Optimization of TiAl support structures for components produced with EBM process

Electron Beam Melting (EBM) is a Powder Bed Fusion (PBF) method that uses an electron beam to melt metallic powder. Powder Bed Fusion processes typically use support structures to stabilize overhanging surfaces, reducing thermal gradients during cooldown and minimizing the risk of warping. This thesis work aims to optimize partially-sintered volumetric supports structures, recyclable through the Powder Recovery System (PRS, a powder recovery station that allows the just-printed build to be cleaned of any residual loose powder), to support LPT Blades overhangs during manufacturing via Electron Beam Melting (EBM) process. This new type of support is intended to eventually replace the current production supports, which are fully melted (and therefore not recyclable back into powder), resulting in less material waste and shorter support-removal times. The primary objective of this research is to produce printed parts that meet the dimensional tolerances applied to blades while ensuring the full recyclability of the volumetric supports. To achieve this, a systematic analysis was conducted through three distinct Design of Experiments (DOE). Each experiment played a crucial role in refining process parameters and support geometries, enhancing the understanding of the interactions between operational variables and their impact on process behavior and dimensional deviations in the resulting parts. Data from each DOE was analyzed and used to improve the setup of the following experiments. This research was carried out at the Turin Additive Laboratory in collaboration with Avio Aero s.r.l., which provided the necessary licenses, technical expertise, additive manufacturing equipment and support for all post-processing operations.