Charge-Neutral Electron Beam Powder Bed Fusion of Niobium Alloys for Aerospace Applications

Electron beam powder bed fusion (EB-PBF) additive manufacturing is an appealing option for producing parts using challenging alloys. Since EB-PBF takes place under a hard vacuum the process is inherently clean and repeatable. Challenges associated with electrical charging of the powder bed have been overcome by introducing a small amount of positively charge ions into the chamber, dramatically reducing the odds of “smoking” the powder and increasing the recyclability and ease of machine turnover. This work presents an overview of using charge-neutral EB-PBF to print C103 (Nb-10Hf-1Ti) and a detailed characterization of the printed material. The material microstructure, surface roughness, and geometric accuracy for several key features of interest will be presented. The results show that while EB-PBF is a highly promising method for producing near net-shape components, careful consideration of the material structure and operating environment must be made during the design and production process.

Jesse G. Callanan, PhD, is an Applications Engineer in the Additive Manufacturing Group at EWI located in Buffalo, NY. He specializes in powder-based additive manufacturing methods including powder bed fusion and blown powder deposition with both laser and electron beam energy sources. Jesse received his PhD in Aerospace Engineering from the University at Buffalo in 2022 with a research focus on multi-physics vibration control and structural dynamics. Prior to joining EWI he was a postdoc and staff scientist at Los Alamos National Laboratory, working on high strain-rate strength of additive materials and novel alloys.