@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{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{JenschSviridovDubininetal., author = {Jensch, Felix and Sviridov, Alexander and Dubinin, Sergej and Karabulut, Fatih and Weiß, Sabine and H{\"a}rtel, Sebastian}, title = {Parameter optimization for low-porosity Ti-6Al-4V parts produced using accelerated PBF-LB process}, series = {Progress in additive manufacturing}, journal = {Progress in additive manufacturing}, publisher = {Springer}, address = {Cham}, issn = {2363-9520}, doi = {10.1007/s40964-025-01510-w}, pages = {1 -- 17}, abstract = {In this study, the influence of various process parameters on the porosity of Ti-6Al-4V parts fabricated via Powder Bed Fusion - Laser Based (PBF-LB) is investigated. Three different layer thicknesses (30 μm, 60 μm, and 120 μm) were analyzed to define process windows enabling a build-rate acceleration while keeping the porosity below 0.1\%. Through iterative parameter refinement, the effects of laser power, scan speed and hatch distance were examined in terms of linear energy density (LED), energy transmission density (ETD) and volumetric energy density (VED), and their influence on the formation of process-related defects such as pores. Correlations between these energy metrics and pore formation types (keyhole vs. lack-of-fusion) are discussed. The results demonstrate that process acceleration by a factor of more than 3 is possible while maintaining high quality of the components in terms of internal porosity. In addition, an accelerated method for manufacturing components using the PBF-LB process is presented, in which components are manufactured at very high build-rates but with increased porosity and then brought to the target porosity of 0.1\% using the HIP process. This has made it possible to accelerate the build-rate in PBF-LB production by a further 32\%. Accounting for the additional time required for HIP, the HIP route is faster than using the accelerated, which achieves the target porosity in as-built condition, for parts larger than 1421 cm3.}, language = {en} }