@misc{BambachFuegenschuhBuhletal., author = {Bambach, Markus and F{\"u}genschuh, Armin and Buhl, Johannes and Jensch, Felix and Schmidt, Johannes}, title = {Mathematical Modeling and Optimization for Powder-Based Additive Manufacturing}, series = {Procedia Manufacturing; Part of Special issue: 23rd International Conference on Material Forming}, volume = {47}, journal = {Procedia Manufacturing; Part of Special issue: 23rd International Conference on Material Forming}, editor = {Bambach, Markus}, issn = {2351-9789}, doi = {10.1016/j.promfg.2020.04.158}, pages = {1159 -- 1163}, language = {en} } @misc{SzczepańskiBambachJenschetal., author = {Szczepański, Łukasz and Bambach, Markus and Jensch, Felix and Ambroziak, Andrzej and Kurzynowski, Tomasz}, title = {Structural investigations of Fe-Zr-Si-Cu metallic glass with low glass-forming ability produced in laser powder bed fusion technology}, series = {Materials \& Design}, volume = {Vol. 210}, journal = {Materials \& Design}, issn = {0264-1275}, doi = {https://doi.org/10.1016/j.matdes.2021.110112}, pages = {7}, language = {en} } @misc{DeillonJenschPalmetal., author = {Deillon, L{\´e}a and Jensch, Felix and Palm, Frank and Bambach, Markus}, title = {A new high strength Al-Mg-Sc alloy for laser powder bed fusion with calcium addition to effectively prevent magnesium evaporation}, series = {Journal of materials processing technology}, volume = {Vol. 300}, journal = {Journal of materials processing technology}, issn = {1873-4774}, doi = {10.1016/j.jmatprotec.2021.117416}, pages = {10}, language = {en} } @misc{JenschEissingRichardetal., author = {Jensch, Felix and Eissing, Katharina and Richard, Williams and Trautmann, Marcus and Yang, Yitong and Dubinin, Sergej and H{\"a}rtel, Sebastian}, title = {Improving the structural integrity of challenging to manufacture LPBF components with toolpath correction}, series = {Materials Research Proceedings}, volume = {41}, journal = {Materials Research Proceedings}, publisher = {Materials Research Forum LLC}, issn = {2474-395X}, doi = {10.21741/9781644903131-12}, pages = {110 -- 119}, abstract = {This work deals with the influence of optimised exposure strategies on the distortion and microstructure of components susceptible to overheating and warpage. Therefore, different distortion-prone specimen geometries of 316L were fabricated with the standard parameters, as well as with exposure strategies optimised by machine learning, which were generated using the AMAIZE software package. The manufactured samples were analysed with regard to distortion. The results of the distortion analysis were then linked with the results of the digital tomography from AMAIZE. Furthermore, components were manufactured that tend to overheat due to their geometry and orientation on the substrate plate. The influence of overheating during the LPBF process on the microstructure and porosity was investigated along the build-up direction by means of an EBSD analysis and a porosity analysis. With the presented approach for optimising the exposure strategy with AMAIZE, it could be shown that a successful production of distortion- prone components with a porosity of less than 1 \% is possible in the first trial.}, language = {en} } @misc{GruegerJenschDittrichetal., author = {Gr{\"u}ger, Lennart and Jensch, Felix and Dittrich, Fabian and H{\"a}rtel, Sebastian}, title = {On the creation of a material bond between L-PBF-manufactured AZ91 and Ti-6Al-4V components in the context of medical applications}, series = {Materials}, volume = {17}, journal = {Materials}, number = {18}, publisher = {MDPI AG}, issn = {1996-1944}, doi = {10.3390/ma17184667}, abstract = {Within the scope of these investigations, the feasibility of a material bond between Ti-6Al-4V and the magnesium alloy AZ91 is analyzed. Ti-6Al-4V is frequently used for implants due to its biocompatibility, corrosion resistance, and specific strength. However, depending on the surface quality, the attachment behavior of the bone to the implant varies. Magnesium implants promote the regeneration of bone tissue and biodegrade as the bone tissue heals. Combining the properties of both materials in one implant enables a reduced implant volume and increased stability. For this reason, this study aims to demonstrate the feasibility of creating a material bond between the materials Ti-6Al-4V and AZ91. For this purpose, Ti-6Al-4V truncated cones and AZ91 sleeves were produced using the additive manufacturing process of laser powder bed fusion (L-PBF). The as-built sleeves were then pressed onto machined truncated cones. Since zinc serves as a lubricant and has good diffusion properties with the materials used as a result of heat treatment, a comparison was made between zinc-coated and the as-built Ti-6Al-4V samples. This showed that a bond was created after hot isostatic pressing and that the push-out force could be increased by more than 4.5 times. Consequently, a proof of feasibility was demonstrated, and a high potential for applications in medical technology was shown.}, language = {en} } @misc{JenschBuhlLaueetal., author = {Jensch, Felix and Buhl, Johannes and Laue, Robert and H{\"a}rtel, Sebastian}, title = {Application of the plane-strain-compression-test to determine the local mechanical properties of LPBF-manufactured 316l components}, series = {Material Forming: The 26th International ESAFORM Conference on Material Forming, Krak{\´o}w, Poland, April 19-21, 2023}, volume = {28}, journal = {Material Forming: The 26th International ESAFORM Conference on Material Forming, Krak{\´o}w, Poland, April 19-21, 2023}, doi = {10.21741/9781644902479-17}, pages = {149 -- 149}, language = {en} } @misc{SchmidtJenschHaertel, author = {Schmidt, Alexander and Jensch, Felix and H{\"a}rtel, Sebastian}, title = {Multi-material additive manufacturing-functionally graded materials by means of laser remelting during laser powder bed fusion}, series = {Frontiers of Mechanical Engineering}, volume = {18}, journal = {Frontiers of Mechanical Engineering}, number = {4}, issn = {2095-0233}, doi = {10.1007/s11465-023-0765-z}, pages = {1 -- 11}, abstract = {Many processes may be used for manufacturing functionally graded materials. Among them, additive manufacturing seems to be predestined due to near-net shape manufacturing of complex geometries combined with the possibility of applying different materials in one component. By adjusting the powder composition of the starting material layer by layer, a macroscopic and step-like gradient can be achieved. To further improve the step-like gradient, an enhancement of the in-situ mixing degree, which is limited according to the state of the art, is necessary. In this paper, a novel technique for an enhancement of the in-situ material mixing degree in the melt pool by applying laser remelting (LR) is described. The effect of layer-wise LR on the formation of the interface was investigated using pure copper and low-alloy steel in a laser powder bed fusion process. Subsequent cross-sectional selective electron microscopic analyses were carried out. By applying LR, the mixing degree was enhanced, and the reaction zone thickness between the materials was increased. Moreover, an additional copper and iron-based phase was formed in the interface, resulting in a smoother gradient of the chemical composition than the case without LR. The Marangoni convection flow and thermal diffusion are the driving forces for the observed effect.}, language = {en} } @misc{AlimovSviridovSydowetal., author = {Alimov, Artem and Sviridov, Alexander and Sydow, Benjamin and Jensch, Felix and H{\"a}rtel, Sebastian}, title = {Additive Manufacturing of Hot-Forming Dies Using Laser Powder Bed Fusion and Wire Arc Direct Energy Deposition Technologies}, series = {Metals}, volume = {13}, journal = {Metals}, number = {11}, issn = {2075-4701}, doi = {10.3390/met13111842}, abstract = {Additive technologies are now widely used for the production of complex precise parts and have high potential for the production of forming dies. In this work, hot-forming dies optimized for additive manufacturing were developed and produced with wire arc direct energy deposition (WA-DED) and laser powder bed fusion (L-PBF) technologies. The concept of lightweight hot-forming dies with a 2D-lattice structure was developed, which reduced the weight of each die by 56\%, from 14.2 kg to 6.1 kg, in production using L-PBF. Maraging/precipitation-hardened steel 17-4PH was used as an alternative to traditional hot-working steels with slightly lower mechanical properties and a much higher processability in the additive manufacturing process. The workability of the manufactured dies was confirmed by forging tests on an industrial screw press.}, language = {en} } @misc{GruegerSzyndlerJenschetal., author = {Gr{\"u}ger, Lennart and Szyndler, Joanna and Jensch, Felix and H{\"a}rtel, Sebastian}, title = {Porosity analysis of L-PBF manufactured AZ91D components}, series = {Materials research proceedings}, volume = {54}, journal = {Materials research proceedings}, publisher = {Materials Research Forum LLC}, address = {Millersville, PA}, isbn = {978-1-64490-359-9}, issn = {2474-395X}, doi = {10.21741/9781644903599-22}, pages = {199 -- 208}, abstract = {Several materials for joint replacement parts approved in medical technology are being investigated. Magnesium alloys are very suitable for implants due to the similar strength properties between magnesium alloys and human bone. Therefore, the present work aims to examine the parameters for producing the magnesium alloy AZ91D. For this purpose, 16 samples were manufactured with varying laser power and exposure speed and examined using µCT analyses. As a result, densities between 99.56 and 95.21 percent were achieved. The samples with the lowest density were subjected to a HIP process to increase the relative density. However, a further µCT analysis revealed only minor positive effects of the HIP process. An analysis of the number and size of the pores indicates that the pores bonded together instead of being closed.}, language = {en} } @misc{SviridovAlimovJenschetal., author = {Sviridov, Alexander and Alimov, Artem and Jensch, Felix and Dubinin, Sergej and H{\"a}rtel, Sebastian}, title = {Influence of surface quality on performance of forging dies produced by additive manufacturing the role of post-processing in LPBF-manufactured X55 steel}, series = {Materials research proceedings}, volume = {54}, journal = {Materials research proceedings}, publisher = {Materials Research Forum LLC}, address = {Millersville, PA}, isbn = {978-1-64490-359-9}, issn = {2474-395X}, doi = {10.21741/9781644903599-27}, pages = {245 -- 253}, abstract = {Laser Powder Bed Fusion (LPBF) has become a key technology in additive manufacturing (AM), enabling the production of highly complex geometries and is increasingly applied in serial production. With the continuous expansion of processable materials, LPBF is now also being considered for the manufacturing of forging dies. However, LPBF application for tool steels such as H11 is limited by their susceptibility to hot cracking. Maraging steels like X55 present a promising alternative due to their superior resistance to such defects. A major advantage of this technology for forging dies lies in the potential elimination of extensive machining required to refine rough as-built surfaces, thereby streamlining and accelerating the production process. Achieving this goal requires systematic investigations into non-machining post-processing techniques for targeted surface modifications, along with a comprehensive evaluation of mechanical properties and surface integrity after post-processing. This study examines the influence of different post-processing methods on the surface quality, mechanical properties, and tribological behavior of LPBF-manufactured X55 (1.2709) specimens. To evaluate surface roughness and mechanical performance, slope specimens and tensile specimens were analyzed in different conditions: as-built, mechanically machined, sandblasted, and treated via Hirtisition®. Additionally, flat dies were produced and subjected to ring compression tests to determine friction factors under varying surface and lubrication conditions. The findings emphasize the crucial role of post-processing in optimizing the surface quality and functional performance of LPBF-manufactured forging tools, offering valuable insights for their further development.}, language = {en} } @misc{OkoloEissingWilliamsetal., author = {Okolo, Chukwuemeka and Eissing, Katharina and Williams, Richard and Jensch, Felix and Fergani, Omar and H{\"a}rtel, Sebastian}, title = {Investigation of the influence of AI-controlled process parameter adjustment on the mechanical properties of LBPF-manufactured parts}, series = {Materials research proceedings}, volume = {54}, journal = {Materials research proceedings}, publisher = {Materials Research Forum LLC}, address = {Millersville, PA}, isbn = {978-1-64490-359-9}, issn = {2474-395X}, doi = {10.21741/9781644903599-24}, pages = {218 -- 227}, abstract = {This study investigates the influence of machine learning (ML) based process parameter adjustments on the microstructure, relative density, and mechanical properties of laser powder bed fusion (LPBF)-manufactured components, focusing on AlSi10Mg and Ti6Al4V. The ML algorithm optimizes the thermal history by adjusting laser power and exposure time at the vector level, ensuring consistent cooling and solidification dynamics. Microscopy revealed a refined and homogeneous microstructure in the optimized AlSi10Mg samples, with reduced grain size (4.92 µm compared to 6.37 µm in non-optimized samples). Relative density analysis showed a significant improvement for optimized samples, achieving consistent values across top, middle, and bottom sections of the specimen. Hardness measurements confirmed the homogenized mechanical properties, with more uniform and elevated hardness values observed in optimized samples. This study demonstrates that ML-based process optimization minimizes defects like porosity and microcracks, enabling improved mechanical performance and efficient process qualification for LPBF-manufactured parts. The findings underline the potential of AI-driven solutions for addressing complex geometrical and thermal challenges in LPBF process.}, language = {en} }