Macroscopic simulation and experimental measurement of melt pool characteristics in selective electron beam melting of Ti-6Al-4V

  • Daniel RiedlbauerEmail author
  • Thorsten Scharowsky
  • Robert F. Singer
  • Paul Steinmann
  • Carolin Körner
  • Julia Mergheim
Open Access


Selective electron beam melting of Ti-6Al-4V is a promising additive manufacturing process to produce complex parts layer-by-layer additively. The quality and dimensional accuracy of the produced parts depend on various process parameters and their interactions. In the present contribution, the lifetime, width and depth of the pools of molten powder material are analyzed for different beam powers, scan speeds and line energies in experiments and simulations. In the experiments, thin-walled structures are built with an ARCAM AB A2 selective electron beam melting machine and for the simulations a thermal finite element simulation tool is used, which is developed by the authors to simulate the temperature distribution in the selective electron beam melting process. The experimental and numerical results are compared and a good agreement is observed. The lifetime of the melt pool increases linearly with the line energy, whereby the melt pool dimensions show a nonlinear relation with the line energy.


Additive manufacturing Selective electron beam melting Ti-6Al-4V Heat transfer simulation Melt pool characteristics 


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© The Author(s) 2016

Open AccessThis article is distributed under the terms of the Creative Commons Attribution 4.0 International License (, which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.

Authors and Affiliations

  • Daniel Riedlbauer
    • 1
    Email author
  • Thorsten Scharowsky
    • 2
  • Robert F. Singer
    • 2
  • Paul Steinmann
    • 1
  • Carolin Körner
    • 2
  • Julia Mergheim
    • 1
  1. 1.Chair of Applied MechanicsFriedrich-Alexander-Universität Erlangen-NürnbergErlangenGermany
  2. 2.Chair of Metals Science and TechnologyFriedrich-Alexander-Universität Erlangen-NürnbergErlangenGermany

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