Spot Melting Strategy for Contour Melting in Electron Beam Powder Bed Fusion

Spot melting is an emerging alternative to traditional line melting in electron beam powder bed fusion, dividing a layer into thousands of individual spots. This method allows for an almost infinite number of spot arrangements and spot melting sequences to tailor material and part properties. To enhance the productivity of spot melting, the number of spots can be reduced by increasing the beam diameter. However, this results in rough surfaces due to the staircase effect. The classical approach to counteract these effects is to melt a contour that surrounds the infill area. Creating effective contours is challenging because the melted area ought to cover the artifacts from the staircase effect and avoid porosity in the transition area between the infill and contour, all while minimizing additional energy and melt time. In this work, we propose an algorithm for generating a spot melting sequence for contour lines surrounding the infill area. Additionally, we compare three different approaches for combining the spot melting of infill and contour areas, each utilizing a combination of large infill spots and small contour spots. The quality of the contours is evaluated based on optical inspection as well as the porosity between infill and contour using electron optical images, balanced against the additional energy input. The most suitable approach is used to build a complex brake caliper.