EBAM® Process and AM Machines Overview

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Questions and Answers

What is a primary disadvantage of open-loop galvanometers compared to closed-loop systems?

Larger footprint

Lower accuracy (correct)

Increased complexity

Higher cost

Which of the following is a common application of wire-fed systems in additive manufacturing?

3D printing with thermoplastics

Laser engraving

Stereolithography

Metal additive manufacturing (correct)

What is one advantage of using laser powder bed fusion (LPBF) in additive manufacturing?

Ability to create complex geometries (correct)

Larger build sizes

Faster production speeds

Unlimited material options

In the context of positioning devices used in additive manufacturing, what is a critical role of these devices?

Precise movement and placement of the print head Signup and view all the answers

What distinguishes the equilibrium phase from the non-equilibrium phase during the solidification of metals in additive manufacturing?

Crystal structure formation Signup and view all the answers

Which type of nozzle is commonly used in the powder bed fusion process for efficient material delivery?

Slotted nozzle Signup and view all the answers

What is a potential drawback of using traditional manufacturing methods over additive manufacturing?

All of the above Signup and view all the answers

Which aspect of machine configuration is vital for effective additive manufacturing?

Dynamic feedback control Signup and view all the answers

Which statement is true regarding wire-fed additive manufacturing systems?

Contact force must be kept constant for part quality. Signup and view all the answers

What is one limitation of the galvanometer scanning system in laser powder bed fusion?

The size and shape of printed objects are restrained by the system's configuration. Signup and view all the answers

How does the coaxial wire-feed system impact part quality?

It enables the wire to be fed into the laser-generated melt pool. Signup and view all the answers

What role do positioning devices play in additive manufacturing?

They facilitate the delivery of the material and control heat sources. Signup and view all the answers

Which aspect does not affect the quality of parts produced in the wire-fed additive manufacturing process?

The complexity of shapes produced. Signup and view all the answers

What is a characteristic of the galvanometer system in terms of laser beam control?

It can perform continuous laser scanning along both x and y axes. Signup and view all the answers

Which statement is true about the size limitations of additive manufacturing machines?

Printing size is influenced by machine size and positioning of device elements. Signup and view all the answers

What is the importance of the precision position detector in a galvanometer motor system?

It is used for closed-loop servo control to adjust mirror angles. Signup and view all the answers

What is the primary benefit of using an oscillating tray in vibratory bed powder feeders?

To achieve better control of powder flow Signup and view all the answers

What is the feeding speed range for vibratory bed powder feeders?

8 to 2000 g/min Signup and view all the answers

Which factor does NOT impact the interactions of powder particles during laser direct energy deposition (LDED)?

Material of the deposition plate Signup and view all the answers

What configuration is used for delivering powder in a lateral nozzle?

From the side Signup and view all the answers

Which of the following is essential for achieving high-quality manufactured parts in AM processes?

Selecting the appropriate nozzle based on material and process Signup and view all the answers

What role does inert gas play in the functioning of a lateral nozzle during powder delivery?

To assist in preventing oxidation Signup and view all the answers

What is the accuracy level that vibratory bed powder feeders can achieve?

± 1% Signup and view all the answers

Which of the following does NOT affect the quality of the printed part during the LDED process?

Surface finish of the deposition plate Signup and view all the answers

Study Notes

EBAM® Process

Sciaky’s Electron Beam Additive Manufacturing (EBAM®) Process can use a lateral or coaxial wire feed system.
The coaxial wire-feed system allows the wire to be fed into the center of the laser-generated melt pool, improving part quality.
Ensuring constant contact force is crucial for high-quality AM parts.
This technology might struggle to create complex parts due to limitations in smooth surface creation and fixed contact force in mobile feeding mechanisms.

AM Machines

AM machines print parts for various applications.
The size of the machine and device element positioning limit the printing of large parts.
Workspace constraints limit the size and shape of printable objects.
CNC and robotic arms are used to handle material delivery systems and heat sources.
The positioning device needs to offer sufficient workspace, speed, and acceleration for part building.
Positioning devices are connected to a controller that regulates their movements, trajectories, speeds, and accelerations.

Laser Powder Bed Fusion (LPBF)

Galvanometer scanners perform x and y laser scanning in LPBF.
A galvo system incorporates a galvo motor, two mirrors controlled by this motor, and a "servo" driver board.
Multiple coils within a magnetic field form galvo DC motors.
When an electric current flows through a coil in a galvo motor, it generates a torque proportional to the current, deflecting the laser beam.
A precision position detector on the shaft measures the mirrors', angular position for closed-loop servo control.
Open-loop galvos are cheaper but less accurate than closed-loop galvos.

Powder Feeders and Delivery Nozzles

Vibratory bed powder feeders have an oscillating tray with various plates arranged at varying angles for better powder flow control.
Vibratory bed powder feeders can accurately feed diverse powders at speeds ranging from 8 to 2000 g/min.
The interactions between powder particles, the laser beam, melt pool, and unmelted surfaces during LDED (powder-fed AM) significantly influence the printed part's quality.
The nozzle type, angle between the powder delivery system and deposition plate, and powder stream diameter all impact these interactions.
The appropriate nozzle selection is crucial for high-quality parts, as it depends on the material and manufacturing process.
Delivery nozzles can have two configurations:
- Lateral
- Coaxial

Lateral Nozzles

In the AM process, powder is delivered from the side when a lateral nozzle is used, assisted by an inert gas that passes through the nozzle, preventing oxidation.

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Description

Explore the basics of Sciaky’s Electron Beam Additive Manufacturing (EBAM®) process and learn about the functionalities of AM machines. Understand how wire-feed systems and CNC devices impact part quality and workspace limitations in additive manufacturing. This quiz focuses on the technological aspects essential for effective production.