Investigation of a novel additive manufacturing process for copper alloys based on the non-vacuum electron beam Technology.

加法制造(AM)是一种制造过程，它提供了减少金属使用量的潜力，以产生制成品的几何形状。AM包含一个流程族，用于以分层方法直接从计算机辅助设计文件生产组件，从而允许创建复杂结构的3-D。目前，激光是粉末床熔融工艺或粉末或线材直接能量沉积最常用的能源，本项目的目的是研究一种利用送丝材料的大气电子束技术进行新型添加剂制造的工艺。为了利用非真空电子束的高功率和高功率密度，大型产品的线性化工艺是本项目的重点。能量转移的效率在很大程度上与材料类型无关。采用NVEB-AM工艺对海水条件下的铜合金进行了研究。这些示例性应用用作该过程的试验台。其他材料、工艺变化和后来的工业应用将从这个项目的结果中衍生出来。这导致了这个研究项目选择了使用送丝材料来生产大型、接近净形状的零件的方法。开发了NVEB AM工艺，利用工艺观察和材料科学研究来增强工艺理解和对所生产材料的表征。主要目标是实现大型组件的高构建速度。因此，该项目使用了全面的理论建模来确定工艺的局限性，并优化策略以实现高生产率。研究将由德国材料科学研究所(IW)和俄罗斯激光与焊接技术研究所(ILWT)共享。IW将主要集中于工艺和控制参数的实验研究以及材料的科学表征。ILWT将应用他们成功的粉末沉积模型来创建该过程的综合模型，以增强对过程的理解。它们还将提供工具，帮助根据材质属性和几何图形选择参数。两位参与者将共同验证模型，得出工艺控制的参数和边界，并为全面评估NVEB AM工艺及其适用性奠定基础。IW的实验调查将包括调查机器和工艺参数的影响，如行程速度、线速、钢丝位置、光束功率和工作距离，以实现现象学工艺描述。由于气体气氛对电子束和熔池动力学都有重要影响，这些研究将使用不同的保护气体导数进行，这些导数是束流功率、行进速度和线速与材料性质的函数依赖关系。

Additive manufacturing (AM) is an manufacturing process that offers the potential for reductions in the use of metal to generate geometric shapes for manufactured products. AM encompasses a process family for producing components directly from a computer aided design file in a layered approach allowing the 3-d creation of a complex structure. Currently, the laser is the most commonly used energy source for powder bed fusion process or powder- or wire-fed direct energy deposition.Aim of the project is the investigation of a novel additive manufacturing process using atmospheric electron beam technology using wire fed material. To utilize the high power and power density of the non-vacuum electron beam, a wire-based process for large products is focus for this project. The efficiency of the energy transfer is largely independent of material type. Copper alloys, which are relevant materials for the use in seawater conditions, are chosen to be investigated using the NVEB-AM process. These exemplary application serves as a test-bed for the process. Other materials, process variations and later industrial applications will be derived from the results of this project.This leads to the approach chosen for this research project using wire fed material to produce large, near net-shape parts. The NVEB AM process is developed, using process observation and material scientific investigation to enhance process understanding and characterize material produced. Main goal is to achieve a high build rate for large components. Due to this, thorough theoretical modelling is used within this project to identify limitations of the process and to optimise strategies to enable high production rates.The investigations will be shared among the Institute of Materials Science (IW) in Germany and the Institute of Laser and Welding Technologies (ILWT) in Russia. IW will mostly focus on experimental investigation of the process and the governing parameters as well as on scientific characterization of the materials. ILWT will apply their successful model for powder-based deposition to create a comprehensive model of the process for enhanced process understanding. They will also provide tools to help with parameter choice depending on material properties and geometry. Together, both participants will verify the model, derive parameters and boundaries for process control and generate the base for a comprehensive assessment of the NVEB AM process and its applicability.Experimental investigations at IW will encompass the investigation of influences of machine and process parameters such as travel speed, wire speed, wire positioning, beam power and working distance to enable a phenomenological process description. As the gas atmosphere is an important influence for both, electron beam and melt pool dynamics, these investigation will be conducted using different shielding gas derivat functional dependencies of beam power, travel speed and wire speed with properties of material.