the simultaneous feeding of two wires into the melt zone, resulting in the local alloying of a model product with the formation of a more complex multiphase structure [42,43].…”

Section: Introductionmentioning

confidence: 99%

Al–Al3Ni In Situ Composite Formation by Wire-Feed Electron-Beam Additive Manufacturing

et al. 2023

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The regularities of microstructure formation in samples of multiphase composites obtained by additive electron beam manufacturing on the basis of aluminum alloy ER4043 and nickel superalloy Udimet-500 have been studied. The results of the structure study show that a multicomponent structure is formed in the samples with the presence of Cr23C6 carbides, solid solutions based on aluminum -Al or silicon -Si, eutectics along the boundaries of dendrites, intermetallic phases Al3Ni, AlNi3, Al75Co22Ni3, and Al5Co, as well as carbides of complex composition AlCCr, Al8SiC7, of a different morphology. The formation of a number of intermetallic phases present in local areas of the samples was also distinguished. A large amount of solid phases leads to the formation of a material with high hardness and low ductility. The fracture of composite specimens under tension and compression is brittle, without revealing the stage of plastic flow. Tensile strength values are significantly reduced from the initial 142–164 MPa to 55–123 MPa. In compression, the tensile strength values increase to 490–570 MPa and 905–1200 MPa with the introduction of 5% and 10% nickel superalloy, respectively. An increase in the hardness and compressive strength of the surface layers results in an increase in the wear resistance of the specimens and a decrease in the coefficient of friction.

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Wire-Feed Electron Beam Additive Manufacturing: A Review

Cited by 21 publications

References 169 publications

Advances in Fatigue Performance of Metal Materials with Additive Manufacturing Based on Crystal Plasticity: A Comprehensive Review

Advances in Fatigue Performance of Metal Materials with Additive Manufacturing Based on Crystal Plasticity: A Comprehensive Review

Elastic modulus and hardness of Ti alloy obtained by wire-feed electron-beam additive manufacturing

Al–Al3Ni In Situ Composite Formation by Wire-Feed Electron-Beam Additive Manufacturing

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