Developing next-gen metal additive manufacturing technologies for 3D printing
The Indian Institute of Science (IISc) has launched a “Centre of Excellence in Additive Manufacturing (AM) for high-performance metallic alloys” called AM-CoE@IISc that will act as an R&D center for next-generation metal additive manufacturing technologies.
Now, the AM-CoE is operating on creating a Selective Electron Beam Melting (SEBM) powder bed additive manufacturing system. This technology is impressive in its capability to manage existing subjects related to thermal management and slowly build rate in the traditional powder bed fusion process. This project is financed by the Department of Heavy Industries (DHI), the Government of India, and Wipro3D, under the Capital Goods Scheme.
Electron beam metal 3D printing or additive manufacturing has across-the-board applications, particularly in organizing bio-medical metallic implants and the aerospace industry. The technologies required for constructing complex metallic objects are Selective Laser Melting (SLM) and Selective Electron Beam Melting (SEBM)-based powder bed processes.
Although SLM is used widely, it has several limitations, including low laser beam velocity (7 m/s), poor photon absorption by the metal powder, significant residual stress, and cracking of non-weldable alloys. The average build rates are 20 cc/hour with a single laser source. However, with the SEBM, the build rates can reach up to 80 cc/hour with a 3 kW single electron beam source.
The AM-CoE’s current prototype machine is based on the SEBM technology, which will increase the beam power density and velocity of the beam and provide improved vacuum levels and a high-temperature build environment with minimum temperature gradients. This machine will be capable of building metallic objects with higher build rates, objects that are complex, with minimum residual stresses, and crack-free non-weldable alloy materials. The project’s current focus is on the characterization of various superalloy materials using the prototype machine and on building complex components.
Apart from working on the SEBM technology and developing high-performance metallic alloy powders for biomedical implants and aerospace components, the AM-CoE will also conduct workshops and hands-on training for new users and AM service providers.
