Electron Beam Deposition Assembly With Magnetic Lens Shaping
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Solution Overview
Problem
Current additive manufacturing methods using electron beam guns require high vacuum conditions, result in inefficient equipment due to multi-stage vacuum systems, and face challenges with feedstock material coordination and melting pool control, leading to rough and unevenly structured three-dimensional objects with poor mechanical properties.
Innovation Solution
The system employs a gas-discharge electron beam gun with a cold annular cathode and a magnetic lens to adjust the electron beam's shape and angle, allowing for flexible positioning and reduced vacuum requirements, preventing metal vapor ingress, and improving visibility and stability of the deposition process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high vacuum conditions are used in the operating chamber, then the electron beam gun can operate reliably, but the equipment complexity and cost increase due to multi-stage vacuum systems
Solution Approach 1:
The patent extracts the vacuum requirement from the entire operating chamber and applies it only to the electron beam gun chamber. This is achieved by separating the gun chamber from the main processing chamber using a viewport, allowing the gun to operate in vacuum while the rest of the system operates in atmospheric conditions, thereby eliminating the need for multi-stage vacuum systems.
Solution Approach 2:
The system is divided into two independent chambers: the electron beam gun chamber maintained under vacuum and the main processing chamber at atmospheric pressure. This segmentation allows each subsystem to operate under its optimal conditions without requiring the entire system to maintain vacuum, reducing overall system complexity.
2Power
If high accelerating voltage is used in the electron beam gun, then the beam energy is sufficient for melting, but X-ray emission increases requiring thicker chamber walls
Solution Approach 1:
The patent extracts the electron beam generation process into a separate vacuum chamber, isolating the X-ray source from the processing area. By placing the high-voltage electron beam gun in its own chamber with a viewport, the harmful X-ray radiation is contained within the gun chamber while the main processing chamber remains accessible and does not require thick radiation-shielding walls.
3Ease of operation
If the electron beam falls perpendicular to the substrate, then the beam delivery is simple, but the feedstock material coordination becomes difficult leading to poor manufacturing precision
Solution Approach 1:
The patent introduces dynamic adjustment capabilities to the feedstock delivery system, allowing the feed angle and position to be varied in real-time to match the movement and orientation of the electron beam. This dynamic coordination enables precise feedstock delivery even when the beam operates in fixed perpendicular orientation, resolving the conflict between operational simplicity and manufacturing precision.
4Manufacturing precision
If increased thermal energy is input to the melting zone, then feedstock coordination difficulties are compensated, but the melting bath size increases causing rough walls requiring more machining
Solution Approach 1:
The patent implements feedback control systems that monitor the melting pool characteristics and adjust the electron beam parameters and feedstock delivery in real-time. This feedback mechanism allows for precise control of the melting process, maintaining optimal melt pool size and shape, thereby achieving good feedstock coordination without creating excessively large melting baths that would require additional machining.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enables continuous reliable operation, flexible adjustment of technological parameters, simplified maintenance, and improved observation and quality of three-dimensional object manufacturing, resulting in more stable and efficient equipment with enhanced mechanical properties.
Implementation Method 1
electron beam, for example by electron beam, and then solidifies when it is leaving heating zone
Implementation Method 2
Said feedstock material is then melt there by energy beam
Implementation Method 3
a magnetic lens placed on the underside of the electron beam gun coaxially with it and with the feedstock guide, and this lens would provide the possibility of transformation of a primary hollow electron beam
Implementation Method 4
Said feedstock material is then melt there by energy beam, and then solidifies when it is leaving heating zone resulting in formation of solid deposited layer of material
Data Source
AI summary
A system for manufacturing of three dimensional objects by layered deposition is provided. The system includes a base substrate for formation of three dimensional objects placed on a supporting plate; a functional assembly comprising a gas-discharge electron beam gun, a feedstock guide, a cold annular cathode and two annular anode electrodes, a high voltage power supply of the gas-discharge electron beam gun, a system of precise positioning of the supporting plate with the base substrate), a vacuum tight operation chamber, a vacuum subsystem for creating of necessary vacuum inside said operating chamber, a control system and a magnetic lens. The lens is placed on the underside of the gas-discharge electron beam gun coaxially with it and with the feedstock guide, providing the possibility of transformation of a primary hollow electron beam to the shape of a hollow inverted cone after leaving the discharge chamber of the gas-discharge electron beam gun.