Electron Beam Additive Manufacturing

The fastest, most cost-effective additive manufacturing process for producing large metal parts

Concurrent Technologies Corporation (CTC) is partnering with Sciaky, Inc. to offer electron beam additive manufacturing (EBAM®), process development, and engineering services to our clients.

Sciaky’s EBAM is a one-of-a-kind metal additive manufacturing technology that delivers on key benefits such as parts made faster, less material waste, reduced machining time and shorter time-to-market. EBAM excels at producing large-scale, high-value metal parts. Large-scale forgings and castings can take many, many months to complete. EBAM, on the other hand, can produce high quality, large-scale metal structures, up to 19’ in length, made of titanium, tantalum, aluminum, steel, tungsten, niobium, stainless steel, and nickel-based alloys in a matter of days, with very little material waste.

Electron Beam Additive Manufacturing reduces the time and costs associated with traditional manufacturing (i.e. forgings and castings). And, compared to other metal additive manufacturing processes, EBAM has a faster deposition rate (by up to a factor of ten) and provides unrivaled scalability for part size and part quality.

Benefits of EBAM
  • Reduces material costs, lead times, and machining times (as much as 80%) vs. conventional manufacturing
  • The fastest, most cost-effective Additive Manufacturing process in the market for producing large metal parts
  • IRISS® (Interlayer Real-time Imaging & Sensing System) Closed-Loop Control Technology ensures process repeatability and traceability (real-time adaptive control)
  • The widest range of material options for large-scale metal applications
  • The Big Metal Experts: Sciaky offers the largest build envelope in the world for 3D printed metal parts
  • The widest range of commercially-available metal Additive Manufacturing systems (in terms of work envelope scalability)
  • EBAM’s exclusive dual wirefeed process can feed two different metal alloys into a single melt pool to create parts made of custom alloys; it also allows designers to vary alloy mixtures to produce graded parts; graded parts can also be produced by switching from thin wire (fine deposition) to thick wire (gross deposition) feedstock
  • EBAM works exceptionally well with refractory alloys and produces significantly less material waste (a big cost-savings advantage!) – Plus, wire feedstock is significantly less expensive than powder feedstock, it is easier to store, and it isn’t highly flammable like some powder feedstocks
  • With EBAM’s pure vacuum environment, the process doesn’t require the use of argon or any inert gas for part shielding
  • Start 3D printing parts in as little as 12 minutes; while EBAM pump down times can vary by chamber size and application, it is still, by far, the fastest metal AM process in the market when you consider EBAM’s industry-leading deposition rate

How does EBAM work
Starting with a 3D model from a CAD program, Sciaky’s electron beam (EB) gun deposits metal (via wire feedstock), layer by layer, until the part reaches near-net shape and is ready for finish machining. Sciaky’s IRISS® is a patented Closed-Loop Control that provides consistent part geometry, mechanical properties, microstructure, metal chemistry and more from the first part to the last. Gross deposition rates range from 7 to 20 lbs. (3.18 to 9.07 kg) of metal per hour, depending upon the selected material and part features. When it comes to producing large, high quality metal parts, no other metal additive manufacturing process in the world works faster–or is more cost-effective–than EBAM.

Plus, with an EBAM dual wirefeed system, you can combine two different metal alloys into a single melt pool, managed with independent program control, to create “custom alloy” parts or ingots. You also have the option to change the mixture ratio of the two materials, depending upon the features of the part that you are building, to create “graded” parts or structures. Furthermore, you can alternate between different wire gauges for finer deposition features (thin wire) and gross deposition features (thick wire). These unique benefits are exclusive to the EBAM dual wirefeed process and are not available with any other metal additive manufacturing process in the market.

Why Concurrent Technologies Corporation
Concurrent Technologies Corporation is an all-encompassing service provider for Additive  Manufacturing solutions. We offer complete process execution including reverse engineering, development of process parameters, powder and substrate characterization, surface profile preparation, material application, finish machining and inspection. We also provide services to evaluate, validate and qualify the repair through mechanical and physical property characterization. All processes are controlled in-house to ensure quality results.

Concurrent Technologies Corporation’s quality management system is certified to the ISO 9001:2015 and AS9100D:2016; CTC’s environmental management system is certified to 14001:2015.

Contact us for your EBAM solutions.

For more information, contact:

Ken Sabo
Senior Director

Phone 814-269-6899
Email additive_manufacturing@ctc.com

Airbus Rear Upper Spar Part
Pictured is a Sciaky EBAM titanium pylon structure which forms the main skeletal structure of an Airbus wing. Photo courtesy of Airbus.
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