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Electron Beam Melting Materials for Extreme Environments

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Electron beam melting (EBM) is a well-established technology especially within the highly regulated aerospace and medical industries, to produce parts out of high-performance materials such as titanium, titanium aluminides and even pure copper. 

Compared to other additive technologies, the hot EBM process leads to a low level of remaining residual stresses and prevent parts from warpage. 

The ability to use the electron beam for heating and melting is the enabler to work with hard-to-process and non-weldable materials for application in extreme environments. Thus, high-temperature processing, fast beam deflection and the controlled vacuum environment offers optimal conditions for efficient processing of high-performance materials like titanium with EBM. 

However, the EBM process is not limited to these materials. GE Additive is continuously working on developing new EBM materials to meet our customer needs now and in the future:

  • Alloy247, a non-weldable high-temperature Ni-based Superalloy material for applications in turbine engines.
  • Highly alloyed Cr - Mo - V – W cold work tool steels showing a carbon content C >1,0 wt.% achieving a Hardness > 70 HRC for tooling application.
  • WC-Ni MMC for ultra-high wear resistance application within Oil and Gas industries.

In this presentation, we demonstrate how EBM can enable a successful and defect-free processing of the three materials and present corresponding mechanical and microstructural properties. 

Learning Objectives:

  • Understand the advantages of EBM technology.
  • Understand the advantages of the descried alloys.
  • Describe the way from material development to industrialization.