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Multi-material metallic structure fabrication using electron beam melting

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Abstract

The fabrication of multi-material structures using Ti–6Al–4V and copper was explored with the additive manufacturing (AM) technology of electron beam melting (EBM). A new method was developed that included multiple build sequences to accommodate both materials. The process was enabled by machining a start plate so that the parts built with the first material could be press fit into the plate, providing a flat surface on which the second material fabrication would occur. This method provided the ability to fabricate simple multiple metallic material components built in the Z and X directions [1]. Registration of the electron beam was performed manually resulting in slight misalignment for the shift of diameters of specimens built in the Z direction, and along the width and length for specimens built in the X direction. Microstructures observed and hardness values measured for copper and Ti–6Al–4V were different to those observed in normally fabricated EBM parts. These observations might be explained by the different processing conditions required for multi-material fabrication in contrast to the regular EBM process where parts are built in a single machine run. The hardness profiles for as-fabricated and HIPed multi-material parts depicted an increase in hardness for both materials close to the interface with values leveling off to those of single material EBM fabricated parts as measurements proceeded away from the interface. As the benefits of EBM processing are exploited, the method introduced in this research can have profound implications in many technological applications including metal extraction, energy production and for the repair of metallic components.

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Authors and Affiliations

  1. W. M. Keck Center for 3D Innovation, University of Texas at El Paso, El Paso, TX, USA

    Cesar A. Terrazas, Sara M. Gaytan, Emmanuel Rodriguez, David Espalin, Francisco Medina & Ryan B. Wicker

  2. Metallurgical and Materials Engineering Department, University of Texas at El Paso, El Paso, USA

    Lawrence E. Murr

Authors
  1. Cesar A. Terrazas
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  2. Sara M. Gaytan
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  3. Emmanuel Rodriguez
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  4. David Espalin
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  5. Lawrence E. Murr
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  6. Francisco Medina
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  7. Ryan B. Wicker
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Correspondence to Cesar A. Terrazas.

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Terrazas, C.A., Gaytan, S.M., Rodriguez, E. et al. Multi-material metallic structure fabrication using electron beam melting. Int J Adv Manuf Technol 71, 33–45 (2014). https://doi.org/10.1007/s00170-013-5449-0

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  • DOI: https://doi.org/10.1007/s00170-013-5449-0

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