TY - JOUR A1 - Meng, Xiangmeng A1 - Bachmann, Marcel A1 - Yang, Fan A1 - Rethmeier, Michael T1 - Porosity prediction in laser beam welding with a multimodal physics-informed machine learning framework N2 - Laser beam welding (LBW) of metallic components is a knowledge‑intensive manufacturing process whose quality depends on the complex multi‑physics. However, its engineering application is often hindered by the occurrence of porosity defects. Achieving a thorough understanding and reliable prediction of porosity defects remains difficult because it demands robust representation and reasoning over nonlinear and hard‑to‑observe physical information. In this study, we propose an integrated multimodal physics-informed machine learning (PIML) framework with the help of multi-physical modelling and experimental data to predict the porosity defects in laser beam welding of aluminum alloys. The whole framework contains a multimodal PIML model for predicting the porosity ratio and an ML-based estimator for relevant physical information. By utilizing the scalar welding parameters and high-dimensional physical information (probability of keyhole collapses, cumulative existing time of collapses, and molten pool geometry) as inputs, the multimodal PIML model shows great superiority in predicting the porosity ratio, with a reduction of the mean square error by 45%, compared with the ML model trained only with welding parameters. The ML-based estimator constructed with an encoder‐decoder architecture can accurately reproduce the critical physical information within a timeframe of seconds. By integrating these two ML models, the proposed framework advances engineering informatics by offering a scalable, physics-knowledge‑centric solution for fast and accurate porosity prediction in LBW manufacturing. KW - Laser beam welding KW - Porosity defect KW - Physics-informed machine learning KW - Multimodal model KW - Simulation PY - 2026 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-657589 DO - https://doi.org/10.1016/j.aei.2026.104611 SN - 1474-0346 VL - 74 SP - 1 EP - 12 PB - Elsevier Ltd. AN - OPUS4-65758 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Biegler, Max A1 - Yang, Keke A1 - Meschut, Gerson A1 - Rethmeier, Michael T1 - Occurrence and avoidance of liquid metal embrittlement in resistance spot welding of springback-afflicted deep-drawn components N2 - This study investigates the occurrence and mitigation of liquid metal embrittlement occurring during resistance spot welding in deep-drawn automotive components, specifically focusing on an S-Rail made from advanced high-strength steel. A simulation-based liquid metal embrittlement risk criterion based on local major component stresses was established and used to quantify and compare liquid metal embrittlement risks between different tests. Experimental and numerical analyses were conducted, revealing that springback significantly impacts liquid metal embrittlement formation. Adjustments in electrode geometry and hold time post-welding were found to mitigate liquid metal embrittlement risks. The effects of stack-up configuration and related parameter settings on liquid metal embrittlement occurrence were identified and liquid metal embrittlement was effectively prevented across both stack-up configurations. These findings advance the understanding of liquid metal embrittlement mechanisms and provide practical approaches to enhance the spot weld quality in AHSS-based body-in-whites. KW - Liquid metal embrittlement KW - Crack KW - Advanced high-strength steels KW - Resistance spot welding KW - Weld current KW - Heat input KW - Simulation KW - Springback KW - Deep drawing KW - S-Rail PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-636577 DO - https://doi.org/10.1177/13621718251340452 SN - 1362-1718 SP - 1 EP - 9 PB - SAGE Publications AN - OPUS4-63657 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Seitz, Georg A1 - Bantle, Patrick A1 - Biegler, Max A1 - Elsner, Beatrix A. M. A1 - Rethmeier, Michael T1 - An Inherent Strain Method Using Progressive Element Activation for Fast Distortion Calculation in Directed Energy Deposition N2 - The finite element analysis (FEA) simulation of directed energy deposition (DED) processes offers many potential cost savings during the build job optimization process, through, e.g., distortion predictions. However, the biggest challenge is the long calculation time, frequently exceeding the actual build time. One way of simplifying the simulation with the aim of reducing the calculation times is the inherent strain method. While this method is already used commercially in the simulation of powder bed-based processes and conventional welding technologies, its use in DED is still the subject of research. In this work, an inverse determination of an inherent strain is carried out on a 20-layer-high, single-track-wide wall, common theories are reviewed, and an approach based on thermal strain is introduced. As a result, the calculation time could be reduced by 83% and the accuracy remained at 92%. KW - Inherent strain method KW - Simulation KW - Finite element analysis KW - Directed energy deposition KW - Additive manufacturing PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-622595 DO - https://doi.org/10.3390/met14121338 SN - 2075-4701 VL - 14 IS - 12 SP - 1 EP - 12 PB - MDPI AN - OPUS4-62259 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Drendel, Jan A1 - Logvinov, Ruslan A1 - Heinrichsdorff, Frank A1 - Hilgenberg, Kai T1 - Simulation-based controlling of local surface temperature in laser powder bed fusion using the process laser N2 - State-of-the-art laser powder bed fusion (PBF-LB/M) machines allow pre-heating of the substrate plate to reduce stress and improve part quality. However, two major issues have been shown in the past: First, with increasing build height the apparent pre-heat temperature at the surface can deviate drastically from the nominal pre-heat temperature in the substrate plate. Second, even within a single layer the local surface pre-heat temperature can show large gradients due to thermal bottlenecks in the part geometry underneath the top surface. Both lead to unwanted changes in microstructure or defects in the final parts. In this study, a first attempt is taken to show the feasibility of pre-heating the top surface with the onboard laser beam to overcome the mentioned issues. A single layer of a group of three parts built from IN718 to a height of 33.5 mm is pre-heated in a commercially available PBF-LB/M machine to an average steady state surface temperature of 200 °C using the onboard laser beam. The parts are continuously heated, omitting powder deposition and melting step. Temperatures are measured by thermocouples underneath the surface. The experiments are supported by a thermal finite element (FE) model that predicts the temperature field in the parts. When heating the parts uniformly with the laser beam, differences in surface temperatures as large as 170 K are observed. To overcome this inhomogeneity, the heat flux supplied by the laser beam is modulated. An optimized, spatial heat flow distribution is provided by the thermal FE model and translated into a scan pattern that reproduces the optimized heat distribution on the PBF-LB/M machine by locally modulating hatch distance and scan velocity. This successfully reduces the differences in surface temperature to 20 K. Thermographic imaging shows that a homogeneous surface temperature can be achieved despite the localized heat input by the beam. The potential for industrial application of the optimized laser-heating technique is discussed. KW - Additive Manufacturing KW - Simulation KW - Surface temperature KW - Laser powder bed fusion PY - 2023 DO - https://doi.org/10.1016/j.addma.2023.103854 SN - 2214-8604 VL - 78 SP - 1 EP - 16 PB - Elsevier B.V. AN - OPUS4-58825 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Yang, K. A1 - Meschut, G. A1 - Seitz, G. A1 - Biegler, M. A1 - Rethmeier, Michael T1 - The Identification of a New Liquid Metal Embrittlement (LME) Type in Resistance Spot Welding of Advanced High Strength Steels on Reduced Flange Widths N2 - Liquid metal embrittlement (LME) cracking is a phenomenon observed during resistance spot welding (RSW) of zinc􀀀coated advanced high􀀀strength steels (AHSS) in automotive manufacturing. In this study, severe cracks are observed at the edge of the sheet under reduced flange widths. These cracks, traversing the AHSS sheet, culminate at the edge with a width of approximately 1.2 mm. Through combined numerical and experimental investigations, and material testing, these cracks are identified and validated as a new type of LME crack. The mechanism behind this crack formation is attributed to unique geometric conditions that, when compared to center welding, amplify radial material flow by ninefold to 0.87 mm. The resultant tangential tensile stresses approximate 760 MPa, which exceed the yield strength of the examined advanced high􀀀strength steel (AHSS) under heightened temperature conditions, and when combined with liquid zinc, promote the formation of this new type of LME crack. KW - Liquid metal embrittlement KW - Crack KW - Advanced high strength steels KW - Resistance spot welding KW - Simulation KW - Flange width PY - 2023 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-586940 DO - https://doi.org/10.3390/met13101754 VL - 13 IS - 10 SP - 1 EP - 13 PB - MDPI AN - OPUS4-58694 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Herr, M. A1 - Borras, F. X. A1 - Spaltmann, Dirk A1 - Kröll, Mirco A1 - Pirker, F. A1 - Cihak-Bayr, U. T1 - How to create trusted tribological characterization data of soft polymers as input for FEM simulations? N2 - Soft polymers such as the investigated polyurethane, characterized by low Young’s moduli and prone to high shear deflection, are frequently applied in pneumatic cylinders. Their performance and lifetime without external lubrication are highly determined by the friction between seal and shaft and the wear rate. FEM simulation has established itself as a tool in seal design processes but requires input values for friction and wear depending on material, load, and velocity. This paper presents a tribological test configuration for long stroke, reciprocating movement, allowing the generation of data which meet the requirements of input parameters for FEM simulations without the geometrical influences of specific seal profiles. A numerical parameter study, performed with an FEM model, revealed the most eligible sample geometry as a flat, disc-shaped sample of the polymer glued on a stiff sample holder. At the same time, the study illustrates that the sensitivity of the contact pressure distribution to Poisson’s ratio and CoF can be minimized by the developed and verified setup. It ensures robust, reliable, and repeatable experimental results with uniform contact pressures and constant contact areas to be used in databases and FEM simulations of seals, enabling upscaling from generically shaped samples to complex seal profiles. KW - Tribologie KW - FEM KW - Simulation KW - Polymere KW - Charakterisierung KW - i-TRIBOMAT KW - Modellierung KW - Polyurethan KW - Dichtungen KW - Upscaling PY - 2023 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-567683 DO - https://doi.org/10.3390/ma16010131 SN - 1996-1944 VL - 16 IS - 1 SP - 1 EP - 20 PB - MDPI CY - Basel AN - OPUS4-56768 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Böhne, C. A1 - Meschut, G. A1 - Biegler, M. A1 - Rethmeier, Michael T1 - The Influence of Electrode Indentation Rate on LME Formation during RSW N2 - During resistance spot welding of zinc-coated advanced high-strength steels (AHSSs) for automotive production, liquid metal embrittlement (LME) cracking may occur in the event of a combination of various unfavorable influences. In this study, the interactions of different welding current levels and weld times on the tendency for LME cracking in third-generation AHSSs were investigated. LME manifested itself as high penetration cracks around the circumference of the spot welds for welding currents closely below the expulsion limit. At the same time, the observed tendency for LME cracking showed no direct correlation with the overall heat input of the investigated welding processes. To identify a reliable indicator of the tendency for LME cracking, the local strain rate at the origin of the observed cracks was analyzed over the course of the welding process via finite element simulation. While the local strain rate showed a good correlation with the process-specific LME cracking tendency, it was difficult to interpret due to its discontinuous course. Therefore, based on the experimental measurement of electrode displacement during welding, electrode indentation velocity was proposed as a descriptive indicator for quantifying cracking tendency. KW - Liquid Metal Embrittlement (LME) KW - Crack KW - Resistance Spot Welding (RSW) KW - Advanced High-Strength Steel (AHSS) KW - Welding Current KW - Heat Input KW - Simulation PY - 2022 DO - https://doi.org/10.29391/2022.101.015 SN - 0043-2296 VL - 101 IS - 7 SP - 197-s EP - 207-s PB - American Welding Society CY - New York, NY [u.a.] AN - OPUS4-55600 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Böhne, Chr. A1 - Meschut, G. A1 - Biegler, M. A1 - Rethmeier, Michael T1 - Avoidance of liquid metal embrittlement during resistance spot welding by heat input dependent hold time adaption N2 - Liquid metal embrittlement (LME) cracking can occur during resistance spot welding (RSW) in zinc-coated advanced high-strength steels (AHSS) for automotive production. In this study, a methodological variation of hold time is performed to investigate the process-related crack influence factors. A combination of numerical and experimental investigations confirms, that the extent of heat dissipation and re-heating of the sheet surface can be influenced and thus the degree of crack formation can be controlled in a targeted manner by the parameterisation of the hold time. The temperature and stress history of crack-free and crack-afflicted spot welds are analysed and a conclusion on the borders defining the LME active region is derived. KW - Liquid metal embrittlement KW - Crack KW - Advanced high-strength steels KW - Resistance spot welding KW - Hold time KW - Heat input KW - Simulation PY - 2020 DO - https://doi.org/10.1080/13621718.2020.1795585 SN - 1362-1718 VL - 25 IS - 7 SP - 617 EP - 624 PB - Taylor Francis Online AN - OPUS4-51096 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -