Available Technology

Use of Beam Deflection to Control Electron-Beam Wire Deposition

Advanced process control technique for electronbeam free-form fabrication and welding
The technology employs rastering of the e-beam in the region of the wire and substrate melt zone. By controlling the raster pattern, the e-beam selectively heats the outer edges of the wire as it strays from the melt zone. With such selective heating, the wire automatically curls back away from the high heat outer edge and back into the region of the molten pool. Thus, with a fixed raster pattern, the process becomes self-correcting without any sensing or external control of process parameters.
Patent Abstract: 
NASA's Langley Research Center researchers have a strong technology foundation in the use of electron-beam (e-beam) deposition for free-form fabrication of complex shaped metal parts. While e-beam wire deposition is of interest for rapid prototyping of metal parts, cost-effective near-net shape manufacturing, and potential use in space, it is also of intense interest for industrial welding and fabrication in a range of applications, from small components to large aerospace structures. Through significant advancements in techniques to improve control of the process, NASA greatly expands upon the capabilities of the e-beam fabrication and welding process.

Self-correcting stabilizes
and optimizes e-beam
heating of the wire during
the deposition process


Welding of metal structures for
automotive, aerospace, and
other industrial and commercial

Free-form fabrication of complex
metal components in remote locations

Near-net shape manufacturing and
rapid prototyping

Applicable to variety of metal
fabrication markets, from automotive
and aerospace to sporting goods and
medical devices

Patent Number: 
Internal Laboratory Ref #: 
Patent Status: 
Patent Issue Date: 
April 30, 2015
Lab Representatives
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