Assignment -

Critical evaluation of electron beam and laser based additive layer manufacturing technologies.

Module Outcomes

D - Design

• To be able to assess sustainability issues and the environmental impact of component manufacture
• To be aware of design for manufacture issues

P - Engineering Practice

• To be able to research and appraise the latest developments associated with rapid manufacture and associated materials
• To appraise and apply materials investigation techniques in order to specify appropriate materials for specific component applications
• To be able to interpret and apply engineering knowledge associated with rapid manufactured and machined components within a case study based environment
• To be able to source information from data sheets, journals, and internet web-sites to select appropriate materials for component manufacture.

Assignment Introduction -

Despite the introduction of new ALM manufacturing technologies that claim to produce metallic components overnight through the use of powdered materials there are still limitations with regard to the quality and durability of parts made by these Additive Layer Manufacturing (ALM) processes.

Currently there are two distinct powder bed processes available for the manufacture of metal ALM parts, these being laser based technologies and electron beam technologies.  The components manufactured by these processes have very different characteristics and therefore applications. Both processes will manufacture titanium based components, however, the part quality and build capability is significantly different.  

Assignment -

Conduct an investigation into the field of electron beam and laser based powder bed production technologies and compare and contrast how these processes operate and produce titanium alloy components. 

Your report should consider metal melting rates, mode of material heating and melting, general difficulties and problems associated with the processes and the resulting quality of components made from the processes.

A case study approach is required as this will be beneficial in addressing the details of the technology and will allow full discussion through direct comparison of the processes considered.