Arcam EBM User´s Manual

4 Maintenance
4.1 The Rake System

Rake positions: Fetch position left, Rest position left, Center position, Rest
position right, Fetch position right.

Rest position: The two rest positions are the positions where the rake
is stopped and waiting when it is not actively raking.

Center position: The center position is in the middle of the build tank.

Fetch position: The fetch positions are defined at a position where a

small volume of powder flows over the rake, like the volume of a pen-
cil (this volume should be enough powder for one layer and the vol-
ume should be about the same on both left and right side).

The zero-point for the rake positions is located at the origin (on the
right side of the build tank) and increase to the right and decrease to
the left.

4.1.1 Setup of Rake Calibration

Start the Setup

Make sure that the rake and build tank is calibrated and aligned
according to instruction in chapter 4.3.

Position the rake at origo (origin) before starting the rake

calibration. Do this by pressing the origo icon.

Menu > Hardware Setup > Powder dispatcher > Rake Calibration
menu:

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1. Min and Max position: Before letting powder out set max and
min positions in the rake calibration by stepping/jogging the rake
until 4 mm from the hoppers on each side (the outermost positions
in the regulator). Save the min position on the left side and max
position on the right side.

Left Hopper Right Hopper

Rake

4 mm

Min position (= outermost position on left side), max position (=outermost

position on right side)

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2. Rest position: to calibrate the two rest positions for the rake; in-
serting the heat shield and jog the rake until the heat shield flap
falls down.
A1: Jog the rake over the powder nipple and set the position when
the edge of the rake is 20 mm from the center of the powder nip-
ple, see picture below. Save both left and right rest positions.
A2: when the heat shield flap falls down, step 5 mm further to-
wards the powder hopper. Move the heat shield towards the left
when setting the left rest position, and move the heat shield to-
wards the right when setting the right rest position. The whole
rake (toblerone) has to pass the powder nipple in order to define
the rest position. Save both left and right rest positions.

Rest Position in A1

3. Center position: Move/jog the rake to the middle of the build

tank and save the center position.

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4. Powder slopes: Let powder out of the hoppers. Be aware how im-
portant it is to have the correct distance between the powder sen-
sor nipple and the base of the powder slope (from the powder
hopper). If new powder is being used, first pull vacuum with the
new powder in the hoppers, then open the chamber and check the
distance to the powder sensor nipple.
A1: If the distance is more than 50 mm, change to hopper outlets
with larger openings (i.e. from 28 mm to 32 mm). If the distance is
less than 40 mm change to smaller opening size. For CoCr 30-50
mm is OK. See picture below and for instructions see 4.1.2.
A2: If the distance is more than 20 mm, change to hopper outlets
with larger openings (i.e. from 28 mm to 32 mm). If the distance is
less than 15 mm change to a smaller opening size, see picture be-
low. For CoCr 10-20mm is OK.

Powder slope calibration

5. Fetch position: Lower the build table so that the powder

will fall down when raking back and forth. Calibrate the
fetch position on each side by stepping the rake towards
the powder hopper. The rake is in the correct place when
a small volume of powder flows over the rake (this volume should
be the same volume amount of a pencil). Save the position and cal-
ibrate the other side. See example in picture below.

Left Hopper Right Hopper

Powder Slope

Rake

Fetched Powder

Fetch position of the Rake

Attention! If the calibrated fetch position is less than
10 mm from the calibrated outer most position, and
the powder slope measurement is inside the range,
contact Arcam Support.

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6. Rake sensors: Check that the powder pipes of the rake sensor are
centered under the screws of the sensor holes. Check the function
of the powder sensors by using the Rake Sensor Activity test on
the service page, Meny > Service Page. Pour a small amount of
powder through the sensor nipples and check for green light on
the screen.

Rake Sensor Activity test

7. When starting a new job: During the first layers, pay attention to
the amount of powder. If necessary, change the Initial Offset.
Press Reset Regulator. Also, if there is not enough powder to cov-
er the build area and still just one raking, increase the Zero
Threshold. During the following layers, check for the Optimal
Pulse Length, and adjust it if necessary (for a complete description
of all rake regulator parameters, see chapter 4.1.3).

4.1.2 Calibration of powder slopes in A1

Depending on the flow ability of the powder in use the length of the
powder slopes out from the feeders may vary. This can be calibrated
by fitting different sizes of outlets.

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To change outlet size:

1. Remove access powder from start plate and table.

2. Undo the wing nuts (5).
3. Unhook the front plate (4). To minimize powder leak, tilt the front
plate towards the door to catch the powder.

4. Now replace the outlet to one of the desirable sizes.

5. Put the front plate back and tighten the wing nut.

4.1.3 The Rake Regulator Parameters

The rake regulator controls the amount of powder in front of the rake
during a build. The pulse values from the rake sensors represents the
amount of powder in front of the rake, and a regulator controls the
positions for fetching powder depending on these values. Note: the
sensor is not in operation during manual movement of the rake.

The rake regulator

On the Menu > Hardware Setup > Powder Dispatcher page some real
time values are shown in the Rake regulator square, see picture below.
The values shown (from left to right) are actual position, last recorded
pulse length and a sensitivity difference value between left and right
sensor. The left side fetch position is controlled by the right side sensor
and vice versa, as the powder volume is controlled after the rake has
passed over the build area. The reset button resets the regulated posi-
tions to the calibrated values with the initial offset added. The set-to-
zero button sets the sensitivity difference value to zero. Every time a
new build is being built the rake regulator resets the regulated posi-
tions.

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The rake regulator parameters are defined in EBM Control on the

Menu > Hardware Setup > Powder Dispatcher page.

Initial Offset (3-8 recommended value)

Offsets the calibrated fetch positions in the direction towards the mid-
dle. This value is set to avoid fetching too much powder when the
melting starts. This is to compensate for the fact that the metal powder
flows better under a vacuum.

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NOTE: The Initial Offset might have to be changed depending on

powder type and machine. If there is far too little powder during the
first layers and/or 3 zero pulses in a row (=Max Zero Pulses) and the
Initial Offset is set to 5 mm on the left side (-5 mm on the right side),
then 5 mm/-5 mm is too much. If 5/-5 mm is too much, decrease the
Initial Offset to 3 mm (-3 mm), press the Reset Regulator icon. Check
the amount of powder coming, and if necessary decrease 2 mm more
(to 1 mm/-1 mm) and press Reset Regulator. If there is still not enough
powder decrease 2 mm more to -1 mm/1 mm (note the sign change!).
Do this until there is enough powder to cover the start plate.

OptimalPulseLength (200-380 recommended value)

The desired pulse length for the rake regulator. This is the value
which the regulator will work towards.

Zero Threshold (100-200 recommended value)

his value is the threshold for treating a pulse length as too low (zero).
If a pulse length is under the threshold the rake regulator will continue
to run the rake, without melting, until either the pulse length is
between the Zero Threshold and Max Threshold value or Max Zero
Pulses are reached. Then the actual position is fixed as the new fetch
position and the sensor is considered as broken. The sensor will be
treated as broken until a pulse length greater than the Zero Threshold
value is recorded.

Advanced setup
The advanced rake regulator parameters are defined in EBM Control
on the Menu > Machine Setup > Machine > Rake Regulator page.

Overall Rake regulator

A normal setup of parameters are shown in the picture below. “Differ-
ential factor”, “General scale factor” and “Proportional factor” are set-
tings for the overall powder regulator.

“Time to wait for pulse” is the time the system will wait for a pulse if
there was a zero-pulse (i.e. an invalid pulse).

“Left and Right sensor max pulse” are time-out in the computer sys-
tem, parameter 120 (=1200ms). It is important that these times are
shorter than the “Time to wait for pulse”.

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“Max optimal pulse length diff” is the max value that the regulator is
allowed to compensate for pulse difference between the left and right
sensors.

Left and Right regulator (advanced)

"Max threshold" is the limit for valid pulses from the powder sensor.
Pulses above the Max threshold will be considered as “Zero Thresh-
old” pulses and treated in the same way.

“Max zero pulses” is the max number of attempt the regulator will try
to get a valid pulse. After for example 3 attempts, the machine will
continue without a valid pulse.

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4.1.4 Replacing the Rake blades in A1

There is a risk of injury. Do not put fingers between the rake unit
and the metal powder hopper or the build tank whenever the rake is
moving. Use protective gloves when changing the rakes.

Replace the rakes if the slits of the rakes are bent, stretched or spread
out.

1. Select the Menu > Setup > Hardware Setup > Powder dispatcher
page within the EBM Control software.
2. Turn on the rake by pressing the On button.
3. Move the rake unit to its center position by pressing the Center
position icon.
4. Turn off the rake by pressing the Off icon.

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5. Loosen the rake unit from the linear vessel by un-tightening the
bolt (1) with a 13 mm wrench.

6. Pull the rake outwards.

7. Place the rake unit upside down on a workbench.
8. Undo the 4 screws holding the metal brackets (2).

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9. Pull out the Rake Insert and remove the Rake Blades.
10. When assembling the set of rakes, install the one pair of rakes mirror-
inverted to the other pair of rakes thus making the slits overlapping each
other.
11. Re-install the new set of rakes attached to the spacer back into the
rake unit.
12. Tighten up the 4 bolts pressing down the Rake Insert.
13. Attention: Vacuum the block before installing the rake unit.
14. Install the rake unit into the linear vessel and tighten the bolt.

4.1.5 Replacing the Rake blades in A2

There is a risk of injury. Do not put fingers between the rake unit
and the metal powder hopper or the build tank whenever the rake is
moving. Use protective gloves when changing the rakes.

Replace the rakes if the slits of the rakes are bent, stretched or spread
out.

1. Select the Menu > Setup > Hardware Setup > Powder dispatcher
page within the EBM Control software.
2. Turn on the rake by pressing the On button.
3. Move the rake unit to its center position by pressing the Center
position icon.
4. Turn off the rake by pressing the Off icon.
5. Loosen the rake unit from the linear vessel by un-tightening the
bolt (a) with a 13 mm wrench.

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6. Pull the rake outwards (b).

7. Disassemble the rake unit by pulling up the spacer (c) then push-
ing it out (d).
8. Attach two rakes to each other to assemble a pair of rakes to each
side of the spacer. There should be two pairs of rakes on each side
of the spacer making a total of four rakes for the assembly.
9. When assembling the set of rakes, install the one pair of rakes mirror-
inverted to the other pair of rakes thus making the slits overlapping each
other.
10. Re-install the new set of rakes attached to the spacer back into the
rake unit.
11. Attention: Before installing the rake unit make sure the upper sur-
face or the unit is smooth at insertion point (e) to prevent that the
rake alignment will be disturbed. If not smooth use some scotch
bright to clean. Also, vacuum the block before installing the unit.
12. Install the rake unit into the linear vessel and tighten the bolt.

4.1.6 Cleaning Linear Axle

Linear actuator with Vacuum 1 lubricant in the bearings

1. Remove the heat shield, powder hoppers and rear protection
plate.
2. Inspect the two sides where the actuator is turning on the shafts
and clean carefully if there is any powder, without spilling any.
3. Don’t clean the area between the two sides, that would cause
grease to disappear from the bearings.

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4. Reinstall the rear protection plate, powder hoppers and heat

shield.

Always do this if you suspect a smoke occurred during the build and
according to maintenance procedures . This is to prevent this powder
from contaminating the “process” powder.

4.1.7 Replace Powder Hopper seal in A1

The Powder Hoppers have a ceramic rope seal that acts as a scraper for
the outlet plate. If needed follow this steps to replace it.

1. Undo the two M4-bolts.

2. Remove the two pieces of sheet metal.
3. Remove the old Ceramic rope.
4. Insert the Outlet Lid.
5. Put the new Ceramic rope (1 mm longer than the groove) in the
groove. The loose ends should not be directed downwards in to
the groove.
6. Place the sheet metals back and tighten up the M4-bolts.
7. Check the function of Outlet lid by opening and closing it.

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4.2 The Electron Beam

4.2.1 Beam Calibration

Attention! Beam calibration should be done by a trained operator or

by an Arcam service engineer only.

Attention! Alignment of the rake and, in A1, alignment of the build

tank must be performed prio to the beam calibration. For instruction
see 4.3.7 for alignment of the rake and 4.3.5 for alignment of the build
tank.

Calibration instruction
To calibrate the beam, place a calibration plate in the chamber and
level the plate with the rake, as done with a start plate. Check the con-
dition of the observation window and the camera glass. Make sure that
the light in the chamber is satisfying. Change the front of the heat
shield to the specific calibration front. Insert the heat shield, fold back
the window blinding and pump vacuum. Turn the power supply on.
Enter the beam calibration page and switch the beam on to around 1
mA.

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During the calibration, the following shortcut keys can be used:

• The O and L keys are used for turning the beam on and off
• The I and K keys are used for increasing and decreasing the beam
current
• The F10 key is used for saving the calibration file
• The tab key is used for switching calibration mode

The first step is to make a rough calibration of the positions. This cali-
bration will be used when obtaining the focus and astigmatism values.

The second step is to calibrate the focus and astigmatism signals.

In the third and last step the positions are fine tuned within the cali-
bration holes. In this step it is important that the calibration plate is at
the right temperature. If the temperature is too low, switch off the
beam and start the heating until the calibration temperature lamp is
green.

To save the calibration in a calibration file, press the Save button on the
top of the page. If you would like to restart the calibration from the last
saved calibration file, press the Undo button at the top of the page.

Rough position calibration:

When entering this calibration mode the chamber light will be turned
on to make it easier to see where the beam is located. Move the beam
with the following keys:

• A - left
• D - right
• W - up
• S - down
or with the arrows in the EBMControl GUI next to the corresponding
letters.

When the beam is within the hole, press Space bar to save the calibra-
tion in that hole or the Save button under the arrows. If the calibration
for this position hasn't been saved before moving to the next calibra-
tion position, the calibration of this point will be lost. Sometimes a
position (especially in the corners) can be very hard to calibrate. In
those cases that position can be ignored by pressing V or the ignore
button. Move to the next calibration position by using the arrow keys
on the keyboard or by pressing the arrows under the section hole in
the EBMControl GUI.

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Focus/Astigmatism calibration:

When you are satisfied with the rough position calibration, move on
to the Focus and astigmatism calibration by pressing the Tab key.

The chamber light will now go off and the beam will appear a bit out-
side the hole to make it possible to determine when the beam is sharp
and round. Increase the beam current to approximately 2.0 mA. It
should be possible to have a sharp and white beam spot when the cor-
rect focus and astigmatism values are obtained.

A practical tip is to start with making the spot as round as possible and
then shrink it. Repeat until the spot is as small and sharp as possible.

The calibration hole is changed in the same way as it is for the rough
position calibration. For every hole:

• The focus is calibrated with Q and A or the plus and minus buttons
close to the letters.
• Astigmatism coil 1 is calibrated with keys W and S or the corre-
sponding plus and minus button.
• Astigmatism coil 2 is calibrated with keys E and D or the corre-
sponding plus and minus button.
In the same way as when the rough position calibration was made
every position needs to be saved or ignored.

There are two special functions for the Focus and astigmatism calibra-
tion: the Focus offset and Set astigmatism buttons. These functions can
be used to reset the values. This could be necessary for instance when
the machine is calibrated for the first time or if some major hardware
devices have been changed (beam column, deflection coils or amplifi-
ers.)

The Focus Offset button will take the difference between the old cali-
brated value and the new value for the point, and apply this difference
to all other points.

The Set astigmatism button will set all the astigmatism values for all
points to zero.

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Fine position calibration:

The last calibration step is the fine position calibration. When moving
to this step the beam jumps down in to the hole again. The procedure
for the fine calibration is similar to the rough position calibration
except that now the temperature must be within the limits. Use as low
current as possible in order to avoid a too high temperature. More-
over, this calibration will be more precise since now the focus and
astigmatism values will be correct.

The light will be turned off in fine position mode. Move the beam
within the hole such that the beam light will be minimized.

When all the calibration steps have been done, the quality of the cali-
bration can be analyzed by pressing the Calculator button and then
moving from the Plate tab to the Charts tab. Once the calculation but-
ton has been pressed, a calculation starts where all points are used to
fit a mathematical expression to the calibration. The difference
between the calculated value and the calibrated value is used to deter-
mine the quality of the calibration in each point. If the difference is
above the allowed value the point will be colored. The color will be red
or orange where red indicates the point with the largest difference.
Note that some points may look opaque. If you are in the position
mode such points mean that focus and astigmatism values are bad and
vice verse.

Before leaving the calibration page all red points should be recali-
brated. Always start with correcting the red point and then redo the
analyses to check if there are still some red points.

To get more information about the calibration and how it could be cor-
rected you can view the charts under the chart tab. Here you will find
five tabs: Pos, Focus calib, Focus calc, Ast calib and Ast calc.

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Pos: The plot under the position tab shows which (if any) positions
that have to be recalibrated. A red arrow indicates the point that dif-
fers most from the calculated value. Orange arrows indicate positions
that also differ too much from the calculated polynomial. Note that the
direction and the length of the arrow indicate the direction and how
much the beam should be moved, use this information when trying to
recalibrate the point.

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Focus calib and Focus calc: Under the Focus Calibration tab and the
Focus Calc tab the focus curves for the calibrated and the calculated
values are shown, respectively. Each color corresponds to a focus
interval. A good focus calibration should have a calculated pattern as
close as possible to concentric circles with a red circle in the middle
and blue in the corners (see figure below).

Ast calib and Ast calc: Under the Ast calib tab and the Ast calc tab the
calibrated and the calculated astigmatism values are displayed as
arrow plots. The x-value and the y-value of the arrows correspond to
the Ast 1 and Ast 2 signals, respectively. Both the direction and the size
of the arrows should follow a smooth pattern with no abrupt changes.

Upon completion of the beam calibration, a beam verification plate

should be run. Instructions on how to perform the beam verification
are available in next chapter, 4.2.2.

4.2.2 Beam Calibration Verification

Instructions for verifying calibration with the Verification Plate

These instructions are valid for the following configurations:

- Arcam EBM systems using EBM Control 3.2 with low 220x220, dia
310 or high 220x220 mm build envelopes

- together with a Beam Verification Plate with Part Number 202293

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Procedure
Align the verification plate with use of the rake on top of a calibration
plate. The verification plate should be placed in the center of the build
tank. When the verification plate is in position make sure there are no
powder particles on the plate. Put in the heat shield, close the chamber
door and pull vacuum.

Load the verification project named:

- BeamVerificationPlate_A2-S12_F60

(is either included in the release EBM Control 3.2 or supplied by

Arcam.)

The Start Z-Level, under Build Setup should be set to 0.4 mm

Go to the Calibration menu.

Choose the right build envelope by selecting theme:

S12: S12 or S12 HIGH

A1: A1

A2: A2WIDE or A2HIGH

Just to be sure check that the right calibration plate has been loaded,
click on edit theme at the build envelope menu. Click Calibration -
Calibration article.
Edit theme
Select theme

S12 - PLATE7X7A
S12HIGH - PLATE7X7AHIGH
A1 - PLATE7X7A
A2LOW - PLATE7X7ALOW
A2HIGH - PLATE7X7AHIGH

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Start up the High Voltage and use filament current 11,0 A (F120). Cen-
ter the verification plate and go to the Beam Alignment page. Do the
Beam Alignment as careful as possible and then press save. Run the
test plates in manual mode by clicking the Manual Controls icon on
the menu page.

The manual controls for melting a single layer will now appear:

Click on the Play button. Don't bother about the warnings saying that
there are no heater activated and that model clipping occurred. Next,
click on the melt same layer button:

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It could take some time before the beam starts (~5 s). This is normal.
When the plate has been melted, Progress bar "Task" reaches 100%,
click on the Stop manual process mode button:

Then, ventilate and remove the plate. Write manually the date and
serial number of the actual machine on the plate. The position of the
Arcam logo should face the door.

Verification
The verification plate consists of four different types of tests.

1. Dimensional accuracy test

2. Beam Alignment test

3. Focus offset and beam sharpness test

4. Deflection system test

Verify the test result by checking the following steps. Schematic draw-
ings will be shown from the BeamVerification Plate_A2S12_F60 plate.

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1. Dimensional accuracy test

Measure the size of rectangular boxes. The dimensional accuracy

should be within +/- 0.3 mm. With A2HIGh some clipping will occur,
but the 218x218 box should be visible.

Schematic view of the verification plate, with the four different tests.

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2. Beam Alignment test

Check that the lines of the inner cross are between the double lines of
the outer cross (cf. left figure below). If the inner and outer crosses do
not align, redo the beam alignment (cf. right figure below).

Good (left) and insufficient (right) beam alignment

3. Focus offset test

At each of the four corners and in the middle there are clusters of 21
lines in either horizontal or vertical direction. Each one of the 21 lines
corresponds to a certain focus offset value. The values range from -60
mA to +60 mA in steps of 20 mA. Note that the -10, -5 mA and +10, +5
mA lines have been skipped.

[ -60 --40 -35 -30 -25 -20 -15 0 +15 +20 +25 +30 +35 +40 +45 +55 +60]

Schematic view of the Focus offset test

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The melted line in the middle of each cluster corresponds to focus off-
set equal to zero. Use a fiber tip pen to mark the last melted lines on
each side of focus offset=0. In the example below the last melted lines
are at -25 mA and +30 mA, respectively. In this case the focus range is
between -25 mA and +30 mA. Calculate the span in focus i.e. from -25
to +30 = 55mA. To be acceptable the focus offset range should be at
least 50mA. Moreover, the variation between different clusters should
not exceed +/- 5mA. As a starting point for the focus offset in the melt
theme the max focus reduced by 10 could be set. i.e. + 30- 10 = 20mA.
A more detailed explanation about focus offset is given in 4.2.3.

Example of how to determine the focus offset range

4. Deflection system test

This test serve to measure the performance of the deflection amplifier

and deflection coils. You should see two distinct lines at each of the
50e-6 markers. If this is not the case contact Arcam for support.

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Example of a correct deflection test pattern

4.2.3 Focus Offset Instruction
Focus offset is a parameter that controls how large and how deep the
melt zone is. At zero focus offset the beam will be as small as possible
creating a deep melt pool. The more the offset are increased the shal-
lower the melt will get and eventually the beam will be so blurry that
the powder is not fully melted. This creates pores in the solid struc-
ture, which will lower the material properties and damage the micro-
structure. To small melt pool can also create defects and pores i the
material du to the narrow spot. Pockets with unmelted powder can be
created between the different melt lines, which creates pores in the
material.

A schematic sketch over how the melt pool is changed with different
focus can be viewed below.

Focus offset 10 Focus offset 25 Focus offset 45

Melt pool with different focus offset

To get good material and mechanical properties it is important to set

the right focus offset value. The proper focus offset can vary between
machines and therefore has to be determined at every machine indi-
vidually.

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The influence of focus offset on the properties of the melted surface is

larger for Ti6Al4V than for CoCr. The description below is therefore
more applicable to Ti6Al4V. For CoCr, use the focus offset set by
Arcam in the process themes.

If the melt surface of a job does not look good, the focus offset value
can be changed in order to create a better surface and a better material.
The surface of the build can be studied to see if to increase or decrease
the offset.

Evaluation of melt surface

A surface where the melt pool has been too wide contais many pores
and voids. If the melt pool has been too narrow and deep, the surface
contains dents and elevations, especially by the contours. In the pic-
ture below melt surfaces with different focus offset can be seen.

Focus offset 10, 15, 25, 40 and 45

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From the picture above it can clearly be seen that different focus offset
effects the melt surface differently. The two melt surfaces to the right
shows how it can look it the focus offset value is too large. Pores and
voids, as described above, can easily be seen.

The two surfaces to the left represents what happens if the melt pool is
too narrow. The pores that can be formed by too narrow spot are hid-
den in the material. The dents and hills aroud the cotours, characteris-
tic of low focus offset can easily be seen. Another sign of too low focus
offset value is that the melt lines are clear ad distinctive.

In this picture the middle surface represents a good melt surface with
a good focus offset, but as stated above this applies only to this
machine.

The above discussion is only applicable to the focus offset in the melt.
Focus offset of the contour is different. Using Multibeam the focus off-
set of the contours should be set to zero.

Edit focus offset

Whe the melt surface has been evaluated and a proper focus offset has
been chosen the melt theme must be edit. Do this through Menu\Pro-
cess Setup in the EBM Control software and then to the melt theme.
Press the edit botton and then Melt\Hatch\Square and under Beam
write the right focus offset value.

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The edited themes is automatically saved as a new user theme and

stored in the user theme folder. Put the theme in the Arcam theme
folder again and write over the existing melt file, in order to avoid con-
fusion. For 3.X software’s the files can be found under C:\Program
Files\Arcam AB\EBMControl3.X\Themes\Process\Your mate-
rial\User. Copy this theme and put it under C:\Program Files\Arcam
AB\EBMControl3.X\Themes\Process\Your material\Arcam.

4.2.4 Disassembling the Control Electrode Unit

There is a burn injury risk. After use, the electron beam col-
umn is very hot. Temperatures of 300 ºC (572 ºF) can be ob-
tained inside the column. Always wait for the column to cool
down at least half an hour before maintenance. If any part of
the body comes in contact with hot surfaces, immediately run
under cold water. If experiencing more severe burns, immedi-
ately consult a medical doctor.

When cleaning the EB-Unit and the vacuum chamber several

different cleaning agents are being used. Always follow ap-
propriate safety regulations for each cleaning agent being
used.

Note: Check inside the electron beam column. If the column is

not clean or if there is powder on the column protection
foil or inside the drift tube, the protection foil must be re-
moved and cleaned. Also clean inside the column, the
control electrode and replace the filament. If the column
and the protection foil are clean, there is no need for clean-
ing unless the filament is being replaced.

Note: Never touch the control electrode unit directly with un-
protected hands. Use clean latex gloves. Always handle
the control electrode unit parts in a clean environment.

1. Open the hatch for access to the EB-Unit.

2. Lift up the upper column and place it in the maintenance stand,
allowing for easy access to disassemble the control electrode unit.

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3. Disassemble the control electrode unit from the corona ring by

turning the bayonet catch ring while counteracting the lower part of
the control electrode unit from this torque (the actual control electrode).
Remove the control electrode unit by pulling it downwards. The
control electrode unit is attached by a bayonet catch.

Corona ring

Bayonet catch ring

Control electrode

Note: Do not use the corona ring to counteract the torque on the upper part
of the upper column when disassembling the control electrode unit, or
the upper column could be twisted apart.

4. Place the control electrode unit on a clean surface.

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4.2.5 Replacing the Filament and Cleaning the Electrode Unit

Note: Replace the filament if filament time will exceed 60 hours
during the next run or if cleaning of the EB-Unit is neces-
sary.

Note: Pursue maximum cleanliness whenever handling the fila-

ment. Never touch the filament directly with bare hands.
Use clean powder free latex gloves. Any dirt on the fila-
ment shortens its life time, deteriorates its function, and
causes problems during the process.
Wipe working surfaces clean before assembling. It is pre-
ferred to use a clean microfiber rag as the surface.
Make sure the tools are free of grease or dirt. If necessary,
clean the tools.

Handle cleaning details with a high sense of cleanliness. Use clean

powder free latex gloves. Make sure the tools are free of grease and
dirt. If necessary, clean the tools. Proper cleaning agents for EB-Unit
parts are:

• Proclean Flux Remover

• EcoSolve
• Master Kleener Blue
• Pharmaceutical quality Acetone

1. Remove the used filament by using the flat pliers. Only use the flat
pliers for replacing the filament. Grab the filament by one of the
two contacts and pull upwards.
2. Clean around and inside the hole on the underside of the control
electrode by rubbing with a cotton swab moistened with the prop-
er cleaning agent.

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3. Clean around the lower diameters and planes on the inner side of
the control electrode (see picture below) with proper cleaning
agent and a cotton swab (Q-tip).

4. Spray the control electrode with the proper cleaning agent, wipe
with a clean micro fiber rag and use compressed air to blow the
dowel holes clean.
5. Put the control electrode aside for re-assemble (protect it from
dirt).
6. Grab the new filament by one of the two contacts using the flat pli-
ers. Gently place the filament straight down in the control elec-
trode, with the notch aligned with the pin. Do not twist and do not
force the filament into place.

Contact

Notch

7. Attention: Always make sure that the tip of the filament is cen-
tered in the small hole.

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4.2.6 Metallized or Contaminated Control Electrode

If the control electrode is very dirty or if it has been soaked with water
or alcohol, it is necessary to take it apart and clean it more thoroughly.

1. Disassemble the locking ring of the bayonet by using the big nut
setter until the bayonet catch ring can be lifted out. Lift out the
bayonet catch ring and the locking ring of the control electrode.

Big nut setter

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2. Remove metallized areas around and inside the hole on the un-
derside of the control electrode, by polishing with Scotchbrite
type “ultra fine”.
3. Rub the lower planes and the center hole of the control electrode
by using a cotton swab (Q-tip), moistened with one of the recom-
mended cleaning agents.

Note: Do not use more cleaning agent than necessary and wipe
away excessive amounts by using a cloth or Q-tip.

4. Spray the control electrode with proper cleaning agent and then
blow the dowel pin holes with well filtered, clean compressed air.
5. Spray the bayonet catch ring and the locking ring with proper
cleaning agent.
6. Before mounting: make sure ever part is DRY.
7. Mount the bayonet catch ring on the control electrode and tight
with the big nut setter. Make sure that the threads are properly
aligned before tightening.
Attention: Make sure that control electrode is tightened properly
with the big nut setter. The gap between the control electrode and
the bayonet catch ring should be about 0.5 mm.
8. Put the control electrode unit aside for re-assembling, while pro-
tecting it from dirt.

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4.2.7 Cleaning the Contactor Pins

Attention: when cleaning the contactor pins and the surrounding
areas maximum cleanness is necessary!

a b

The Contactor Pins: casings (a) and springs (b)

The Filament Contactor Feedthrough (the bronze part)

1. Use clean powder free latex gloves and place a clean paper sheet
on a table.
2. Remove the copper contactor pin casings (a) from the copper con-
tactor springs. Clean the metallization from the tip of the casings
with Scotchbrite. Place them on the clean paper sheet.
3. Remove the copper contactor springs (b) from the filament con-
nector feedthrough. Place them on the clean paper sheet.
4. Use a “pressed-together” Q-tip, (press together the cotton part of
the Q-tip with help of the flat pliers), spray the Q-tip with Eco-
Solve. Repeat with new Q-tips until there is no more dirt visible.
5. Inside the filament contactor feedthrough: Clean the two ceramic
cylinders (c), thoroughly with the flattened cotton swab.
6. Also, clean all surfaces inside the filament contactor feedthrough
until the Q-tip looks clean.
7. Place the copper contactor springs in the filament connector pins

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8. Place the copper contactor casings by slowly rotating the casing

while pushing up over the contactor spring. Make sure that they
end up parallel.
9. Finally, press one copper contactor pin up at a time to test that it
moves back to its start position without getting stuck. If it gets
stuck, polish inside and if it still gets stuck contact Arcam support.

4.2.8 Cleaning the Anode

1. Use clean latex gloves and unscrew the anode manually and re-
move it.
2. Brush inside the drift tube with a conical bottle brush. If necessary,
remove the drift tube from the column by removing the anode
plate. Re-install the Drift Tube assembly into the middle column
after cleaning.
3. Clean the inside of anode with a cotton swab. Blow with clean
compressed air.
4. If the tip of the anode is not shiny, brush it with Scotchbrite "ultra
fine" type before cleaning.
5. Clean the outside of the anode with a micro fiber rag moistened
with the proper cleaning agent.
6. Hand tighten the Anode into the Anode Plate.

Anode

Anode Plate

Drift Tube

The Anode

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4.2.9 Re-install the Control Electrode Unit

1. Re-install the control electrode into the upper column. Align the
dowel pins with the holes of the control electrode and push the
control electrode upwards. Turn the bayonet catch ring while
counter-acting this torque by holding on to the control electrode.
Loosen the tools and tighten one more time.
2. Clean the outer side of the control electrode unit and corona ring
with the proper cleaning agent. Make sure the corona ring is tight-
ened in the proper direction. Hand tighten only.

Upper column Tightening direction

Corona ring

Bayonet catch ring

Control electrode

Middle column

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4.2.10 Re-installing the Upper Column

1. Vacuum the o-ring groove clean and wipe the inside of the middle
column with a clean cloth.
2. Clean inside the middle column with the proper cleaning agent
and a clean micro fiber rag.
3. Re-install the o-ring.

Re-installing the upper column

4. Place the upper column on top of the middle column.

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4.2.11 Recommended Filament Current

Before powering the filament (or even staring the vacuum pumps), the
operator must answer if the filament has been changed or not (under
“Filament Changed“ on the Hardware Setup page). When the power
supply is switched on from the Hardware Setup page, the filament
current will automatically be ramped up to a suitable current. If the fil-
ament has been changed, the current will be ramped up to 11 A. If the
filament from the last run is going to be used, the filament current will
be adjusted with respect to the last build and the currently loaded start
plate theme. If the filament is switched on from the Advanced Power
Supply page, the adjustment has to manually be done by the operator.

For New Filaments

Normal current value for the F120 (part no 201669) is 11 A max.

To warm-up and during alignment: 10.6 A

To heat start plate 150 mm - 180 mm = 10.8 A

To heat start plate 190 mm or more = 11 A

For Old Filaments

To manually adjust the filament current, check the log file and notice
Process.FilamentTuningControl.MaxCurrentOfLayer and OPC.PowerSup-
ply.Filament.FilamentCurrentDemand at the last layer that was built.
Increase or decrease 0.1 A of filament current for every 6 mA of beam
current that differs between the previous run and what beam current
that is to be used for heating the start plate in the next run. Then add
0.2 A of filament current. If there are any obscurities, aim for a higher
current, since the current will peak down rather quickly during heat-
ing of the start plate.

Setting and Adjusting the Filament Current

In order to emit electrons the filament needs to be heated. The hotter it
is, the easier it can emit electrons but the shorter its life will become.
The filament temperature will be determined by the filament current
and it will change during its life. Therefore the filament current needs
to be adjusted, not only to preserve the filament, but also in order to
get a bright (dense) beam.

The software does these adjustments automatically. This procedure is

called “Filament tuning & control“. During heating of the start plate,
the software will decrease the filament current in steps until the ulti-
mate filament current is reached. When the bottom temperature has
reached the desired temperature and the melting process starts, the fil-
ament current will be adjusted according to what beam current will be
used during the melting process.

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4.3 The Build Tank

4.3.1 Table Calibration

Note! Only applicable to machies with active cooling.

The heat sink will be automatically activated by the machine. After a

build has been stopped the build table is lowered down to the Heat
Sink until the calibrated position is reached. The Heat Sink will then
draw heat from the build into the vacuum chamber floor that is cooled
by the heat exchanger. This helps to reduce cool-down time. The table
position shown on the table calibration page is the table position rela-
tive to the last saved table calibration.

Calibration of Heat sink

1. To set up the Heat Sink go to Table Calibration under Calibration

in the software.
2. Place a start plate on top of the adjustment screws.
3. Lower the table until the Heat Sink hits the start plate and lifts it
clear from the adjustment-screws. Don’t lower the build table un-
der the edge of the build tank or the ceramic rope can be damaged.
4. When the table is in the correct position, press the save button. The
calibrated Heat Sink table position will now be set to 0, but the ta-
ble position on other pages will not be affected.
5. The Heat Sink is now calibrated and the build table will go to this
position when a build is done.

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Maintaining the Heat Sink

To achieve a fast cool down time the contact between the Heat Sink
and the start plate is critical. It’s therefore recommended that the Heat
Sink top is cleaned from powder before every run. With the build table
turned off and in the top position simply brush of the top with your
fingers, use gloves.

4.3.2 Build Tank Insulation Plate

The Start Plate Insulation insulates the start plate from the build table.
This enables the start plate to reach start up temp quickly and mini-
mize heat loss throughout the build. The insulation plate is divided
into Insulation Sheets and two Spacer Nets that are stacked on top of
each other. When installing the insulation, start with a Spacer Net then
an Insulation Sheet.

Installing the insulation plate

1. Start with empty build tank.

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2. Install the adjustment screws in the build tank (4 x M4). As a guide

you should aim for a distance of 22mm from build table to top of
adjustment screw.

3. Pull the thermocouple and copper wire through the M8 hole

(placed in the middle front part of build table).
4. Place two spacer nets on top of the adjustment screws.
5. Then place a sheet metal on top of the net, make sure to feed the
thermocouple and copper wire through the hole in the sheet met-
al.
Spacer net
Adjustment wheel Insulation sheet

Insulation plate

6. Repeat 4 and 5 until you have 3 layers of sheet metals.

7. Place one adjustment wheel on each adjustment screw.
8. Lock down the adjustment wheel with a M4 nut.

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Attach the thermocouple and the copper wire to the thermocouple

holding plate. No excess thermocouple should be placed on top of top
sheet metal, it will be destroyed by the heat.

Thermocouple and Thermo plate

Installing the start plate on the insulation plate

1. Make a center mark on the start plate.
2. Place the start plate on top of the Adjustment Screws.

Start plate on top of insulation plate

3. Put some powder on top of the start plate and run the rake over it.
4. Adjust the start plate by turning the Adjustment Wheels.
5. The aim of the adjustment should be to get a powder surface that
resembles a leopard skin.
6. When the start plate is adjusted to the rake, make sure that the
start plate rest on all four screws. Do this by pressing down on
each corner of the plate. If there is a play, adjust that screw up-
wards.
7. Lower the build table 0.5 mm.

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8. Remove the powder on top of the start plate (there should howev-
er be powder around the start plate).

4.3.3 Unloading the Build Tank in A2

For big jobs or for jobs that are taken out at high temperatures it might
be necessary to take out the whole build tank.

Change of build tank

Unload the build tank

1. Lower the build table (a) to its lowest point. The limit switch will
stop the table at the right level. You may want to raise the table a
little to unattach the connections.
2. Remove the heat shield from the chamber.
3. Select the Control > Powder dispatcher view within the EBM con-
trol software. Lower the build tank almost all the way down to its
lowest position by pressing the Jog Down button.
4. Activate the control lock by pressing the Off button to avoid the
z-table or rake from moving.
5. Use a vacuum cleaner to remove excessive powder inside the ma-
chine and pull out the protective plate from the chamber; which is
located above the build tank.
6. Unhook the eccentric lock and push the locking arms (b) to the
side.
7. Disconnect the ground cable and thermocouple.

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8. Use the trolley to lift the build tank out of the machine. Adjust the
trolley’s fork to the appropriate height. Carefully slide the fork
into the holders on the Build Tank in order to lift it out of the
chamber.
9. Bring the lifting carriage and its load to the Powder Recovery Cab-
inet (PRS), see chapter 4.3.4.

Load the build tank

1. Ensure that the build table is in its lowest position.
2. Lift the build tank using the trolley. The build tank should slide on
the racks on the floor of the chamber.
3. Push the build tank all the way in. It will stop against the U shaped
connection located on the plate of the Z-movement.
4. Lock the build table with the locking mechanism by pushing the
two arms together. (You should not have to use great force, if you
need too much force something is wrong. Maybe the connection
(d) on the build table needs adjustment e.g. add some shims).

4.3.4 Changing the Build Tanks in A2

1. Remove heat shield (a), rake unit (b), build tank (c), powder hop-
pers (d), metallization plate (e), powder table (f), table brackets (g)
and corner boxes (h).

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2. Remove the V-block (i) and the extension block (j) (or put it back
if you are installing the 350x350x200 build unit).

3. Remove the powder sensors (k) with brackets (l). Replace the
brackets with the brackets of the appropriate size. Install the pow-
der sensors in the new brackets.
4. Flick the limit switch trigger (m) over.

5. If installing the 250x250x350 build unit; install the alternative cor-

ner boxes and pin the sealing plate in behind the corner boxes.

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6. Mount the powder table brackets.

7. Load the build tank and slide the powder table in place.
8. On the rake move the Flap Deflection bar out for Wide and in for
Tall Buildtank
9. Fasten the rake unit and recalibrate the rake. Make sure the rake
does not hit or scrape anything inside the camber.

10. Install the metallization plate, powder hoppers and heat shield.
11. In the calibration menu change to the right build envelope. Verify
the beam calibration according to chapter 4.2.1.

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4.3.5 Alignment of build tank in A1

The build tank should be lined up with to the z-axis. Calibrate the
build tank so the walls of the build tank are parallel to the z-movement
within +/- 0.15 mm over 100mm of travel. This will assure a smooth
travel of the build table. The build table is integrated in the z-axis and
should not be detached from it.

Don't have Ceramic Rope installed during calibration.

1. Place the build tank over the build table and attach it with the four
M6 bolts.
2. The build tank is adjustable with four M8 bolts, as a starting point
for calibration adjust the build tank to 451mm from chamber ceil-
ing.

3. Check the space between the build tank and table to make sure it
runs free.
4. Attach the micrometer to the M8 hole of the build table.
5. Place the micrometer pick-up against the inside of the left wall.
Move the build table until the micrometer is at the top end of the
build tank wall.
6. Move the build table down, using the software and the hand-held
keyboard. Note the value of the micrometer after the initial jerk.
The value shouldn't change more than +/-0.15 during a table
movement of 100mm.
7. To adjust the build tank, undo the M6 bolt and adjust with the M8
screws.
8. When the left wall is acceptable repeat the procedure with the
front wall.
9. As a confirmation you could test the right wall and the back wall.

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10. Check that the space between the build table and the build tank is
even all around.
11. Install the insulation rope.

4.3.6 Installation of insulaton rope in A1

1. With the build tank in place and calibrated.
2. Remove the plate on top of the build table by undo the four bolts.

3. Put the ceramic rope in the groove along the walls of the build
tank.
4. Cut the ends of the rope diagonal to let them overlap each other.
5. Put the plate back and tighten the screws.

4.3.7 Alignment of rake

Rake alignment contains two important steps:
• Rake bar offset to powder table.
• Z-table alignment towards rake linear bars

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Calibration rake

Step 1:

1. Remove the powder hoppers and the back plate.

2. Loosen the mounting bolts for the rake bars (2 each side) and the
locking nut for the adjusting bolt.
3. Adjust the alignment of the bars using the adjustment screws. Po-
sition the rake in both left and right resting position and measure
the distance from the rake edge (triangle) down to the table. Nom-
inal value should be 12 mm.
4. Tighten mounting bolts for rake bars.
5. Position the rake in the middle and remove rake bar.
6. Move the build table to lowest possible position.
7. Mount the calibration rake and place the indicator clock on the
build table at one side of the calibration rake (it might be necessary
to move the rake slightly left or right). Carefully raise the table.
Avoid measuring during the first part of the z-movement, as the
build table makes a slight "jerk" when starting or shifting direc-
tion. Do not let table touch the calibration rake.
8. Adjust the position of the clock so you can see both a positive and
a negative value. Zero the scale.
9. Lower the table and note any difference of start and stop point.
10. Loosen the mounting bolts for the rake bars (2 each side) and the
locking nut for the adjusting bolt.
11. Adjust the alignment of the bars using the adjustment screws.

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12. Tighten mounting bolts for the rake bars.

13. Repeat 8 to 12 until good results are achieved, approved is 0.05
mm over approx. 100 mm table travel.

Step 2:

1. Move the rake to the most left position (in the tank) and place the
indicator clock in front of the calibration rake. Carefully raise the
table. Avoid measuring during the first part of the z-movement, as
the build table makes a slight "jerk" when starting or shifting di-
rection. Do not let table touch the calibration rake.
2. Adjust the position of the indicator clock so you can see both a
positive and a negative value. Zero the scale.
3. Lower the table and note any difference of start and stop point.
4. Loosen the mounting bolts for rake bars (2 each side).
5. Adjust the alignment of the bars using shims (or pieces of rake
blades (0,1mm thick)) behind the rake bar blocks.
6. Tighten mounting bolts for the rake bar blocks.
7. Repeat 2 to 7 until good results are achieved, approved is 0.05 mm
over approx. 100 mm table travel.
8. Then do the same on the right side. When it's ok on the right side,
check again the left again to be sure.

Step 3:
After alignment of the rake towards the build table it is necessary to
check the rake towards the powder table.

1. Remove the calibration rake and mount the rake.

2. Move the rake between the left and right rest positions and ensure
that the nominal distance from rake edge (triangle) down to the
table is 12 mm.
3. With powder on the table check that the rake blade is just passing
over the powder sensor holes. There should not be any funnel in
the powder as it flows down to the sensor.
4. Perform a beam calibration, see section 4.2.1.

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4.4 The Insulated Heat Shield

Warning sharp edges!

Use gloves!

The Insulated Heat Shield has exchangeable sheet metals. These sheet
metals allows a clean inside surface of the heat shield for every build.
The clean, reflective surface reflects the heat, insulating the build area.
Clean shields will also minimize metallization flakes and oxygen
pickup in the powder. One layer of sheet metals are used for Ti6Al4V
and two layers are used for CoCr and TiAl.

4.4.1 Replacing the sheet metals

1. After a build remove the Heat Shield from the machine. Try to
shake off as much powder as possible inside the machine. (If you
have had a smoke you may want to place the heat shield on a tray
to catch as much powder as possible).
2. Remove the old sheet metals.
3. Squeeze the top sheet metals out of its slot.
4. The frame is now empty.

5. Check the metallization flaps, wire and key rings for damage. Re-
place if necessary.
6. Clean the frame from metallization on the inside corners.

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7. Place new sheet metals on the frame. The old sheet metals can be
used on the second and third layer (if used). As these sheet metals
have a longer lifespan.
8. With the shield in an upright position, start hanging the side sheet
metals on the hooks. Starting with the inner slot first. Two sheet
metals should never use the same slot as this short-cuts the heat
insulation.

9. The top sheet metal is installed by carefully bending it and fitting

it inside the slots.
10. When the machine is loaded and ready to run the next job, put the
heat shield on the rails and push it all the way until the front plate
hits the front of the rails.

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4.5 The Loading Trolley for A2

For instructions on handling any maintenance regarding the trolley,
see the user guide from Logitrans (the manufacturer of the Trolley).
These instructions are only guidelines and it is highly advised to read
the User Guide from Logitrans before using the trolley.

The hydraulic loading trolley

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The Trolley Battery

Use the external battery charger to charge the trolley. There is a main-
tenance free gel-battery in the trolley. See pictures below.

Battery location

Location of Trolley Battery

Trolley Battery

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The Trolley Stand

The Trolley Stand with the Quick Lock

When placing a tool in the stand, you need to open the quick lock
before the tool can be released.

If you find it difficult to align the trolley with the machine when load-
ing/unloading powder hoppers in the machine, it is suggested to cre-
ate guide lines using tape on the floor to help the alignment.

Observe: If you have any problem with the Trolley Stand or the Trol-
ley Tools contact an Arcam personnel immediately.

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Picking up a tool
The tools for the build tank and the powder hoppers are shown on the
stand in the picture below.

Powder Hopper and Build Tank tools on the

1. Position the trolley in front of the desired tool.

2. Push the horizontal trolley bar towards the desired tool to attach
it to the quick-locks.
3. Raise the horizontal bar upwards.
4. Ensure that the horizontal bar has caught the desired tool and the
quick-lock has engaged.

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Unloading a tool to the trolley stand

Unloading the Powder Hopper tool

1. Position the trolley in front of the stand.

2. Ensure that the tool is positioned correctly in the stand.
3. Open both quick-locks as shown in the picture above.
4. Lower the horizontal bar.
5. When the tool comes into its desired location on the stand, the hor-
izontal bar will slide out from the quick-locks and the tool is un-
loaded.

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Lifting with the barrel tool

Lifting with the barrel tool

1. Position the clamp fittings according to barrel position.

2. Turn the gripping handle (position 1, see above) counter-clock-
wise to open the gripping arm as much as necessary.
3. Move the barrel turner forward until the clamp fittings are above
the center of the barrel.
4. Lower the gripping arms until their center is positioned at the cen-
ter of the barrel.
5. Turn the gripping handle (position 1) clockwise and lock it to pre-
vent the drum from sliding when lifted.
6. Turn the handle upwards to prevent the grip around the barrel
from loosening (B). The barrel can now be lifted.
7. Turn the gear handle (position 2) to tilt the barrel. The barrel can
be tilted 360 degrees in both directions.
8. The self-locking gear is able to hold the barrel in any position.

Never walk under the lifted or elevated barrel! Be aware of moving

parts. Be aware that the contents of the barrel can splash out of the
barrel.

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Maintenance of the barrel tool

Lubricate spindle rods and spindle supports regularly to ensure opti-
mum barrel turning performance.

Lubrication of the barrel tool

For further instructions read Logitrans Drum (barrel) turner supple-

mental instruction.

4.6 The Vacuum System

The vacuum system consists of three pumps: the rough pump, the
chamber turbo pump and the EB-Unit turbo pump.

It is important to run the ballast on the main pump for 5-10 minutes on
level 1 every 100 hours, especially during the summer when humidity
is high. The switch is located on the main pump.
Attention: never stop the vacuum pumps when the pressure is below
400 mBar.

4.7 Powder Maintenance and Recovery

The metal powder can be reused several times in the EBM process,
without sacrificing the quality of the built parts, provided that a high
degree of cleanliness is kept throughout the powder recycling proce-
dure.

To remove the powder surrounding the melted parts after a build, use
the powder recovery system (PRS). It uses the powder itself as a clean-
ing media, and most powder may be recycled and reused. Add one
scoop of powder before starting the cleaning process. Clean most of
the powder out of the recovery cabinet and lower collection box after
each cleaning.

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4.7.1 The Powder Recovery System (PRS)

Always use gloves when removing the metal residue from the mag-
netic separator. This is a strong magnet, so ensure all cell phones,
credit cards etc do not come near the magnet.

Follow the safety recommendations in the Material Safety Data Sheet

(MSDS) supplied with the powder. This information is also found in
chapter 1.3 Powder Safety. Prepare the EBM machine according to
the standard procedure described in Chapter 6 for titanium or Chap-
ter 7 for CoCr.

General maintenance of the PRS

1. Gloves: check that the gloves are okay i.e. no damages, holes etc.
2. Filters: drain the oil/dirt filters (3pcs) once/month.
3. Magnetic separator: clean the separator after PRS usage by re-
moving the metal residue. Clean by using paper tissue or a floor
vacuum cleaner.

4.7.2 The Sieve

The sieve is used to sift the powder. There are different sizes of the
mesh depending on what powder sizes are being sifted.

Manual Sieve
It is important not to turn the manual sieve inside the powder barrel
since this may result in contamination of the powder. When the sieve
is clogging use clean air to remove the metal residue.

Pneumatic Sieve
Make sure that the right mesh is used for the pneumatic sieve. When
the sieve is clogged use clean air to remove the metal residue.

4.7.3 Change Powder Batch or Type

To ensure the chemical composition of the Arcam Material, the follow-
ing steps should be followed whenever the powder batch or powder
type is changed in the EBM system.

OBSERVE: Take extra care when changing material (i.e. Ti to CoCr).

One “teaspoon” of Ti can damage the specification for 100kg of CoCr.

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EBM Machine
1. Remove powder hoppers from the machine and empty them into
a barrel. Vacuum clean and wipe the hoppers with ECO-solvent.
2. Remove the powder table and its brackets on the chamber walls.
3. Remove the build tank from the chamber.
4. Remove the heat protection plate in the back of the chamber
(blocking the linear vessels of the rake system).
5. Vacuum clean the chamber, pay attention around feed throughs
in the back wall and the mesh in front of the turbo pump.
6. Wipe all chamber surfaces with ECO-solvent.
7. Restore the chamber and load the hoppers with the new powder.
8. Perform Rake Calibration, according 4.1.1, and look over the Rake
Regulator Parameters, 4.1.3.
Attention! It is important to do this after changing powder since
different powder has different flow ability, even if it is the same
material.

PRS System when changing powder batch

1. Start the cleaning by removing the old powder and/or other con-
taminates from the cabinet. Use the air hose.
2. Empty the container in the back of the PRS. Clean the magnetic
separator.
3. Empty and clean the mesh filter above the magnetic separator.
4. Vacuum clean the PRS firmly in the cabinet and the return hose in
the bottom of the cabinet.
5. Take about one deciliter (4 ounces) of the powder from the batch
of material that will be used next and run it through the cabinet.
This will help to clean out the last remains of the powder or dust
inside the cabinet and inside the tubes. Note: this powder shall be dis-
carded, do not us/mix in vacuum cleaner for production powder.
6. Vacuum clean the PRS firmly in the cabinet and the return hose in
the bottom of the cabinet. Note: use a “floor” vacuum cleaner since
this powder should be deposited.
7. If a new material is to be used within the PRS, all internal surfaces
shall be wiped with ECO-solve.

Powder Barrels
Vacuum clean and wipe with ECO-solvent.

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Sift when changing powder

Case A: new powder batch, same material

1. Remove mesh from sifter housing

2. Clean the mesh with pressurized air from “backside” of the mesh.
Preferable the air hose within the PRS can be used to prevent pow-
der dust in the room.
3. Wipe the sifter housing with ECO-solvent.
4. Restore the mesh in the sifter housing
Case B: new material

When changing to a new material, Arcam strongly recommends that a

new mesh is installed in the sifter to prevent cross contamination.

4.7.4 Analysis and Quality

In order to keep quality of the built parts, material samples should be
analyzed on a regular basis. Arcam recommends that a small solid
material piece with dimensions specified by your local laboratory
(typically a block of size 15x15x30 mm) is included in every 5th job ini-
tially. The block should be sent for chemical analysis. Ask Arcam if
you need assistance to find a suitable laboratory.

• If the chemical composition complies with the requirements, see ta-

bles below, then the powder is still acceptable and it can be used for
another 5 jobs.
• If the chemical composition does not comply with the requirements,
then the powder is no longer acceptable.
• Once a clean and reliable routine has been established, the number
of jobs between each chemical analysis can be increased up to 10.

Recycled powder can be blended with new powder whenever needed.

Make sure to blend the powders carefully to avoid inhomogeneous
composition of the final solid metal parts.

Requirement(1) for continued recycling of Arcam Ti6Al4V ELI powder

Element Requirement (%)

Carbon (C) max 0,07

Iron (Fe) max 0,22

Oxygen (O) max 0,11

Aluminium (Al) 5,5-6,5

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Vanadium (V) 3,5-4,5

Titanium (Ti) balance

Nitrogen (N) (2) max 0,05 (2)

Hydrogen (H) (2) max 0,012 (2)

Requirement(1) for continued recycling of Arcam Ti6Al4V powder

Element Requirement (%)

Carbon (C) max 0,09

Iron (Fe) max 0,27

Oxygen (O) max 0,19

Aluminium (Al) 5,5-6,75

Vanadium (V) 3,5-4,5

Titanium (Ti) balance

Nitrogen (N) (2) max 0,05 (2)

Hydrogen (H) (2) max 0,015 (2)

Note 1: Observe that the table refers to the composition of a solid material sample built with
the powder, not the composition of the powder itself.

Note 2: Nitrogen (N) and hydrogen (H) need to be analyzed only under special circumstances,
e.g. if hot powder has been inadvertently exposed to air. During a normal recycling procedure,
there is no need to analyze N and H.

Mixing powder
A good procedure for mixing powders is to mix in small portions fol-
lowed by sifting. For example:

Assume that 30 kg of Powder A shall be mixed with 70 kg of Pow-

der B. Pour 3,0 kg of Powder A and 7,0 kg of Powder B into a clean
bucket. Put a tight lid on the bucket and shake it vigorously for 1-
2 minutes. Sift the 10,0 kg mixed powder through the standard
sieve.
Repeat this procedure 10 times until all powder has been mixed and
sifted.

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Important: Never take chances with powder cleanliness!

• Take every measure to avoid cross-contamination between different
types of metal powders.
• If you are not sure whether equipment/tool is clean, clean it or do
not use it.
• If you suspect that a powder might be contaminated, do not use it.
Send a powder sample for chemical analysis and wait for the an-
swer.
• Never run the EBM process if the vacuum is poor. Solve the vacuum
problem first.
• Do not use the Powder Recovery System for surface finishing of sol-
id parts since this will deteriorate the metal powder quickly.

4.7.5 Chemical Analysis of Arcam Material

In order to achieve reliable data of the chemical composition of Arcam
materials, the material specimen must be prepared carefully. The
chemical analysis is supposed to reveal the bulk chemistry of a solid,
fully-melted piece of material.

Here are some examples in which the chemical analysis could give
unreliable results:

1. The analysis is performed on a raw "as-built" vertical surface con-

taining semi-melted powder particles. Semi-melted powder does
not have the same composition as the bulk material.
2. The analysis is performed on the raw downfacing surface, which
contains contamination from the steel start plate.
3. The analysis is performed on the raw "as-built" top surface, which
might have picked up contamination from the vacuum during the
cooling time in the EBM chamber.
4. The analysis is performed on a surface which has been improperly
cut, ground or milled. An improper cutting method could for ex-
ample leave contamination of silicon carbide on the surface. Ma-
chining in presence of air, without proper cooling, could result in
an oxide layer.
5. The analysis is performed on a poorly washed surface, with re-
maining contamination of e.g. cutting fluids or grease.
Arcam recommends the following practice in order to get reliable
chemical data:

1. Make sure to develop a good procedure and follow this procedure

every time you build, prepare and send a specimen for chemical
analysis. Find a trustworthy laboratory and stick to this lab for all
your chemical analysis.

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2. Always build a special specimen with a standardized geometry.

Never use waste material, like wafer supports, for the chemical
analysis. The size of the specimen might be different depending
on the demands from your lab (typical 15x15x30).
3. Make sure that the powder used for building the specimen is ho-
mogeneous. If the powder is e.g. a poorly blended mixture of dif-
ferent powder lots, then your specimen will not get a
homogeneous chemical composition.
4. All surfaces of the specimen should be composed of dense bulk
material. We recommend machining down to a depth of 0.5-1 mm.
Avoid using material pieces which contains the surface facing the
start plate, where there is a brittle and hard Ti-Fe intermetallic
contamination which is difficult to remove. If you have to use such
a piece, make sure to machine off a minimum of 1-2 mm.
5. Use a machining method which leaves the final surface as clean as
possible. Cutting with an abrasive disc is not a good method, since
it may leave abrasive particles on the surface. Arcam uses a work-
shop milling machine. During the milling operation, we keep a
steady flow of argon gas over the specimen surface to minimize
the risk of oxidation.
6. Wash the specimen in a proper solvent after machining and put it
in a clean plastic bag.
7. When sending the specimen to your lab, make sure to tell them
which surface of the specimen should be analyzed. Always ana-
lyze the same surface. At Arcam, we usually perform the analysis
on a horizontal surface, 13x28 mm, originating from the upper
part of the built specimen block.

4.7.6 Oxygen Pick-Up in Titanium

The main reason for oxygen pickup in the EBM machine for the Ti pro-
cess is WATER. Moisture, bound to the Ti powder and to the EBM
chamber walls, is slowly released into the vacuum throughout the
build process. The H2O molecules crack on the hot titanium surface,
forming O+H. Oxygen is incorporated into the titanium; whereas,
hydrogen desorbs back into the vacuum as H2.

The oxygen pickup occurs only in titanium which is exposed to the

electron beam, i.e. the melted part and the preheating box. The powder
inside the hoppers does not pick up oxygen.

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Water is a more crucial factor for oxygen pickup than air leaks. A
water pressure in the high 10-5 mbar range gives the same oxygen
pickup as an air leak of about 1x10-3 mbar. As a matter of fact, we
always have water in the 10-5 mbar range in the EBM machine. The
vacuum is dominated by water at all times.

The highest water pressure is during the first 1-2 hours of a build.
Therefore, material built during the first 1-2 hours will have a higher
oxygen content than the rest of the build. Thus, if you perform a chem-
ical analysis with Ti material from the early layers, you might get a
oxygen content which is not representative for the whole build.

Recommendations
1. The best storage for Ti powder is inside the EBM machine,
pumped down to vacuum or filled with a dry gas (He, Ar, N2).
2. When a build is finished and has cooled down below 100C in 400
mbar He, the powder remaining in the hoppers has gone through
a “vacuum-drying process”. To keep this powder dry, fill up the
chamber to 1000 mbar with a dry gas (He, Ar, N2). This is better
than filling with ordinary air, because ordinary air contains mois-
ture which will go right into the dry powder.
3. Reload the EBM machine as quickly as possible, to minimize ex-
posure to moist air. Do not leave the machine open for hours.
4. Whenever possible, let the machine pump overnight before start-
ing the next build.
5. Pack the Ti parts as tightly as possible on the start plate. Remem-
ber: it is only titanium inside the preheating box that picks up ox-
ygen. The more powder you preheat, the more oxygen you pick
up.
6. Keep a low relative humidity (RH) in all areas where powder is
handled. We recommend dehumidifiers.
7. If powder is stored outside the EBM machine, keep it in closed
containers away from moisture. Do not “store” Ti powder inside
the PRS cabinet. To avoid condensation, do not store powder be-
low room temperature.
8. Take every measure to keep water away from the powder. For ex-
ample, do not wet sweep the floor while the EBM machine is open.
A wet floor immediately gives a very high RH.
9. Make sure that the pressurized air in the PRS is dry (and oil-free
of course).

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4.8 Operator Maintenance Schedule

4.8.1 Every 100 hours

Inside the EB-Unit (use clean plastic powder free gloves!)

 Filament: Pull out the filament and use Scotchbrite to clean the
grid cup from metallization (especially the “cone” inside). Also,
remove all powder grains etc.
 Contactor pins: Check the movement of the copper cylinders:
they should spring back after pushing them up.
 Oil leak: Check carefully inside and around the EB-Unit for oil
and clean if present. If there is any oil leaking from the expansion
tube, tighten the tube at the bottom and also on top (tighten the
top by hand and slightly more with pliers). If any oil is present af-
ter tightening, please consult with Arcam personnel.
 O-ring: Clean the o-ring and inspect it and the sealing surfaces for
damage.
 Middle Column Bottom: Vacuum if there is any powder present
inside the chamber
 Metallization: Scrape the metallization from all surfaces inside
the chamber and the inside of the door. Vacuum up the dust and
debris after scraping.
 Rake: Clean the surfaces of the rake arm from metallization and
wipe it with alcohol. Note if the rake arm is attached in the correct
way i.e. not touching the powder table. If it does, loosen it and
clean the contact surfaces from powder and check for damages. If
the problem remains, contact Arcam personnel.
 Rake positions: Verify the rake positions. A good tip is to mark
positions on the powder table: this is an easy way to check the rake
position between every build e.g. right, left and rest positions.
 Film camera: Check that the camera and the lamp are working.
 Build platform: Verify that the build platform is not leaking pow-
der.
 Ground cables: Check that the ground cable is ok between the
build tank and the chamber; as well as, between the sight window
shutter and the chamber door. Check that the copper ground cable
for the start plate is well tightened to the build tank ground cable.
 Heat shield: Check the flaps, ground wire and key rings. Clean
heavy metallization off the heat shield frame and replace inner In-
sulation Sheets. Note that heavy metallization causes faster oxy-
gen pickup in the powder.
 Chiller: Check the water level and fill it up if necessary. Also,
check that it is running well.

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 Rough pump: Run the ballast on the rough pump for 10 minutes
on level 2 to clear out any moisture trapped in the pump.

Vacuum Cleaner
 Check that the filters are OK and that they sit correctly.

PRS Cabinet
 Check that the gloves are OK.
 Check that the Magnetic Separator is clean.

Helium Bottle
 Check the level of Helium and that the pressure is ~ 1bar.

4.8.2 Every 200 hours

Do all of the above tasks and,

Inside the chamber

 Rear protection plate: Scrape the rear protection plate thoroughly
on the front side, check if there are scratches on the backside,
grind the backside if needed.
 Inlet Filter: Vacuum the inlet filter (from the inside) and shafts,
holders, holes for sensor, cable feed-throughs and so on.
 Rake system: Remove the heat shield, powder hoppers and rear
protection plate. Inspect the two sides at actuators end of travel on
the shafts and clean carefully if there is any powder (without spill-
ing any powder, use tissue under the rake system to prevent dirty
powder to mix with the clean powder). Don’t clean the area be-
tween the two sides, that would remove grease from the bearings.
Reinstall the rear protection plate, powder hoppers and heat
shield (also, see Chapter 4.1.5).

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4.8.3 Every 400 hours

Do all of the above tasks and,

Inside the EB-Unit

 Anode: Remove the anode/drift tube assembly and clean the in-
ner and outer surfaces. Polish the anode top with ultra fine Scotch-
brite if necessary.
 Column: Clean the inside of the upper column thoroughly. Vacu-
um the bottom of the EB-Unit. Reinstall the anode/drift tube as-
sembly.
 Contactor pins: Loosen the filament contactor pins and clean
above them by using a "pressed" Q-tip, especially on the ceramic
of the pins, use many Q-tips. Wipe the filament contactor pins
with EcoSolve E or Master Cleaner Blue (where they make contact
to the filament), see Chapter 4.2.5. Polish the contact surfaces with
ultra fine Scotchbrite.

Inside the chamber

Remove the heat shield, powder hoppers and rear protection plate

 Powder sensors: If there is compressed air near the machine, go

ahead and blow carefully in the "powder sensor box" i.e. not in the
pipe but in the square hollow box to get rid of powder dust. If no
compressed air is available, pull the sensors out, clean and rein-
stall them in the same position.
 Rake arm: Remove the rake arm. Grind it with fine sand paper
and/or scotch brite and wipe it with EcoSolve E.
 Rake shafts: Place the rake actuator in the middle position, loosen
the left and right side of it, but try to keep the rope seal inside and
move them as close to chamber wall as possible. Add grease (VAC
1) on the rake shafts on a ~4cm wide area on the 2 shafts, smooth
out the grease with your fingers (gloves on), make it ~0.5 mm
thick. Move the linear actuator across the grease, smooth out the
grease again, and move linear actuator across again. Repeat this
5times. Move the linear actuator to one side, wipe the 4cm area of
grease. Put back the sides with the rope seal.
 Camera house: Remove camera house. Pull out the o-ring, clean
the groove and the o-ring, put back the camera house again and
make sure to put it back in parallel position to the chamber frame.
Tighten it a little bit (same on both sides, tighten it a bit more while
having vacuum.
 Chamber door: Remove the chamber door o-ring, but only the
bottom part and about 100mm up on each side. Clean the groove
with a micro fiber rag and vacuum it. Clean the o-ring with the mi-
cro fiber rag and re-install it.

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Outside the machine

 Keyboard shelf: Clean the outer surfaces and the keyboard shelf
with a wet cloth.
 Touch screen: Clean the touch screen with a soft damp cloth if
necessary.
 Computer: Vacuum the computer filter in front.
 Cabinets: Clean inside and outside of the electrical and chamber
cabinets i.e. also on top of the chamber roof etc.

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