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<p>Additive manufacturing (3D printing) of metals and alloys in powder bed fusion methods affords many advantages such as increased design freedom and reduced waste, but involves an intricate matrix of co-dependent parameters that have major effects on the produced part and its properties. Extensive studies are dedicated to refine validation and verification processes, improve repeatability, and detect imperfections. Developing tools for monitoring, controlling, and analyzing the increasingly widespread process of AM is thus an industry focus. The tools under development require thorough interdisciplinary research and understanding of the underlying mechanisms that govern a specific AM process. Arguably, the most crucial parameter is the temperature field that develops during the printing process, since the temperature regime strongly affects resulting microstructure, mechanical properties, and residual stresses of final parts. Using IR cameras for thermographic imaging is a promising method of measuring temperature regimes in-situ. However, such imaging usually requires expensive equipment, modification of the printer and arduous calibration. This study shows that it is possible to use a stock, built-in defect detection feature (LayerQam) on a regular Arcam Q20 Plus Electron Beam Melting machine in order to produce thermographic imaging of layers during a build process and calibrate the temperature versus recorded intensity without adding to or modifying the machine. A relatively simple and cost-effective calibration process that allows using acquired IR images to provide an insight into the thermal processes of a print job is introduced. Its applicability for different materials is demonstrated by applying the procedure to both 304L stainless steel and Ti6Al4V alloy. The proposed approach successfully calibrated intensity maps to temperature within practically acceptable accuracy limits. Thus, a novel method is suggested to help quantify the thermal history of printed parts. Its major innovation is in using a relatively simple approach in order to obtain a tailored calibration of temperature fields in a users’ machine that accounts for the differences in material, optical path, and other factors encountered in real-life systems.</p>

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Thermo-topographic analysis of electron beam additive manufacturing using stock Arcam Q20 plus

  • 期刊论文

  • 发表日期：

    2026年5月13日

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  • Yaron I. Ganor,
  • Eitan Tiferet,
  • Dor Braun,
  • Eran Landau,
  • Nahum Frage,
  • Gennady Ziskind

摘要

Additive manufacturing (3D printing) of metals and alloys in powder bed fusion methods affords many advantages such as increased design freedom and reduced waste, but involves an intricate matrix of co-dependent parameters that have major effects on the produced part and its properties. Extensive studies are dedicated to refine validation and verification processes, improve repeatability, and detect imperfections. Developing tools for monitoring, controlling, and analyzing the increasingly widespread process of AM is thus an industry focus. The tools under development require thorough interdisciplinary research and understanding of the underlying mechanisms that govern a specific AM process. Arguably, the most crucial parameter is the temperature field that develops during the printing process, since the temperature regime strongly affects resulting microstructure, mechanical properties, and residual stresses of final parts. Using IR cameras for thermographic imaging is a promising method of measuring temperature regimes in-situ. However, such imaging usually requires expensive equipment, modification of the printer and arduous calibration. This study shows that it is possible to use a stock, built-in defect detection feature (LayerQam) on a regular Arcam Q20 Plus Electron Beam Melting machine in order to produce thermographic imaging of layers during a build process and calibrate the temperature versus recorded intensity without adding to or modifying the machine. A relatively simple and cost-effective calibration process that allows using acquired IR images to provide an insight into the thermal processes of a print job is introduced. Its applicability for different materials is demonstrated by applying the procedure to both 304L stainless steel and Ti6Al4V alloy. The proposed approach successfully calibrated intensity maps to temperature within practically acceptable accuracy limits. Thus, a novel method is suggested to help quantify the thermal history of printed parts. Its major innovation is in using a relatively simple approach in order to obtain a tailored calibration of temperature fields in a users’ machine that accounts for the differences in material, optical path, and other factors encountered in real-life systems.