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Design of a Cost-Effective and Statistically Validated Test Specification with Selected Machine Elements to Evaluate the Influence of the Manufacturing Process with a Focus on Additive Manufacturing

  • Due to their versatile advantages, the use of additively manufactured components is growing. In addition, new additive manufacturing processes are constantly being developed, so that a wide range of printing processes are now available for metal. Despite the same starting material, the microstructure and thus also the final mechanical properties differ greatly compared to conventional processes. In most cases, only direction-dependent characteristic values from the uniaxial tension are used to qualify a printing process before it is used. The literature, on the other hand, demonstrates that the results are not transferable to other loading conditions. In this work, several engineering tests were integrated into a single test specimen so that they can be determined on the same specimen. The test specimen can be used to test tooth root strength, bending strength, notched bar impact energy, and thread strength depending on the mounting direction, thus representing industrial loading cases. In this study, test specimens were fabricated byDue to their versatile advantages, the use of additively manufactured components is growing. In addition, new additive manufacturing processes are constantly being developed, so that a wide range of printing processes are now available for metal. Despite the same starting material, the microstructure and thus also the final mechanical properties differ greatly compared to conventional processes. In most cases, only direction-dependent characteristic values from the uniaxial tension are used to qualify a printing process before it is used. The literature, on the other hand, demonstrates that the results are not transferable to other loading conditions. In this work, several engineering tests were integrated into a single test specimen so that they can be determined on the same specimen. The test specimen can be used to test tooth root strength, bending strength, notched bar impact energy, and thread strength depending on the mounting direction, thus representing industrial loading cases. In this study, test specimens were fabricated by conventional manufacturing (machining), L-PBF (Laser Powder Bed Fusion), and WA-DED (Wire Arc Direct Energy Deposition), and the results were compared using statistical methods. Factors to capture manufacturing influence and buildup direction were statistically validated on 316L. The work shows a benchmark with a typical initial microstructure of rolled and milled material, L-PBF, and WA-DED parts on loads close to the application and thus simplifies an industry-oriented evaluation of a new manufacturing process.show moreshow less

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Metadaten
Author: Lennart GrügerORCiD, Benjamin Sydow, Ralf WollGND, Johannes BuhlORCiD
URL:https://www.mdpi.com/2075-4701/13/11/1900
DOI:https://doi.org/https://doi.org/10.3390/met13111900
Document Type:Report
Language:English
Year of publication:2023
Tag:316L; benchmark geometry; laser powder bed fusion; manufacturing factor; significance; statistical method; testing specification; wire arc direct energy deposition
Number of pages:49
Way of publication:Open Access
Faculty/Chair:Fakultät 3 Maschinenbau, Elektro- und Energiesysteme / FG Hybride Fertigung
Fakultät 3 Maschinenbau, Elektro- und Energiesysteme / FG Qualitätsmanagement
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