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Papers by Bernd Baufeld
DVS 395, 2024
In the case of wire electron beam additive manufacturing (WEBAM), in-process ELO can document the... more In the case of wire electron beam additive manufacturing (WEBAM), in-process ELO can document the stability of the process and report potential instabilities such as the wobbling of the wire, dripping of the molten wire, non-melting of the wire and others. In addition, the development of the weld bead width and the position of the wire tip can be observed over the entire production time. Irregularities such as lack of fusion in multi-track additive manufacturing can also be monitored.
Progress in Additive Manufacturing, Nov 21, 2023
Additive manufacturing achieves increasingly more acceptance for industrial applications. Electro... more Additive manufacturing achieves increasingly more acceptance for industrial applications. Electron Beam Additive Manufacturing (EBAM) supplies a very efficient, high power energy source which easily couples with metals promising one of the highest deposition rates for all metal additive manufacturing technologies. The processing in high vacuum is ideal for reactive alloys. CNC is standard for most of the EBW setups allowing easy application of an automated build strategy. This presentation aims to present an overview of EBAM builds realised at the Nuclear AMRC. A variety of complex shaped components made out of different materials such as steel and titanium and their mechanical properties will be presented.
The Nuclear AMRC was established in the UK as an arm of the University of Sheffield to support in... more The Nuclear AMRC was established in the UK as an arm of the University of Sheffield to support industry and secure contracts in the nuclear sector – a wide scope of activities including nuclear new build, plant operations and decommissioning & waste management systems. One of the key goals is to work with industry partners in reducing unit cost, fabrication time, and risk associated with traditional manufacturing processes, whilst also striving to improve quality and engage with the industry regulators. The Nuclear AMRC’s facility was designed to accommodate large component development programmes and is capable of producing demonstrator components, using an array of state-of-the-art fabrication & manufacturing solutions. Acknowledging the great potential of electron beam welding (EBW) for modern manufacturing the Nuclear AMRC operates 2 EBW facilities. One of them is the largest electron beam facility in the UK, with a vacuum chamber volume of 208 m3, allowing EBW of large scale com...
Journal of Physics: Conference Series
The potential of additive manufacturing of copper components is not yet sufficiently investigated... more The potential of additive manufacturing of copper components is not yet sufficiently investigated despite the existence of a large market for copper products, especially in the energy, mobility, and aerospace sectors. Wire arc additive manufacturing (WAAM) and laser directed energy deposition (DED) with conventional lasers, the latter due to the high light reflection in copper, have difficulties in the additive manufacturing of this material. The electron beam, on the other hand, achieves a high energy input even with copper and thus the desired efficiency. Wire electron beam additive manufacturing (WEBAM) is capable to produce pore free copper components with high deposition rates in the range of 2 kg/h. The microstructure of pure copper WEBAM parts exhibits large, elongated grains growing epitaxially and additional structures related to the layered approach specific for additive manufacturing. The company pro-beam additive GmbH investigates several applications required by differe...
Material tvořený substratem s oznacenim IN100 a ochranným povlakem tvořeným prvky NiAlCrCoY byl s... more Material tvořený substratem s oznacenim IN100 a ochranným povlakem tvořeným prvky NiAlCrCoY byl studovan po testovani v zařizeni umožňujicim cyklickou aplikaci mechanicke zatěže v teplotnim gradientu (TGMF), tedy simulujicim praci lopatek v turbinach leteckých motorů, a po tepelnem žihani v intervalu 770-1100 C po dobu 24 h bez mechanicke zatěže. Vytvořena mikrostruktura materialu, objemove zastoupeni fazi a jejich chemicke složeni byly zkoumany prostřednictvim skenovaci a transmisni elektronove mikroskopie (SEM, TEM). Změny v mikrostruktuře byly vysvětleny na zakladě teoretických výpoctů fazových diagramů zkoumaných soustav s využitim programu ThermoCalc pro výpocet fazových rovnovah.
Les aubes de turbine a gaz dans des propulseurs ou pour la production d'electricite sont soum... more Les aubes de turbine a gaz dans des propulseurs ou pour la production d'electricite sont soumises a de fortes sollicitations thermiques qui surviennent de maniere cyclique et rendent la surface metallique rugueuse. Selon la presente invention, la surface metallique est pourvue d'un revetement mince en ceramique d'une epaisseur inferieure a 50 µm, ce qui permet d'eviter que ladite surface ne devienne rugueuse.
We report the results on a Ni-based superalloy with two different types of NiCoCrAlY coatings. Th... more We report the results on a Ni-based superalloy with two different types of NiCoCrAlY coatings. The phase structure dependence on temperature and composition in the coatings was investigated after heat treatment at temperatures between 770C and 990C and the results were compared with thermodynamic modelling of phase equilibria using ThermoCalc software package and commercial database of thermodynamic data for Ni-base superalloys.
DVS 395, 2024
In the case of wire electron beam additive manufacturing (WEBAM), in-process ELO can document the... more In the case of wire electron beam additive manufacturing (WEBAM), in-process ELO can document the stability of the process and report potential instabilities such as the wobbling of the wire, dripping of the molten wire, non-melting of the wire and others. In addition, the development of the weld bead width and the position of the wire tip can be observed over the entire production time. Irregularities such as lack of fusion in multi-track additive manufacturing can also be monitored.
Progress in Additive Manufacturing, Nov 21, 2023
Additive manufacturing achieves increasingly more acceptance for industrial applications. Electro... more Additive manufacturing achieves increasingly more acceptance for industrial applications. Electron Beam Additive Manufacturing (EBAM) supplies a very efficient, high power energy source which easily couples with metals promising one of the highest deposition rates for all metal additive manufacturing technologies. The processing in high vacuum is ideal for reactive alloys. CNC is standard for most of the EBW setups allowing easy application of an automated build strategy. This presentation aims to present an overview of EBAM builds realised at the Nuclear AMRC. A variety of complex shaped components made out of different materials such as steel and titanium and their mechanical properties will be presented.
The Nuclear AMRC was established in the UK as an arm of the University of Sheffield to support in... more The Nuclear AMRC was established in the UK as an arm of the University of Sheffield to support industry and secure contracts in the nuclear sector – a wide scope of activities including nuclear new build, plant operations and decommissioning & waste management systems. One of the key goals is to work with industry partners in reducing unit cost, fabrication time, and risk associated with traditional manufacturing processes, whilst also striving to improve quality and engage with the industry regulators. The Nuclear AMRC’s facility was designed to accommodate large component development programmes and is capable of producing demonstrator components, using an array of state-of-the-art fabrication & manufacturing solutions. Acknowledging the great potential of electron beam welding (EBW) for modern manufacturing the Nuclear AMRC operates 2 EBW facilities. One of them is the largest electron beam facility in the UK, with a vacuum chamber volume of 208 m3, allowing EBW of large scale com...
Journal of Physics: Conference Series
The potential of additive manufacturing of copper components is not yet sufficiently investigated... more The potential of additive manufacturing of copper components is not yet sufficiently investigated despite the existence of a large market for copper products, especially in the energy, mobility, and aerospace sectors. Wire arc additive manufacturing (WAAM) and laser directed energy deposition (DED) with conventional lasers, the latter due to the high light reflection in copper, have difficulties in the additive manufacturing of this material. The electron beam, on the other hand, achieves a high energy input even with copper and thus the desired efficiency. Wire electron beam additive manufacturing (WEBAM) is capable to produce pore free copper components with high deposition rates in the range of 2 kg/h. The microstructure of pure copper WEBAM parts exhibits large, elongated grains growing epitaxially and additional structures related to the layered approach specific for additive manufacturing. The company pro-beam additive GmbH investigates several applications required by differe...
Material tvořený substratem s oznacenim IN100 a ochranným povlakem tvořeným prvky NiAlCrCoY byl s... more Material tvořený substratem s oznacenim IN100 a ochranným povlakem tvořeným prvky NiAlCrCoY byl studovan po testovani v zařizeni umožňujicim cyklickou aplikaci mechanicke zatěže v teplotnim gradientu (TGMF), tedy simulujicim praci lopatek v turbinach leteckých motorů, a po tepelnem žihani v intervalu 770-1100 C po dobu 24 h bez mechanicke zatěže. Vytvořena mikrostruktura materialu, objemove zastoupeni fazi a jejich chemicke složeni byly zkoumany prostřednictvim skenovaci a transmisni elektronove mikroskopie (SEM, TEM). Změny v mikrostruktuře byly vysvětleny na zakladě teoretických výpoctů fazových diagramů zkoumaných soustav s využitim programu ThermoCalc pro výpocet fazových rovnovah.
Les aubes de turbine a gaz dans des propulseurs ou pour la production d'electricite sont soum... more Les aubes de turbine a gaz dans des propulseurs ou pour la production d'electricite sont soumises a de fortes sollicitations thermiques qui surviennent de maniere cyclique et rendent la surface metallique rugueuse. Selon la presente invention, la surface metallique est pourvue d'un revetement mince en ceramique d'une epaisseur inferieure a 50 µm, ce qui permet d'eviter que ladite surface ne devienne rugueuse.
We report the results on a Ni-based superalloy with two different types of NiCoCrAlY coatings. Th... more We report the results on a Ni-based superalloy with two different types of NiCoCrAlY coatings. The phase structure dependence on temperature and composition in the coatings was investigated after heat treatment at temperatures between 770C and 990C and the results were compared with thermodynamic modelling of phase equilibria using ThermoCalc software package and commercial database of thermodynamic data for Ni-base superalloys.