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Characterization and comparison of materials produced by Electron Beam Melting (EBM) of two different Ti-6Al-4V powder fractions
Uppsala University, Disciplinary Domain of Science and Technology, Technology, Department of Engineering Sciences, Applied Materials Sciences.
Uppsala University, Disciplinary Domain of Science and Technology, Technology, Department of Engineering Sciences, Applied Materials Sciences.
2013 (English)In: Journal of Materials Processing Technology, ISSN 0924-0136, E-ISSN 1873-4774, Vol. 213, no 12, 2109-2118 p.Article in journal (Refereed) Published
Abstract [en]

Electron Beam Melting (EBM) has been recognized as a revolutionary technique to produce mass-customized parts to near-net-shape from various metallic materials. The technique produces parts with unique geometries from a powder stock material and uses an electron beam to melt the powder layer-by-layer to fully solid structures. In this study we have investigated the use of two different Ti-6Al-4V powders of different size fractions in the EBM process; a larger 45-100 mu m powder, and a smaller 25-45 mu m powder. We have also investigated the effects of two build layer thicknesses, 70 mu m and 50 mu m. respectively. We hypothesize that the smaller powder has the potential to improve surface resolution of parts produced in the EBM process. The EBM as-built parts were investigated regarding surface and bulk chemistry, surface oxide thickness, macro- and microstructure, surface appearance and mechanical properties. We conclude from the results that both powders and both build layer thicknesses are feasible to use in the EBM process. The investigated material properties were not significantly affected by powder size or layer thickness within the studied range of process parameters. However, the surface appearance was found to be different for the samples made with the different powder sizes.

Place, publisher, year, edition, pages
2013. Vol. 213, no 12, 2109-2118 p.
Keyword [en]
Electron Beam Melting, Titanium alloy, Chemical properties, Surface analysis, Microstructure, Mechanical properties
National Category
Engineering and Technology
Research subject
Engineering Science with specialization in Materials Science
Identifiers
URN: urn:nbn:se:uu:diva-210166DOI: 10.1016/j.jmatprotec.2013.06.010ISI: 000325236200006OAI: oai:DiVA.org:uu-210166DiVA: diva2:661671
Available from: 2013-11-04 Created: 2013-11-04 Last updated: 2017-12-06Bibliographically approved
In thesis
1. Optimization of Electron Beam Melting for Production of Small Components in Biocompatible Titanium Grades
Open this publication in new window or tab >>Optimization of Electron Beam Melting for Production of Small Components in Biocompatible Titanium Grades
2015 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Additive manufacturing (AM), also called 3D-printing, are technologies where parts are formed from the bottom up by adding material layer-by-layer on top of each other. Electron Beam Melting (EBM) is an AM technique capable of manufacturing fully solid metallic parts, using a high-intensity electron beam to melt powder particles in layers to form finished components. Compared to conventional machining, EBM offers enhanced efficiency for production of customized and patient specific parts such as e.g. dental prosthetics. However, dental prosthetics are challenging to produce by EBM, as their small sizes mean that mechanical and surface properties may be altered as part sizes decreases.

The aim of this thesis is to gain new insights that could lead to optimization for production of small sized components in the EBM. The work is focused to understand the process-property relationships for small size components production.

To improve the surface resolution and part detailing, a smaller sized powder was used for production and compared to parts made with standard sized powder. The surface-, chemical and mechanical properties were evaluated for parts produced with both types of powders. The results indicate that the surface roughness may be influenced by powder and build layer thickness size, whereas the mechanical properties showed no influence of the layer-wise production. However, the mechanical properties are dependent on part size. The outermost surface of the parts consists of a surface oxide dominated by TiO2, formed as a result of reaction between the surface and residual gases in the EBM build chamber. The surface oxide thickness is comparable to that of a conventionally machined surface, but is dependent on build height.

This work concludes that the surface resolution and component detailing can be improved by various measures. Provided that proper process themes are used, the EBM manufactured material is homogenous with properties comparable to conventional produced titanium. It has also been shown that the material properties will be altered for small components. The results point towards different ways of optimizing manufacturing of dental prosthetics by EBM, which will make dental prosthetics available for an increased number of patients.

Place, publisher, year, edition, pages
Uppsala: Acta Universitatis Upsaliensis, 2015. 80 p.
Series
Digital Comprehensive Summaries of Uppsala Dissertations from the Faculty of Science and Technology, ISSN 1651-6214 ; 1206
Keyword
Additive Manufacturing, 3D-printing, Electron Beam Melting, Titanium alloys, Chemical properties, Mechanical properties, Surface properties, Additiv tillverkning, 3D-skrivare, Electron Beam Melting, Titan, Kemiska egenskaper, Mekaniska egenskaper, Ytegenskaper
National Category
Production Engineering, Human Work Science and Ergonomics Metallurgy and Metallic Materials Medical Materials
Research subject
Engineering Science with specialization in Materials Science
Identifiers
urn:nbn:se:uu:diva-236709 (URN)978-91-554-9110-9 (ISBN)
Public defence
2015-01-23, Polhemsalen, Ångströmlaboratoriet, Lägerhyddsvägen 1, Uppsala, 13:15 (English)
Opponent
Supervisors
Available from: 2014-12-17 Created: 2014-11-21 Last updated: 2015-02-03

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Karlsson, JoakimEngqvist, Håkan

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