Maintaining Consistent Conditions over a Wide Range of Material Deposition Rates in Beam - Based Additive Manufacturing :

109 2:50 PM Maintaining Consistent Conditions over a Wide Range of Material Deposition Rates in Beam-Based Additive Manufacturing: Jack Beuth1; Shane Esola1; Raymond Walker2; 1Carnegie Mellon University; 2Keystone Synergistic Enterprises Signifi cant advances have been made in the development of laser and electron beam-based freeform fabrication processes using powder injection, powder bed or wire feed systems for material delivery. Electron beam-based deposition is currently receiving serious consideration for additive manufacturing and repair applications in the aerospace industry. To be successful, these processes must work over a wide range of material deposition rates to combine affordability (requiring high deposition rates) with the ability to precisely deposit fi ne geometries (requiring low deposition rates). The goal of this modeling research is to identify paths through processing space yielding consistent melt pool sizes independent of material deposition rate, ultimately yielding rules of thumb useable by processing engineers. Process variables to be controlled are beam power and translational speed.