Electron Beam Freeform Fabrication
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Electron Beam Freeform Fabrication
Electron-beam freeform fabrication (EBF3) is an additive manufacturing process that builds near-net-shape parts. It requires far less raw material and finish machining than traditional manufacturing methods. EBF3 is done in a vacuum chamber where an electron beam is focused on a constantly feeding source of metal, which is melted and applied as called for by a three-dimensional layered drawing - one layer at a time - on top of a rotating metallic substrate until the part is complete. History The use of electron beam welding for additive manufacturing was first developed by Vivek Davee in 1995 as part of his PhD thesis at MIT. The process was referred to as electron beam solid freeform fabrication (EBSFF). A team at NASA Langley Research Center (LaRC) led by Karen Taminger developed the process, calling it electron beam freeform fabrication (EBF3). EBF3 is a NASA-patented additive manufacturing process designed to build near-net-shape parts requiring less raw material and finis ...
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NASA EBF3 2007 Test
The National Aeronautics and Space Administration (NASA ) is an independent agency of the US federal government responsible for the civil space program, aeronautics research, and space research. NASA was established in 1958, succeeding the National Advisory Committee for Aeronautics (NACA), to give the U.S. space development effort a distinctly civilian orientation, emphasizing peaceful applications in space science. NASA has since led most American space exploration, including Project Mercury, Project Gemini, the 1968-1972 Apollo Moon landing missions, the Skylab space station, and the Space Shuttle. NASA supports the International Space Station and oversees the development of the Orion spacecraft and the Space Launch System for the crewed lunar Artemis program, Commercial Crew spacecraft, and the planned Lunar Gateway space station. The agency is also responsible for the Launch Services Program, which provides oversight of launch operations and countdown management f ...
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Mars
Mars is the fourth planet from the Sun and the second-smallest planet in the Solar System, only being larger than Mercury (planet), Mercury. In the English language, Mars is named for the Mars (mythology), Roman god of war. Mars is a terrestrial planet with a thin atmosphere (less than 1% that of Earth's), and has a crust primarily composed of elements similar to Earth's crust, as well as a core made of iron and nickel. Mars has surface features such as impact craters, valleys, dunes and polar ice caps. It has two small and irregularly shaped moons, Phobos (moon), Phobos and Deimos (moon), Deimos. Some of the most notable surface features on Mars include Olympus Mons, the largest volcano and List of tallest mountains in the Solar System, highest known mountain in the Solar System and Valles Marineris, one of the largest canyons in the Solar System. The North Polar Basin (Mars), Borealis basin in the Northern Hemisphere covers approximately 40% of the planet and may be a la ...
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3D Printing Processes
A variety of processes, equipment, and materials are used in the production of a three-dimensional object via additive manufacturing. 3D printing is also known as additive manufacturing, therefore the numerous available 3D printing process tend to be additive in nature with a few key differences in the technologies and the materials used in this process. Some of the different types of physical transformations which are used in 3D printing include melt extrusion, light polymerization, continuous liquid interface production and sintering. Types of 3D printing processes There are many different 3D printing processes, that can be grouped into seven categories: * Vat photopolymerization * Material jetting * Binder jetting * Powder bed fusion * Material extrusion * Directed energy deposition * Sheet lamination Each process and piece of equipment has pros and cons associated with it. These usually involve aspects such as speed, costs, versatility with respect to feedstock ma ...
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NASA Programs
This is a list of NASA missions, both crewed and robotic, since the establishment of NASA in 1958. There are over 80 currently active science missions. X-Plane program Since 1945, NACA (NASA's predecessor) and, since 1958, NASA have conducted the X-Plane Program. The program was originally intended to create a family of experimental aircraft not intended for production beyond the limited number of each design built solely for flight research. The first X-Plane, the Bell X-1, was the first rocket-powered airplane to break the sound barrier on October 14, 1947. X-Planes have set numerous milestones since then, both crewed and unpiloted. Human spaceflight NASA has successfully launched 166 crewed flights. Three have ended in failure, causing the deaths of seventeen crewmembers in total: Apollo 1 (which never launched) killed three crew members in 1967, STS-51-L ( the ''Challenger'' disaster) killed seven in 1986, and STS-107 ( the ''Columbia'' disaster) killed seven more ...
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Electron Beams In Manufacturing
The electron ( or ) is a subatomic particle with a negative one elementary electric charge. Electrons belong to the first generation of the lepton particle family, and are generally thought to be elementary particles because they have no known components or substructure. The electron's mass is approximately 1/1836 that of the proton. Quantum mechanical properties of the electron include an intrinsic angular momentum ( spin) of a half-integer value, expressed in units of the reduced Planck constant, . Being fermions, no two electrons can occupy the same quantum state, in accordance with the Pauli exclusion principle. Like all elementary particles, electrons exhibit properties of both particles and waves: They can collide with other particles and can be diffracted like light. The wave properties of electrons are easier to observe with experiments than those of other particles like neutrons and protons because electrons have a lower mass and hence a longer de Broglie wavel ...
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Electron-beam Additive Manufacturing
Electron-beam additive manufacturing, or electron-beam melting (EBM) is a type of additive manufacturing, or 3D printing, for metal parts. The raw material (metal powder or wire) is placed under a vacuum and fused together from heating by an electron beam. This technique is distinct from selective laser sintering as the raw material fuses having completely melted. Metal powder-based systems Metal powders can be consolidated into a solid mass using an electron beam as the heat source. Parts are manufactured by melting metal powder, layer by layer, with an electron beam in a high vacuum. This powder bed method produces fully dense metal parts directly from metal powder with characteristics of the target material. The EBM machine reads data from a 3D CAD model and lays down successive layers of powdered material. These layers are melted together utilizing a computer-controlled electron beam. In this way it builds up the parts. The process takes place under vacuum, which makes it ...
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Computer-aided Design
Computer-aided design (CAD) is the use of computers (or ) to aid in the creation, modification, analysis, or optimization of a design. This software is used to increase the productivity of the designer, improve the quality of design, improve communications through documentation, and to create a database for manufacturing. Designs made through CAD software are helpful in protecting products and inventions when used in patent applications. CAD output is often in the form of electronic files for print, machining, or other manufacturing operations. The terms computer-aided drafting (CAD) and computer aided design and drafting (CADD) are also used. Its use in designing electronic systems is known as '' electronic design automation'' (''EDA''). In mechanical design it is known as ''mechanical design automation'' (''MDA''), which includes the process of creating a technical drawing with the use of computer software. CAD software for mechanical design uses either vector-based graphics ...
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Moon
The Moon is Earth's only natural satellite. It is the fifth largest satellite in the Solar System and the largest and most massive relative to its parent planet, with a diameter about one-quarter that of Earth (comparable to the width of Australia). The Moon is a planetary-mass object with a differentiated rocky body, making it a satellite planet under the geophysical definitions of the term and larger than all known dwarf planets of the Solar System. It lacks any significant atmosphere, hydrosphere, or magnetic field. Its surface gravity is about one-sixth of Earth's at , with Jupiter's moon Io being the only satellite in the Solar System known to have a higher surface gravity and density. The Moon orbits Earth at an average distance of , or about 30 times Earth's diameter. Its gravitational influence is the main driver of Earth's tides and very slowly lengthens Earth's day. The Moon's orbit around Earth has a sidereal period of 27.3 days. During each synodic period ...
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Additive Manufacturing
3D printing or additive manufacturing is the construction of a three-dimensional object from a CAD model or a digital 3D model. It can be done in a variety of processes in which material is deposited, joined or solidified under computer control, with material being added together (such as plastics, liquids or powder grains being fused), typically layer by layer. In the 1980s, 3D printing techniques were considered suitable only for the production of functional or aesthetic prototypes, and a more appropriate term for it at the time was rapid prototyping. , the precision, repeatability, and material range of 3D printing have increased to the point that some 3D printing processes are considered viable as an industrial-production technology, whereby the term ''additive manufacturing'' can be used synonymously with ''3D printing''. One of the key advantages of 3D printing is the ability to produce very complex shapes or geometries that would be otherwise impossible to construct ...
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Feedstock
A raw material, also known as a feedstock, unprocessed material, or primary commodity, is a basic material that is used to produce goods, finished goods, energy, or intermediate materials that are feedstock for future finished products. As feedstock, the term connotes these materials are bottleneck assets and are required to produce other products. The term ''raw material'' denotes materials in unprocessed or minimally processed states; e.g., raw latex, crude oil, cotton, coal, raw biomass, iron ore, air, logs, water, or "any product of agriculture, forestry, fishing or mineral in its natural form or which has undergone the transformation required to prepare it for international marketing in substantial volumes". The term ''secondary raw material'' denotes waste material which has been recycled and injected back into use as productive material. Ceramic While pottery originated in many different points around the world, it is certain that it was brought to light mostly through ...
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Zero-gravity
Weightlessness is the complete or near-complete absence of the sensation of weight. It is also termed zero gravity, zero G-force, or zero-G. Weight is a measurement of the force on an object at rest in a relatively strong gravitational field (such as on the surface of the Earth). These weight-sensations originate from contact with supporting floors, seats, beds, scales, and the like. A sensation of weight is also produced, even when the gravitational field is zero, when contact forces act upon and overcome a body's inertia by mechanical, non-gravitational forces- such as in a centrifuge, a rotating space station, or within an accelerating vehicle. When the gravitational field is non-uniform, a body in free fall experiences tidal effects and is not stress-free. Near a black hole, such tidal effects can be very strong. In the case of the Earth, the effects are minor, especially on objects of relatively small dimensions (such as the human body or a spacecraft) and the over ...
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