Electronic Prototype and Electron Beam Melting Information
and Definition for this alternative to rapid prototyping.
Electron Beam Melting or EBM is a great new alternative
method, that can be used instead of both rapid prototyping and manufacturing of
metal products. The method is especially useful to the aerospace industry.
The technology is becoming very popular because it has the
ability to build dense parts that are similar to any wrought material. Besides,
the cost for manufacturing parts through this process is substantially less as
compared to the other additive fabrication or metal based methods that are
common employed. EBM has also opened the doors to configurations for several
new designs.
The technology is very useful as it can help produce parts
using titanium within hours as opposed to days. The technology also creates low
volume products, which are essential for the aerospace industry. The time and
the cost factors involved in creating titanium products are major obstacles for
the aerospace industry. However, with the help of EBM, ready to install
titanium parts can be created in an efficient manner.
Working of Electron Beam Melting: Like the
name suggests, the Electron Beam Melting device consists of an electron beam
that has the ability to melt metal powder. The machine lays down layers of the
powder metal successively, after reading data from 3 ? D CAD model. The parts
of the machines are computer controlled, and it builds the finished model by
laying one layer over another, of the metal.
The system consists of beam gun that emits the electrons.
There is a tungsten filament that releases a cloud of electron when it
incandesces. The electrons that are emitted pass through the gun at around ½
the speed of light. The electron movement is organized and directed with the
help of a magnetic field within the system. The magnetic field also acts like a
lens and directs the beam in the direction that is desired so that the powder
can melt to create an appropriate design. The second magnetic field deflects
the beam at the desired point on the target powder.
When the electrons hit the metal powder, the kinetic energy
of the electrons gets converted into thermal energy. As a result of which, the
temperature is raised above the melting point of the metal powder and the
powder liquefies.
In the Electron Beam Melting system, the electron gun
remains stationary while there are mechanical parts that move and thus deflect
the electron beam so that the metal can be build into a desired shape.
The complete process is carried out in a vacuum so as to
avoid any kind of energy loss, which may occur, if the electrons are allowed to
collide with gas or air molecules. The system is 95 % efficient when it comes
to energy consumption.
Besides, the melted product that is formed is in the pure
form and thus there is thermal treatment is not required on the product formed.
Another major advantage of using the machine is that it is capable of creating
strength to weight components. Besides , with the help of the machine only one
component can be created instead of the multi piece components that need to be
assembled later.
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Tags: aerospace industry, cad model, doors, ebm, electron beam, electron movement, electronic prototype, electrons, finished model, magnetic field, obstacles, rapid prototyping, reading data, speed of light, titanium products, tungsten filament, volume products
