Surface Roughness Characterisation and Analysis of the Electron Beam Melting (EBM) Process

Area of Science:

• Additive Manufacturing
• Materials Science
• Surface Engineering

Background:

• Electron Beam Melting (EBM) is a key metal powder bed fusion (PBF) process utilized in mass production.
• Surface roughness is a significant limitation in as-built EBM parts, impacting their performance and application.
• Understanding factors influencing surface roughness is crucial for optimizing EBM processes.

Purpose of the Study:

• To investigate the impact of surface orientation and slope on surface roughness in EBM.
• To analyze machine repeatability by assessing roughness at different build positions.
• To identify process factors affecting surface morphology in EBM.

Main Methods:

• Design and fabrication of a specific artifact using an Arcam A2X machine with Ti6Al4V powder.
• Measurement of surface roughness on upward and downward surfaces at various slopes.
• Application of descriptive and inferential statistical methods to analyze process effects.

Main Results:

• Significant differences in surface roughness were observed between upward and downward surfaces.
• Upward surfaces exhibited lower roughness compared to downward surfaces.
• The slope angle linearly influenced the roughness of upward surfaces, while heat distribution was critical for downward surface roughness.

Conclusions:

• Surface orientation is a critical factor influencing surface roughness in EBM.
• The findings provide insights into controlling surface quality in EBM mass production.
• Further research into heat distribution effects can lead to improved EBM surface finish.