Improved Resolution of Porous, Lightweight Structures In Ti6Al4V Direct Manufactured with Electron Beam Melting

Electron Beam Melting (EBM) is a technology for Additive Manufacturing of metal parts. The parts are produced in a vacuum chamber by additive consolidation of thin layers of metal powder. EBM opens up new degrees of freedom in the design of complex 3D geometries. With its production-like environment it delivers full traceability from ingot to the final part, and complies with the applicable industry standards for aerospace and medical applications. The process is particularly attractive for titanium and its alloys. EBM is used for series production of orthopedic implants in Ti6Al4V since 2007, and pre-production of low pressure turbine blades in γ-TiAl since 2010.

The new MultiBeam^TM functionality together with finer powder and thinner layers enables higher resolution and more fine-meshed structures than before. The aim of the ongoing study is to be at par or better than any available Additive Manufacturing method for producing high-resolution lightweight structures. We will report the first results of this new “high-resolution” EBM process, including basic material properties and a SEM investigation of the porous structures.