TY - GEN A1 - Grüger, Lennart A1 - Fischer, Tim Sebastian A1 - Woll, Ralf A1 - Buhl, Johannes T1 - Absicherung von Risiken beim Prozess des Wire Arc Additive Manufacturing T2 - Industry 4.0 Science KW - Additive Manufacturing KW - Wire Arc Additive Manufacturing KW - Failure Mode and Effects Analysis Y1 - 2024 U6 - https://doi.org/10.30844/I4SD.24.1.63 SN - 2942-6154 VL - 2024 IS - 1 SP - 63 EP - 69 ER - TY - GEN A1 - Grüger, Lennart A1 - Fischer, Tim Sebastian A1 - Woll, Ralf A1 - Buhl, Johannes T1 - Safeguarding Against Risks in the Wire Arc Additive Manufacturing Process T2 - Industry 4.0 Science N2 - In this article, the potential risks in wire arc additive manufacturing are analyzed using failure mode and effects analysis. To achieve this, 186 possible causes of risk were analyzed and the five most critical risks were discussed in detail. Four significant risk factors were identified in the construction process. The fifth risk relates to the shielding gas flow. This is only one influencing factor among the welding parameters, which have strong interactions with each other. Therefore, their relationships should be analyzed on the basis of numerous tests. KW - additive manufacturing KW - wire arc additive manufacturing KW - failure mode and effects analysis Y1 - 2024 U6 - https://doi.org/10.30844/I4SE.24.1.63 SN - 2942-6170 VL - 2024 IS - 1 SP - 63 EP - 69 ER - TY - CHAP A1 - Grüger, Lennart A1 - Fischer, Tim Sebastian A1 - Woll, Ralf ED - Gapiński, Bartosz ED - Ciszak, Olaf Stanisław ED - Ivanov, Vitalii ED - Machado, Jose Mendes T1 - Investigation of the Wire Arc Direct Energy Deposition-Process and Possible Interactions T2 - Advances in Manufacturing IV N2 - The Wire Arc Direct Energy Deposition (WA-DED) process is highly regarded as part of additive manufacturing. Compared to other additive manufacturing processes, it is characterized above all by its high deposition rate and low system costs. Despite many years of experience in the build-up welding process, WA-DED still holds a number of challenges in terms of process stability. This article analyses the interactions in the WA-DED process. To this end, the process was visualized and described with the help of Structured Analysis and Design Technique (SADT). Building on this, a process Failure Mode and Effects Analysis (FMEA) was presented to identify and priorities risks. Finally, the results of the Taguchi tests were analyzed and visualized. The results illustrate the strong interactions between the influencing factors. These have a material-specific effect on the production results. Each new material composition therefore requires a systematic analysis in order to determine quantitative correlations. In future, these can be supported by machine learning approaches. KW - Additive Manufacturing KW - Structured Analysis and Design Technique KW - Failure Mode and Effects Analysis KW - Design of Experiments Y1 - 2024 SN - 9783031564659 U6 - https://doi.org/10.1007/978-3-031-56463-5_14 SN - 2195-4356 VL - 2024 SP - 176 EP - 194 PB - Springer Nature Switzerland CY - Cham ET - 4 ER - TY - GEN A1 - Ertugrul, Gökhan A1 - Alimov, Artem A1 - Sviridov, Alexander A1 - Härtel, Sebastian T1 - Machine learning application for optimization of laser directed energy deposition process for aerospace component rapid prototyping in additive manufacturing T2 - Materials Research Proceedings N2 - Abstract. The paper proposes a methodology for determining the optimal L-DED parameters based on the minimum number planned of L-DED trials. A dataset compiled from planned L-DED experiments was used to train a machine learning model. The algorithm demonstrated a robust ability to predict the output metrics with notable accuracy and proposed a theoretical framework that modeled the complex relationships between the input variables and the resulting critical welding properties for AM. The application of the developed model and its comparison with conventional methods thus offers a methodical approach to determining the optimum process parameters in advance. This is a step towards the development and production of additively manufactured components for future digital twin application in the aerospace industry. Y1 - 2024 U6 - https://doi.org/10.21741/9781644903131-31 SN - 2474-395X VL - 41 SP - 271 EP - 282 PB - Taylor&Francis ER - TY - GEN A1 - Schmidt, Alexander A1 - Emdadi, Aliakbar A1 - Härtel, Sebastian T1 - A holistic approach for near-net-shape processing of iron aluminides by means of Laser Directed Energy Deposition with cored wires T2 - 77th IIW Annual assembly and international conference on welding and joining, 7-12 July 2024, Rhodes N2 - Iron aluminides are characterized by high corrosion resistance, excellent mechanical properties and dimensional stability at high temperatures. With a low density this material offers technological and economic advantages over Ni-based alloys in the aerospace sector. Because of the excellent mechanical properties machining is the current challenge in processing Fe-Al. Due to the possibility of near-net-shape manufacturing along with high material efficiency additive manufacturing processes such as L-DED with wires seem to be predestined for the processing of Fe-Al. In this paper, a holistic approach for processing Fe-Al including manufacturing of wires and the actual processing of the wires is described. Since the wire drawing of iron aluminides is not possible due to low forming characteristics, a rotary swaging process was applied for manufacturing cored wires with a steel shell and aluminum core. On the one hand, the usage of unalloyed raw materials with suitable forming properties are advantageous. On the other hand, cored wires require in-situ alloying of the steel shell and aluminum core during the application process. Thus, the weldability of such cored wires was investigated in preliminary tests, initially using a tungsten inert gas welding process. The wires and the welding results were characterized by scanning electron microscopy, hardness measurement, and X-ray analyses. Y1 - 2024 UR - www.erasmuscorp.gr/IIW2024/ProceedingFiles/FP375.pdf VL - 2024 ER - TY - GEN A1 - Jensch, Felix A1 - Eissing, Katharina A1 - Richard, Williams A1 - Trautmann, Marcus A1 - Yang, Yitong A1 - Dubinin, Sergej A1 - Härtel, Sebastian T1 - Improving the structural integrity of challenging to manufacture LPBF components with toolpath correction T2 - Materials Research Proceedings N2 - 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. KW - LPBF-Process, Machine Learning, Microstructural Investigation Y1 - 2024 UR - https://d21zja6o12zyp0.cloudfront.net/9781644903131.pdf U6 - https://doi.org/10.21741/9781644903131-12 SN - 2474-395X VL - 41 SP - 110 EP - 119 PB - Materials Research Forum LLC ER - 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 - Apel, Markus A1 - Härtel, Sebastian A1 - Szyndler, Joanna T1 - Prediction of the microstructure morphology after the WAAM process based on the FEM simulation results T2 - Materials Research Proceedings N2 - To improve understanding of the material behavior of additive-produced components, this paper focuses on the development of a numerical model that reproduces a Wire Arc Additive Manufacturing (WAAM) process, with particular attention given to the evolution of the microstructure. In this study, a finite element model in Simufact Welding software is developed, that replicates a real wire arc welding process of building a multilayer straight wall. Microscopy analysis of the weld wall cut in the middle of its length gave information about the expected microstructure morphology at different levels of the build wall. The whole experimental setup is reproduced in the software Simufact Welding. Simulation results in the form of temperature-time and temperature gradient-time history are then used as superimposed thermal conditions to simulate the microstructure evolution at different areas of the welded part by using MICRESS software. Y1 - 2024 U6 - https://doi.org/10.21741/9781644903131-3 VL - 41 SP - 22 EP - 31 ER - TY - GEN A1 - Härtel, Sebastian A1 - Szyndler, Joanna A1 - Pakdel Sefidi, Moein A1 - Jäger, Reyk T1 - Prediction of the evolution of material properties during the AM process based on the FEM simulation and experimental results T2 - Materials Research Proceedings N2 - To deepen the understanding of material behavior after additive manufacturing, this article focuses on the prediction of material properties after the Wire Arc Additive Manufacturing (WAAM) process. Particular attention is put on the temperature curves in the various phases of the welding process, which influence the final material properties, especially the hardness of the resulting part. A total of nine components in the form of walls were produced using the WAAM process, with the number of layers varying from 1 to 9. By experimentally analyzing the welded parts, which were cut in the middle of their length, it was possible to gain insights into the development of hardness at selected points. The entire test setup was simulated in the Simufact Welding FE-software. The simulation results in the form of temperature-time diagrams were then correlated with the real hardness measurements at the corresponding points. In this way, a model was developed that for the first time considers the development of hardness as a result of cooling after the welding process as well as the change in hardness as a result of reheating due to the application of additional layers. Y1 - 2024 U6 - https://doi.org/10.21741/9781644903131-5 VL - 41 SP - 40 EP - 49 ER - TY - GEN A1 - Grüger, Lennart A1 - Härtel, Sebastian A1 - Sahin, Emre T1 - Simulierte Produktionsumgebung heute – Evaluation der numerischen Prozesssimulation des selektiven Laserschmelzens T2 - Industry 4.0 Science Y1 - 2024 U6 - https://doi.org/10.30844/I4SD.24.4.70 SN - 2942-6154 VL - 2024 IS - 4 SP - 70 EP - 77 PB - GITO mbH Verlag ER - TY - GEN A1 - Bambach, Markus A1 - Ünsal, Ismail A1 - Sviridov, Alexander A1 - Hama-Saleh, Rebar A1 - Weisheit, Andreas T1 - Hybrid manufacturing of sheet metals and functionalizing for joining applications via hole flanging T2 - Production Engineering KW - Hybrid manufacturing KW - Laser metal deposition KW - Lightweight design KW - Hole flanging Y1 - 2021 U6 - https://doi.org/10.1007/s11740-020-01016-0 SN - 0944-6524 SN - 1863-7353 VL - 15 IS - 2 SP - 223 EP - 233 ER -