High-power E-PBF Processing of Refractory and Aerospace Alloys

The inertia-free beam control and high deflection speeds of electron beam powder bed fusion (E-PBF) enable unique spot melting strategies for processing challenging materials. Using a high-power electron gun (0-6 kW) with precise beam control, we demonstrate the processing of pure tungsten, copper, and Ti-6Al-4V through innovative scanning patterns. The vacuum environment ensures material purity, while the actively cooled build tank enables continuous high-power processing with optimal thermal management.

Process optimization for pure tungsten has achieved densities exceeding 99.9% without cracking, enabling critical applications including hypersonic leading edges, armor-piercing penetrators, and rocket nozzle components. The spot melting strategy enables precise control of energy input and cooling rates, resulting in controlled microstructure development. For copper applications requiring high thermal conductivity, the process achieves superior density while maintaining material purity, and Ti-6Al-4V processing demonstrates mechanical properties meeting or exceeding industry standards.

Material characterization reveals the relationship between spot melting parameters, microstructural evolution, and resultant properties. The research demonstrates how advanced E-PBF processing enables both superior material quality and processing efficiency for applications requiring exceptional thermal and mechanical performance in defense, energy, and medical sectors.