Electron-beam freeform fabrication (EBF3) is an additive manufacturing process that builds near-net-shape parts. It requires far less raw material and finish machining than traditional manufacturing methods. EBF3 is done in a vacuum chamber where an electron beam is focused on a constantly feeding source of metal, which is melted and applied as called for by a three-dimensional layered drawing - one layer at a time - on top of a rotating metallic substrate until the part is complete.
The use of electron beam welding for additive manufacturing was first developed by Vivek Davee in 1995 as part of his PhD thesis at MIT.[1] The process was referred to as electron beam solid freeform fabrication (EBSFF). A team at NASA Langley Research Center (LaRC) led by Karen Taminger developed the process, calling it electron beam freeform fabrication (EBF3).[2][3] EBF3 is a NASA-patented additive manufacturing process designed to build near-net-shape parts requiring less raw material and finish machining than traditional manufacturing methods. EBF3 is a process by which NASA plans to build metal parts in zero-gravity environments; this layer-additive process uses an electron beam and a solid wire feedstock to fabricate metallic parts. Future astronauts stationed on the Moon or Mars may be able to employ EBF3 to produce replacement parts locally rather than relying on parts launched from Earth, possibly even mining feedstock from the surrounding soils. The aviation industry has the most potential for the procedure, say experts at the NASA LaRC, because significant progress should be made in reducing machining waste byproducts. Typically, an aircraft maker would start with a 6,000-pound block of titanium and use thousands of liters of cutting fluid to reduce it to a 300-pound item, leaving 5,700 pounds of material that needed to be recycled. According to Taminger, "With EBF3 you can build up the same part using only 350 pounds of titanium and machine away just 50 pounds to get the part into its final configuration. And the EBF3 process uses much less electricity to create the same part."[4]
Processedit
The operational concept of EBF3 is to build a near-net-shape metal part directly from a computer-aided design (CAD) file. Current computer-aided machining practices start with a CAD model and use a post-processor to write the machining instructions (G-code) defining the cutting tool paths needed to make the part. EBF3 uses a similar process, starting with a CAD model, numerically reducing it into layers, then using a post-processor to write the G-code defining the deposition path and process parameters for the EBF3 equipment.[5] It uses a focused electron beam in a vacuum environment to create a molten pool on a metallic substrate. The surface of the substrate translates the beam while the metal wire is fed into the molten pool. The deposit solidifies immediately after the electron beam has passed, having sufficient structural strength to support itself. The sequence is repeated in a layer-additive manner to produce a near-net-shape part needing only finish machining. The EBF3 process is scalable for components from fractions of an inch to tens of feet, limited mainly by the size of the vacuum chamber and the amount of wire feedstock available.[6]
Electron Beam Freeform Fabrication for Cost-Effective Near-Net Shape
From Nothing, Something: One Layer at a Time
Electron-Beam Free-Form Fabrication System
Device like ‘Star Trek’ replicator is in the works
December 20, 2023
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This article s use of external links may not follow Wikipedia s policies or guidelines Please improve this article by removing excessive or inappropriate external links and converting useful links where appropriate into footnote references October 2023 Learn how and when to remove this template message Electron beam freeform fabrication EBF3 is an additive manufacturing process that builds near net shape parts It requires far less raw material and finish machining than traditional manufacturing methods EBF3 is done in a vacuum chamber where an electron beam is focused on a constantly feeding source of metal which is melted and applied as called for by a three dimensional layered drawing one layer at a time on top of a rotating metallic substrate until the part is complete Contents 1 History 2 Process 3 See also 4 References 5 External linksHistory editThe use of electron beam welding for additive manufacturing was first developed by Vivek Davee in 1995 as part of his PhD thesis at MIT 1 The process was referred to as electron beam solid freeform fabrication EBSFF A team at NASA Langley Research Center LaRC led by Karen Taminger developed the process calling it electron beam freeform fabrication EBF3 2 3 EBF3 is a NASA patented additive manufacturing process designed to build near net shape parts requiring less raw material and finish machining than traditional manufacturing methods EBF3 is a process by which NASA plans to build metal parts in zero gravity environments this layer additive process uses an electron beam and a solid wire feedstock to fabricate metallic parts Future astronauts stationed on the Moon or Mars may be able to employ EBF3 to produce replacement parts locally rather than relying on parts launched from Earth possibly even mining feedstock from the surrounding soils The aviation industry has the most potential for the procedure say experts at the NASA LaRC because significant progress should be made in reducing machining waste byproducts Typically an aircraft maker would start with a 6 000 pound block of titanium and use thousands of liters of cutting fluid to reduce it to a 300 pound item leaving 5 700 pounds of material that needed to be recycled According to Taminger With EBF3 you can build up the same part using only 350 pounds of titanium and machine away just 50 pounds to get the part into its final configuration And the EBF3 process uses much less electricity to create the same part 4 Process editThe operational concept of EBF3 is to build a near net shape metal part directly from a computer aided design CAD file Current computer aided machining practices start with a CAD model and use a post processor to write the machining instructions G code defining the cutting tool paths needed to make the part EBF3 uses a similar process starting with a CAD model numerically reducing it into layers then using a post processor to write the G code defining the deposition path and process parameters for the EBF3 equipment 5 It uses a focused electron beam in a vacuum environment to create a molten pool on a metallic substrate The surface of the substrate translates the beam while the metal wire is fed into the molten pool The deposit solidifies immediately after the electron beam has passed having sufficient structural strength to support itself The sequence is repeated in a layer additive manner to produce a near net shape part needing only finish machining The EBF3 process is scalable for components from fractions of an inch to tens of feet limited mainly by the size of the vacuum chamber and the amount of wire feedstock available 6 See also editElectron beam additive manufacturingReferences edit Dave Vivek Ramesh 1995 Electron beam EB assisted materials fabrication Thesis thesis Massachusetts Institute of Technology hdl 1721 1 11505 Taminger Karen January 19 2023 Research Gate Karen Taminger Research Gate Karen Taminger Publications Retrieved January 19 2023 HQ Lillian Gipson NASA 2015 03 06 From Nothing Something One Layer at a Time NASA Retrieved 2023 01 20 Dave Vivek October 2008 Electron beam EB assisted materials fabrication PDF ntrs nasa gov Retrieved 2022 11 07 HQ Lillian Gipson NASA 2015 03 06 From Nothing Something One Layer at a Time NASA Retrieved 2022 11 07 Group SAE Media Portable Electron Beam Free Form Fabrication System www techbriefs com Retrieved 2022 11 07 External links editVideo EBF3 Electron Beam Free Form Fabrication Electron Beam Freeform Fabrication for Cost Effective Near Net Shape From Nothing Something One Layer at a Time Electron Beam Free Form Fabrication System Device like Star Trek replicator is in the works Retrieved from https en wikipedia org w index php title Electron beam freeform fabrication amp oldid 1178299740, wikipedia, wiki, book, books, library,
