EBWireAM - UK Electron Beam Additive Manufacturing Platform

Wire-based Additive Manufacturing (AM) is able to rapidly deposit a large volume of material,
followed by a final machining operation to reach the final dimensional tolerances for parts. This
fabrication method offers a considerable improvement in material usage for components that
are machined from solid - commonly known as buy-to-fly ratio for aerospace and space
industries. Existing wire-based AM systems used either ARC or laser as the heat input source,
but both of these approaches have a fundamental limitation in controlling the heat input; which
leads to distortion and residual stress in the final parts. An electron beam (EB) heat source do
not suffer from this problem as the beam can be manipulated at very high frequencies -- leading
to very precise heat input and avoiding residual stress fields.
Our project aims to develop a UK EB wire AM platform -- adapted from a best-in-class EB
welding system -- primarily targeting use in the aerospace, power and mining sectors for
'difficult to deposit' and high value Ni, Ti and Al based materials. High deposition rate, large
build volume EB AM has been developed to a rudimentary level, with a single commercial
system supplier capable of producing parts made by Sciaky in the US.
Demonstrator components will be fabricated to address the challenges of:
Achieving commercially viable build rates
Fabricating industrially relevant complex structures
Producing high integrity deposits (minimising the development of undesirable grain growth)
Meeting the industry standard mechanical property requirements
Minimising any distortion arising from the process
The market for the EB wire AM process appears to be particularly promising for expensive and
difficult to machine materials such as Nickel and Titanium -- which are commonly welded using
EB systems (in aerospace and automotive sectors). Initial cost analysis calculations suggest a
40% reduction in costs of EB wire AM over rough machining from solid for a simple titanium
aerospace component.
We envisage being able to develop and supply \>10 systems per annum on a commercial basis
by 2020-2022; all manufactured in the UK. This would represent a boost of \>£15m to the
partners in the project and help to secure more than 75 jobs.