Electron Beam Melting

Powder Bed Fusion (PBF) is the cornerstone of our part-to-print manufacturing success. The process uses thermal energy to selectively fuse defined regions of a powder bed. CalRAM uses Electron Beam Powder Bed Fusion (ePBF) and Laser Powder Bed Fusion (lPBF) technologies to process a full spectrum of materials — everything from lightweight metals to super alloys. More materials mean more possibilities.

ePBF takes 3D CAD files and converts them into thin, two-dimensional slices. Depending upon its requirements, the part can be net-shape or near-net shape. If finishing is required, machine or grind stock can be easily added to the model.

Beam position, spot diameter, and power instructions are generated for each layer, which is then “printed” by moving the electron beam along the surface of the powder bed. After completing a layer, the build tank is lowered, fresh powder is raked over the work surface, and the process continues until the component is complete.

Because ePBF requires a hard vacuum to prevent scattering of the electron beam, it frees EBM-fabricated metals of tramp contaminants. The high temperatures (700 to 1000°C) used in the powder bed foster material consolidation, which leads to stress-free parts that retain their shape upon cooling to room temperature.

Materials:

  • Ti 6AI-4V
  • Ti 6Al-4V ELI
  • Cobalt Chrome ASTM F75
  • Alloy