Refine
Year of publication
Document Type
Way of publication
- Open Access (6)
Keywords
Institute
- FG Qualitätsmanagement (118)
- FG Hybride Fertigung (5)
- FG ABWL, insbesondere Marketing (4)
- FG Flug-Triebwerksdesign (2)
- FG Industrielle Informationstechnik (2)
- FG ABWL, insbesondere Organisation und Unternehmensführung (1)
- FG Füge- und Schweißtechnik (1)
- FG Polymerbasierter Leichtbau (1)
- FG Technische Akustik (1)
BTU
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 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.
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.
According to the Kano model, companies would be required to use a continuous adaptation of audit criteria. If the ever-changing customer necessities are not neglected, the relevancy of defined audit criteria and the framework conditions of the production start for product audits cannot be permanently ensured. For this reason, companies should compare and adjust the quality standards of all concerning employees with that of the customer, so that the audit criteria can also be reconciled and adjusted accordingly. In this respect, a procedure for matching quality standards has been developed together with a vehicle manufacturer and a feasibility study has been carried out. The focus of the study was on possible differences regarding the detection of defects between the employees, dealers, and customers, as well as the recording and analysis of the visual focus areas. For the study, the participants had to complete a written questionnaire and make a practical defect detection directly on the vehicle. The study results have shown a variety of potentials for action that can be applied at other companies. These include the regular internal matching of the quality standards, the continuous training of the employees as well as the integration of the customers and their changing product requirements after the start of product production.