Electron beam near-net-shape processing using wire feed

Three-dimensional (3D) electron beam (EB) deposition processing takes place by introducing metal feed-stock into a molten pool that is created and sustained using a focus-controlled EB in a high vacuum environment. A majority of the EBDM development work has been performed on aluminum and titanium alloys and a variety of weldable alloys can be processed using the EBDM processes. The EBDM process offers the potential for improved performance through control of microstructures and compositions at a much finer scale than parts machined from thick products. As the EB deposition processes tend to operate continuously in transient rather than steady-state thermodynamic conditions, maintaining consistent output parameters requires real-time monitoring and adjustments to one or more of the input parameters. Certification efforts are currently underway to enable application of EB deposition parts to enter into service trials for the aerospace industry for structural aircraft components, and in the medical industry custom-designed medical implants.