Discover Wayland Additive’s innovative Melt Pool strategy for Metal AM at Formnext 2021


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Discover Wayland Additive’s innovative Melt Pool strategy for Metal AM at Formnext 2021

EBeam’s new AM powder bed fusion metal technology is a big step forward over existing PBF systems

Posted: Monday November 1st, 2021 – 12:00 PM

(Wayland Additive: Huddersfield, UK) – Wayland Additive will present its original and highly efficient metal additive manufacturing (AM) system, Calibur3, with the NeuBeam process, at Formnext 2021 to be held in Frankfurt, Germany from 16 to November 19. 2021. A key feature that attendees can discuss with the team is the proprietary merger strategy developed by Wayland.

The NeuBeam process offers a whole new approach to eBeam powder bed fusion (PBF) metal AM technology that represents a big step forward over existing PBF systems. The technology overcomes the tradeoffs most businesses face when using the AM PBF Metal Laser or eBeam, so design engineers can revisit applications that were previously thought to be troublesome or impossible and start new ones. development projects with a clearer view of the process and the possibilities that can now be achieved.

Neubeam effectively neutralizes the charge buildup generated by an electron beam. This provides greater flexibility than the PBF laser while overcoming the stability issues of the PBF eBeam. In addition, this means that the NeuBeam process allows metallurgical requirements to be matched to the requirements of the application rather than keeping the printing process within the narrow limits allowed by the process. These process capabilities, along with the greatly improved ease of process development, also open up the use of a much wider range of metallic materials.

There are many unique aspects to the NeuBeam process, with the new fusion strategy having a significant impact on the results, as well as the type and validity of parts that can be produced on Calibur3.

“Our new proprietary merge pool strategy uses the power and speed of an eBeam more efficiently,” says Peter Hansford, director of business development at Wayland Additive. “EBeams are characterized by their high power and high sweep speed, and at Wayland we have been working on how best to use that power and speed. Our system divides each layer of a part under construction into small areas and assigns a weld puddle to each area. Our fusion strategy is both energy efficient, and by fusing different zones in parallel, it enables higher productivity rates regardless of geometry.

“The power and beam speeds required using traditional fusion strategies are incredibly dependent on geometry. One common approach has been to dynamically alter the energy based on key geometry characteristics (overhangs, line lengths, end-of-line turning points) to maintain precise geometry and material quality. People using alternative eBeam technologies will be all too familiar with phrases like “turning point function”, “thickness function”, “speed function” and “current compensation function”, which are all set. through long experimentation. This makes the process complicated and unintuitive for the user, and it is extremely difficult to diagnose the precise cause of problems when they are not working for particular geometries. At Wayland, we have solved all of these issues with our new merger strategy.

See a video of Wayland’s proprietary merge pool strategy here.

“Other systems can print some the same parts as Calibur3, but only after many attempts, trial and error, and only with enormous process knowledge, which is a huge barrier to entry, ”says Will Richardson, CEO of Wayland. “Alternative eBeam systems are also inherently unstable due to the build-up of charges in the build chamber, which can lead to powder scattering or ‘smoke events’ which deform the current layer of build and therefore compromise the whole construction. Our new fusion strategy has many tangible advantages, including its high productivity (20-40% savings compared to traditional eBeam systems), better consistency across multiple types of geometries, lower investment and easier calibration by compared to multiple laser systems. . In addition, with the Calibur3 fusion strategy, there is more control over the thermal history and therefore the microstructure of the material. The NeuBeam fusion strategy also opens up the possibility of producing fully dense parts in difficult-to-process materials (such as refractory metals and highly reflective alloys), and of building large and bulky parts.

NeuBeam is a hot room process rather than a hot bed process. This effectively creates residual stress-free parts as the high temperatures are only applied to the part and not to the bed, ensuring free flow of the powder after fabrication (no sinter cake) and stress-free parts with a reduced energy consumption. Additionally, the process overcomes many limitations for manufacturing large components: no residual thermal stress, no gas cross-flow, and a much simpler powder removal process than existing eBeam systems. With Neubeam, there is no need for structural supports (or the use of EDM to remove them), nor specific build plates, which means that the time and money spent on post-processing is considerably. reduced. There are also shorter warm-up and cool-down times, which means improved productivity.

The Wayland team will be on hand to discuss the new fusion strategy integrated with the Calibur3 metal fabrication system at Formnext, and attendees can book meeting times with the team using the online meeting link here.

NeuBeam technology has been developed in-house from scratch by a team of physicists who have worked for many decades with electron beam technology and industrial systems in the semiconductor industry. Science, combined with extensive expertise and experience, has enabled Wayland Additive to develop a high performing and reliable system rather than emulating existing systems or adapting standard components and reusing them.

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