GE ArcamEBM Spectra H User manual
Original language 02 OM-710430 en-GB
OOMM
Operation Manual
Spectra H
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Table of contents
02 OM-710430 en-GB i
TTaabbllee ooff ccoonntteennttss
1 Arcam Electron Beam Melting (EBM) .................................................................................................1
2 Revision Notes .................................................................................................................................3
3 Change Log .....................................................................................................................................5
4 About This Manual............................................................................................................................7
5 Safety............................................................................................................................................13
6 Hardware Overview ........................................................................................................................35
7 Software Overview .........................................................................................................................67
8 Build Preparation Checklist............................................................................................................171
9 Build Preparation..........................................................................................................................179
10 PM-U Electron Beam Unit Checklist .............................................................................................211
11 PM-U Machine Checklist .............................................................................................................213
12 PM-U Preventive Maintenance.....................................................................................................217
13 Technical Data ...........................................................................................................................259
14 Declaration Of Conformity ...........................................................................................................267
Table of contents
ii 02 OM-710430 en-GB
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1 Arcam Electron Beam Melting (EBM)
11 AArrccaamm EElleeccttrroonn BBeeaamm MMeellttiinngg ((EEBBMM))
In the Arcam EBM®process fully dense metal components are built up, layer-by-
layer of metal powder, melted by a powerful electron beam. Each layer is melted to
the exact geometry defined by a CAD model.
The electron beam is managed by electromagnetic coils providing beam control
that allows several melt pools to be maintained simultaneously.
The vacuum system provides a base pressure throughout the entire build cycle.
During the actual melt process, a partial pressure of helium is introduced to keep a
stable build environment.
For each layer in the build the electron beam heats the entire powder bed to an op-
timal ambient temperature, specific for the material used.
02 OM-710430 en-GB 1
Table of contents
ii 02 OM-710430 en-GB
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2 Revision Notes
22 RReevviissiioonn NNootteess
The notes in this log are written by Arcam EBM and reflect what differs from the latest revision of this man-
ual. The changes do not reflect minor changes in grammar or spelling, but only focus on major changes
such as added or removed instructions, changes due to SOP (Start of Production) releases.
AAddddeedd // RReemmoovveedd IInnffoorrmmaattiioonn DDeessccrriippttiioonn
Build Preparation Content has been updated.
Build Preparation Checklist Content has been updated.
PM-U Preventive Maintenance Chapter has been restructured and content is updated.
PM-U Checklist Content is updated and the checklist has been divided into
two checklists; PM-U Electron Beam Unit and PM-U Machine.
02 OM-710430 en-GB 3
3 Change Log
33 CChhaannggee LLoogg
This log is to be filled in by the customer or Arcam Field Service Engineers (FSE) to keep the documenta-
tion updated. Please write SOP-revision (Start of Production) or other useful information about why the
chapter was replaced.
NNoottee
Only complete chapters should be replaced.
DDaattee CChhaapptteerr DDeessccrriippttiioonn CCoommppaannyy NNaammee &&
SSiiggnnaattuurree
02 OM-710430 en-GB 5
4 About This Manual
44 AAbboouutt TThhiiss MMaannuuaall
4.1 General.........................................................................................................................................8
4.2 Validity..........................................................................................................................................8
4.3 Document Updates ........................................................................................................................8
4.4 Proper Use....................................................................................................................................9
4.5 Improper Use ................................................................................................................................9
4.6 Acronyms....................................................................................................................................10
02 OM-710430 en-GB 7
4 About This Manual
44..11 GGeenneerraall
This manual describes the operation of the machine. The scope of this manual is to ensure a smooth oper-
ation of the equipment and to take advantage of all the technical features it offers and point out potential
risks involved with the use of the equipment.
44..22 VVaalliiddiittyy
CCaauuttiioonn
Read this manual with full attention before you start to work with the equipment.
The information provided in this manual refers to the current develop-
ment state and manufacturing release of the product at the time of
issue.
This manual is produced by:
AArrccaamm EEBBMM
Krokslätts Fabriker 27A
SE 431 37 Mölndal
Sweden
Phone: +46-31-710 32 00
www.arcam.com
44..33 DDooccuummeenntt UUppddaatteess
Future changes and development of the product might out-date the information in this document.
Earlier product versions might also differ from information given in this document, in such cases please re-
fer to earlier document versions.
8 02 OM-710430 en-GB
4 About This Manual
44..44 PPrrooppeerr UUssee
Always use the tools and equipment delivered in the Start Pack and Site Pack. The tools are dedicated for
each machine model/type and shall not be altered.
The equipment is only designed and tested for the use within an Arcam EBM System solution for produc-
tion of metal components.
This includes:
EEBBMM MMaacchhiinneess Layer based EBM manufacturing
PPRRSS MMaacchhiinneess Powder recovery from Arcam EBM Machines.
Only metal powders supplied by Arcam or specifically sanctioned by Arcam are to be used within the Arcam
EBM System.
NNoottee
The manufacturer’s declaration of conformity (CE) and this documentation becomes invalid if the
end user makes unauthorised modifications or changes to the product.
44..55 IImmpprrooppeerr UUssee
DDAANNGGEERR
Improper usage can result in severe body injury and/or cause equipment damage including dam-
age to the site of installation.
Usage of the equipment for other than the described purposes in this document is NOT supported. All
claims for liabilities and warranties caused by improper use will be forfeit.
Improper use and or nonintegrated use will include, but are not limited to:
• Operating the equipment in potential hazardous area
• Operating the equipment remotely
• Building parts in unapproved materials
• Operate the EBM with deviating inert gas
• Aiming the electron beam towards other targets than start plates and metal powder.
• Venting the vacuum chamber at elevated temperature
• Recovering metal powder at elevated temperatures
02 OM-710430 en-GB 9
4 About This Manual
44..66 AAccrroonnyymmss
AABBCC Auto Beam Calibration
AABBFF Arcam Build File
A (zipped) collection of compressed layer files (*.clf) in a build, needed to start a build in an
Arcam EBM machine.
AABBPP Arcam Build Project
A (zipped) collection of compressed layer files (*.clf) and themes (process step settings) in
a build needed to start a build in an Arcam EBM machine.
AAllllooyy 771188 Nickel-Based Alloy 718
AAMM Additive Manufacturing
AATTEEXX ATmosphères EXplosibles, an EU directive to protect employees from explosion risk
BBCCUU Beam Control Unit
CCAADD Computer Aided Design
CCLLFF Compressed Layer File
A 2D slice format with compression optimised for fast reading.
CCooCCrr Cobalt Chrome
CCPPMM Customer Project Manager
CCPPPP Critical Process Parameters
CCPPUU Central Processing Unit
CCQQAA Critical Quality Attribute
CCRRMM Customer Relationship Management
CCVV--EEBBMM Controlled Vacuum Pressure
EEBB Electron Beam
EEBBMM Electron Beam Melting
EEBBUU Electron Beam Unit
EELLII Extra Low Interstitials
EEMMLL Electromagnetic Lens
EEOOLL End of Life
10 02 OM-710430 en-GB
4 About This Manual
EEPPRROOMM Erasable Programmable Read-only Memory
EEQQ Equipment Qualification
FFAAQQ Frequently Asked Questions
FFSSEE Field Service Engineer
FFSSII Field Service Instructions
FFSSEE PPMM Preventive Maintenance performed by Arcam Field Service Engineers
FFTTPP File Transfer Protocol
HHAASSPP Hardware Against Software Piracy
HHCCUU High Voltage Control Unit
HHMMII Human Machine Interface
HHVV High Voltage (60 kV)
HHVVUU High Voltage Unit
HHWW Hardware
IIMM Installation Manual
IIOOQQ Installation and Operational Qualification
IIQQ Installation Qualification
LLEEDD Light-emitting Diode
MMII Maintenance Instructions
MMIILL Military Standard
MMMM Maintenance Manual
MMMMCCFF Magics Machine Configuration File
MMSSDDSS Material Safety Data Sheet
OOMM Operation Manual
OOPPCC Open Platform Communications
OOQQ Operational Qualification
PPBBFF Powder Bed Fusion
PPEE Protective Earthing
02 OM-710430 en-GB 11
4 About This Manual
PPIIGG Pre-Installation Guide
PPIICC Pre-Installation Checklist
PP&&IIDD Piping and Instrumentation Diagram
PPLLCC Programmable Logical Controller
PPMM Preventive Maintenance
PPMM--UU Preventive Maintenance performed by the user
PPPPEE Personal Protection Equipment
PPQQ Performance Qualification
PPRRCC Powder Recovery Cabinet
PPRRSS Powder Recovery Station
PPRRSS2200 PRS for Arcam EBM Q20/Q20plus
PPSSDD Powder Size Distribution
PPSSII Pound force per Square Inch
RRCCCCBB Residual-Current Circuit Breaker
RRHH Relative Humidity
RRooWW Rest of the World
SSMM Schematics Manual
SSPPCC Spare Parts & Consumables
SSTTLL Stereolithography 3D object
A 3D model format based on triangles.
SSWW Software
TTii Titanium
TTiiAAll Titanium Aluminide
UUPPSS Uninterruptible Power Supply
UUSSBB Universal Serial Bus
VVAACC Volt Alternating Current
12 02 OM-710430 en-GB
5 Safety
55 SSaaffeettyy
5.1 Required Competence .................................................................................................................14
5.2 Personal Protective Equipment PPE..............................................................................................14
5.3 Safety Signs ................................................................................................................................16
5.4 Safety Equipment ........................................................................................................................18
5.4.1 Interlocks...........................................................................................................................18
5.4.2 Light Curtain ......................................................................................................................18
5.4.3 Safety Override Switch .......................................................................................................19
5.4.4 Safety Components............................................................................................................19
5.5 First Aid Measures ......................................................................................................................21
5.6 Hazards ......................................................................................................................................22
5.6.1 Heavy Lifting......................................................................................................................22
5.6.1.1 Indicated Maximum Weights ......................................................................................23
5.6.2 High Voltage ......................................................................................................................24
5.6.3 X-radiation (composed of X-rays) Emission ..........................................................................25
5.6.4 Hot Surfaces ......................................................................................................................26
5.6.5 Crush and Pinch Hazards ...................................................................................................26
5.6.6 Arcam Powder ...................................................................................................................27
5.6.6.1 Handling And Storage Of Metal Powder......................................................................29
5.6.7 Fire-Fighting Measures .......................................................................................................30
5.6.7.1 Fire Extinguisher.......................................................................................................30
5.7 Remaining Dangers .....................................................................................................................31
5.8 Vacuum Hygiene .........................................................................................................................32
5.8.1 Handling Vacuum Chamber Parts........................................................................................32
5.8.2 Handling Column Parts .......................................................................................................33
5.8.3 Cleaning Solvents ..............................................................................................................34
02 OM-710430 en-GB 13
5 Safety
55..11 RReeqquuiirreedd CCoommppeetteennccee
All personnel that operates or performs maintenance on any part of the Arcam EBM System must have
completed corresponding training program provided by Arcam EBM. This training program includes build
file preparation, reload of the machine and safety.
This will ensure that the system is operated in both a safe and correct manner. Depending of type of usage
and profession Arcam EBM offers various sets of trainings, see
http://www.arcam.com/company/arcam-product-training/.
The general operating procedure is described in the Operation Manual.
The graphical user interface (GUI) called EBM Control has four levels of user access, read more about this
in the Operation Manual.
55..22 PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt PPPPEE
SSttaaggee EEaarr
PPrrootteeccttiioonn
PPrrootteeccttiioonn
GGlloovveess
SSaaffeettyy
ggllaasssseess
RReessppiirraattoorryy
PPrrootteeccttiioonn
MMaasskk
SSaaffeettyy
SShhooeess
LLoonngg
SSlleeeevveess
FFuullll BBooddyy
PPrrootteeccttiioonn
Powder
Handling
- ● ● ● ● ● ○
Reload of
machine be-
fore build
- ● ● ● ● ● ○
Build removal
and post
processing
● ● ● ● ● ● ○
Clean the
chamber
- ● ● ● ● ○ ○
Powder recy-
cling routine
● ● ● ● ● ● ○
KKeeyy:
●RREEQQUUIIRREEDD
○RREEQQUUIIRREEDD When working with Cobalt chrome and Alloy 718, it is important to always wear full protective equipment, for
more information see safety data sheet for specific powder.
-NNOOTT RREEQQUUIIRREEDD
14 02 OM-710430 en-GB
5 Safety
EEaarr PPrrootteeccttiioonn Wear ear protection where applicable during normal operation of the ma-
chine and associated peripheral equipment of the machine.
PPrrootteeccttiioonn GGlloovveess Wear protection gloves (latex type) when working with vacuum exposed
parts to avoid contamination. Always use protective gloves whenever
needed for personal protection, for example whenever working with powder
handling.
SSaaffeettyy GGllaasssseess Use when handling metal powder and working with removal of support
structures from produced parts.
RReessppiirraattoorryy PPrrootteeccttiioonn
MMaasskk
Always use a respiratory protection mask with a fine dust filter whenever
handling metal powder. Full-face mask covering both eyes and nose shall
be used when handling Alloy 718, see SDS.
SSaaffeettyy SShhooeess Always wear safety shoes during operation of the equipment, risk when
handling heavy parts.
LLoonngg SSlleeeevveess Personal protection when handling metal powder and for protection against
contamination of parts that is placed in the chamber.
FFuullll PPrrootteeccttiioonn CCllootthheess When handling metal powder Alloy 718, see SDS, use full body protection
overall for personal safety and for protection against contamination of parts
that is placed in the chamber.
02 OM-710430 en-GB 15
5 Safety
55..33 SSaaffeettyy SSiiggnnss
The safety instructions contained within this document are the result of risk evaluations. The different safety
signs inform the operator and other personnel working with, or close to the Arcam EBM®system of any po-
tential hazards or dangers which may exist.
Different symbols are used to emphasise information. The following safety symbols are frequently used.
NNoottee
This symbol is used for additional information and tips.
DDAANNGGEERR
This symbol is used to warn about immediate danger of fatal and/or severe body injury and/or
fatal equipment damage.
CCaauuttiioonn
This symbol is used to warn about certain actions that mmiigghhtt cause lesser body injuries and/or
lesser equipment damage. This caution can be levelled up to IImmppoorrttaanntt and then WWaarrnniinngg de-
pending on the severity of the warning.
CCaauuttiioonn
This symbol is used to warn about crush and/or pinch hazards.
CCaauuttiioonn
This symbol is used to warn about a serious risk of electric shock injury.
CCaauuttiioonn
This symbol is used to warn about hot surfaces (>50 ºC) and indicates a risk of burn injury.
CCaauuttiioonn
This symbol is used to warn about risk of ignition and/or fire.
CCaauuttiioonn
This symbol is used to warn about emitted X-radiation (composed of X-rays).
CCaauuttiioonn
This symbol is used to warn about moving mechanical parts.
CCaauuttiioonn
This symbol is used to warn about fragile parts, handle with care.
16 02 OM-710430 en-GB
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