Date of Award

Summer 2012

Document Type


Degree Name

Master of Science (MS)


Engineering Management & Systems Engineering


Engineering Management

Committee Director

Resit Unal

Committee Member

C. Ariel Pinto

Committee Member

Charles B. Daniels

Call Number for Print

Special Collections LD4331.E555 Q54 2012


The Electron Beam Freeform Fabrication (EBF3 ) System is a material depositing, layer additive technique that produces three dimensional (3D) parts out of a wide range of metals in high vacuum, using an electron beam and wire feedstock. Screening deposition trials on a titanium alloy, Ti-6Al-4V, at the National Aeronautics Space Administration (NASA) revealed selective vaporization of the aluminum content of linear prototypes when subjected to chemical analysis. In this study, the aluminum content, bead height and bead width output responses were analyzed from a systematic study of the effects that the interactions of the EBF3 processing parameters had on the finished parts. Results were derived from mathematical models (equations) using regression and the Analysis of Variance (ANOVA) statistics. These models were used to predict the optimum values of the processing parameters to promote the maximum aluminum content and optimal bead geometry to support future validation experiments. Optimization of EBF3 processing is vital to realizing the vision of manufacturing high quality and reliable replacement parts for space transportation.


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