TY - GEN A1 - Grüger, Lennart A1 - Jensch, Felix A1 - Dittrich, Fabian A1 - Härtel, Sebastian T1 - On the creation of a material bond between L-PBF-manufactured AZ91 and Ti-6Al-4V components in the context of medical applications T2 - Materials N2 - 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. KW - AZ91 KW - Ti6-Al-4V KW - L-PBF KW - implant technology Y1 - 2024 U6 - https://doi.org/10.3390/ma17184667 SN - 1996-1944 VL - 17 IS - 18 PB - MDPI AG ER - TY - GEN A1 - Alimov, Artem A1 - Sviridov, Alexander A1 - Sydow, Benjamin A1 - Jensch, Felix A1 - Härtel, Sebastian T1 - Additive Manufacturing of Hot-Forming Dies Using Laser Powder Bed Fusion and Wire Arc Direct Energy Deposition Technologies T2 - Metals N2 - 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. KW - additive manufacturing KW - hot-forming dies KW - L-PBF KW - WA-DED KW - WAAM Y1 - 2023 UR - https://www.mdpi.com/2075-4701/13/11/1842 U6 - https://doi.org/10.3390/met13111842 SN - 2075-4701 VL - 13 IS - 11 ER - TY - GEN A1 - Grüger, Lennart A1 - Szyndler, Joanna A1 - Jensch, Felix A1 - Härtel, Sebastian T1 - Porosity analysis of L-PBF manufactured AZ91D components T2 - Materials research proceedings N2 - 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. KW - A91D KW - Additive Manufacturing KW - L-PBF KW - HIP KW - Process Parameter Analysis Y1 - 2025 SN - 978-1-64490-359-9 U6 - https://doi.org/10.21741/9781644903599-22 SN - 2474-395X VL - 54 SP - 199 EP - 208 PB - Materials Research Forum LLC CY - Millersville, PA ER - TY - GEN A1 - Sviridov, Alexander A1 - Alimov, Artem A1 - Jensch, Felix A1 - Dubinin, Sergej A1 - Härtel, Sebastian T1 - Influence of surface quality on performance of forging dies produced by additive manufacturing the role of post-processing in LPBF-manufactured X55 steel T2 - Materials research proceedings N2 - 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. KW - Additive manufacturing KW - L-PBF KW - Forging dies KW - Hot bulk forging KW - Friction KW - X55 Y1 - 2025 SN - 978-1-64490-359-9 U6 - https://doi.org/10.21741/9781644903599-27 SN - 2474-395X VL - 54 SP - 245 EP - 253 PB - Materials Research Forum LLC CY - Millersville, PA ER -