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

增材制造（AM）是一种制造工艺，它提供了减少金属使用的潜力，以产生制造产品的几何形状。增材制造包括一个工艺家族，用于直接从计算机辅助设计文件中以分层方法生产组件，从而允许复杂结构的三维创建。目前，激光是粉末床熔合工艺或粉末或电线直接能量沉积最常用的能量来源。该项目的目的是研究一种使用大气电子束技术的新型增材制造工艺。为了利用非真空电子束的高功率和功率密度，本项目将重点研究大型产品的线基工艺。能量传递的效率在很大程度上与材料类型无关。选择铜合金作为海水条件下使用的相关材料，采用NVEB-AM工艺进行了研究。这些示例应用程序可作为流程的试验台。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。这导致了本研究项目选择的方法，使用丝喂材料来生产大型，接近净形状的零件。开发了NVEB AM工艺，利用工艺观察和材料科学研究来提高工艺理解和表征所生产的材料。主要目标是实现大型组件的高构建率。因此，在该项目中使用了全面的理论模型来确定工艺的局限性，并优化策略以实现高生产率。研究成果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）共同完成。IW将主要集中在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一个全面的过程模型，以增强对过程的理解。他们还将提供工具来帮助根据材料属性和几何形状选择参数。双方将共同验证模型，推导过程控制的参数和边界，并为NVEB AM过程及其适用性的综合评估提供基础。IW的实验调查将包括对机器和工艺参数的影响的调查，如行进速度、线材速度、线材定位、光束功率和工作距离，以实现现象过程描述。由于气体气氛对电子束和熔池动力学都有重要影响，因此这些研究将使用不同的保护气体衍生的束流功率、行进速度和导线速度与材料性能的函数依赖关系进行。

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.