International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

xBeam 3D metal printing is an advanced wire-feed electron-beam DED technology based on a unique coaxial “hollow conical electron beam–wire” configuration. This review summarizes the relationships between process design, microstructure evolution, mechanical properties, and engineering applications.
The technology utilizes a low-voltage (<20 kV) gas-discharge electron gun operating in medium vacuum (10⁻¹–10⁻² mbar), improving process efficiency, reducing alloying-element losses, and extending cathode lifetime. Studies show that xBeam processing promotes a columnar-to-equiaxed transition of primary β grains in Ti–6Al–4V, producing weakly textured equiaxed structures without grain refiners. After heat treatment, tensile strengths of 950–1020 MPa and elongations of 12–15% are achieved. Recent developments include titanium-based cored wires for in-situ fabrication of Ti–6Al–4V + 40%TiC composites and functionally graded materials. Ballistic studies demonstrate enhanced energy dissipation in layered titanium structures, while successful copper–stainless steel bimetallic fabrication confirms the ability to minimize brittle interfacial layers. Overall, xBeam has evolved from a manufacturing technique into a versatile platform for microstructure engineering, advanced material development, and multimaterial additive manufacturing..