Electron beam sintering (EBS) process for Ultra-High Temperature Ceramics (UHTCs) and the comparison with traditional UHTC sintering and metal Electron Beam Melting (EBM) processes

Ultra-high temperature ceramics (UHTCs) are refractory materials with unusual properties making them strong contenders for applications involving adverse and chemically aggressive environments. This paper presents an effort to process UHTCs using additive manufacturing method, specifically Electron Beam Sintering (EBS) - adoption of the powder-bed fusion (PBF) process. Such a shows that processing consolidation phenomenon different from what is observed in traditional sintering Melting (EBM) typical metals or alloys. In this article, EBS studied. The differences between two aforementioned methods analyzed. scientific hypotheses have been backed by experimental results on ZrB2 – 30 vol% ZrSi2 UHTC mixture electron beam via Liquid Phase (LPS) theory. Efforts develop conditions fabricate dense defect-free components explored help finite element (FE) simulations. Characterization processed samples Scanning Microscopy (SEM) coupled Energy Dispersive X-ray Spectroscopy (EDS) Diffraction (XRD) revealed unique needle-like patterned grains matrix. Our findings demonstrate feasibility produce layers coatings, potential three-dimensional, as well complex-shaped applications.