TY - JOUR A1 - Hlavacek, Petr A1 - Gluth, Gregor A1 - Lüchtenborg, Jörg A1 - Sturm, Patrick A1 - Mühler, T. A1 - Kühne, Hans-Carsten A1 - Günster, Jens T1 - A Novel Approach to Additive Manufacturing of Alkali-activated Materials: Laser-induced Slip Casting (LIS) of Lithium Aluminate/Silica Slurries N2 - Additive manufacturing of alkali-activated materials currently attracts a lot of attention, because of the possibility to produce customized high-performance elements for a range of applications, potentially being more resource-efficient than conventionally produced parts. Here, we describe a new additive manufacturing process for alkali-activated materials that is based on selective laser-heating of lithium aluminate/microsilica slurries. The new process-material combination allows to manufacture elements with complex geometries at high building rates and high accuracy. The process is versatile and transferrable to structures of sizes differing by orders of magnitude. The mechanical strength of the obtained materials was in the range of values reported for conventional metakaolin-based geopolymers, and superior to what has been hitherto reported for alkali-activated materials produced by additive manufacturing. This mechanical performance was obtained despite the fact that the degree of reaction of the lithium aluminate and the microsilica was low, suggesting that significant reactions took place only at the surface of the microsilica particles. KW - Laser-induced slip casting KW - Alkali-activated materials KW - Additive manufacturing PY - 2019 U6 - https://doi.org/10.29272/cmt.2018.0011 SN - 2612-4882 VL - 1 IS - 2 SP - 138 EP - 144 PB - Techna Group AN - OPUS4-49142 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Zocca, Andrea A1 - Lüchtenborg, Jörg A1 - Mühler, T. A1 - Wilbig, Janka A1 - Mohr, Gunther A1 - Villatte, T. A1 - Léonard, Fabien A1 - Nolze, Gert A1 - Sparenberg, M. A1 - Melcher, J. A1 - Hilgenberg, Kai A1 - Günster, Jens T1 - Enabling the 3D Printing of Metal Components in μ-Gravity N2 - As humanity contemplates manned missions to Mars, strategies need to be developed for the design and operation of hospitable environments to safely work in space for years. The supply of spare parts for repair and replacement of lost equipment will be one key need, but in-space manufacturing remains the only option for a timely supply. With high flexibility in design and the ability to manufacture ready-to-use components directly from a computeraided model, additive manufacturing (AM) technologies appear extremely attractive. For the manufacturing of metal parts, laser-beam melting is the most widely used AM process. However, the handling of metal powders in the absence of gravity is one prerequisite for its successful application in space. A gas flow throughout the powder bed is successfully applied to compensate for missing gravitational forces in microgravity experiments. This so-called gas-flow-assisted powder deposition is based on a porous Building platform acting as a filter for the fixation of metal particles in a gas flow driven by a pressure difference maintained by a vacuum pump. KW - Additive manufacturing KW - µ-gravity KW - Laser beam melting KW - Parabolic flight KW - 3D printing PY - 2019 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-492190 SP - 1900506 PB - WILEY-VCH Verlag GmbH AN - OPUS4-49219 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Lüchtenborg, Jörg A1 - Mühler, T. A1 - Léonard, Fabien A1 - Günster, Jens T1 - Laser-induced slip casting (LIS) – a new additive manufacturing process for dense ceramics demonstrated with Si3N4 N2 - Up to now, there exists a lack of methods for the additive manufacturing of voluminous ceramic parts with properties comparable to those of conventionally manufactured ones. A high density after sintering is needed to reach the superior properties of ceramic materials. We have developed a new additive manufacturing method, Laser-Induced Slip casting (LIS), to generate ceramic green bodies with high particle packing density and with virtually no restriction in the particle size of the feedstock, especially in terms of small particles. This is achieved by laser-induced local drying of slurries, with the process resembling many features of the well-established stereolithography, but without the excessive use of polymeric material. Thus, unlike the stereolithography process, the resulting green bodies can be processed like traditionally produced ceramic parts. This method allows large and dense additive-manufactured parts to be obtained from conventional water-based ceramic slurries. As an example, we will demonstrate the application of this novel technique with Si3N4. KW - Additive manufacturing KW - Ceramics PY - 2017 U6 - https://doi.org/10.4416/JCST2017-00091 SN - 2190-9385 VL - 8 IS - 4 SP - 531 EP - 540 PB - Göller Verlag CY - Baden-Baden AN - OPUS4-43738 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Zocca, Andrea A1 - Wirth, Cynthia A1 - Mühler, T. A1 - Günster, Jens T1 - Powder-bed stabilization for powder-based additive manufacturing N2 - The most successful additive manufacturing (AM) technologies are based on the layer-by-layer deposition of a flowable powder. Although considered as the third industrial revolution, one factor still limiting these processes to become completely autonomous is the often necessary build-up of support structures. Besides the prevention of lateral shifts of the part during the deposition of layers, the support assures quality and stability to the built process. The loose powder itself surrounding the built object, or so-called powder-bed, does not provide this sustenance in most existent technology available. Here we present a simple but effective and economical method for stabilizing the powder-bed, preventing distortions in the geometry with no need for support structures. This effect, achieved by applying an air flow through the powder-bed, is enabling an entirely autonomous generation of parts and is a major contribution to all powder-based additive manufacturing technologies. Moreover, it makes powder-based AM independent of gravitational forces, which will facilitate crafting items in space from a variety of powdery materials. KW - Additive manufacturing KW - Powder bed PY - 2014 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-314244 SN - 1687-8132 SN - 1687-8140 N1 - Geburtsname von Wirth, Cynthia: Gomes, C. M. - Birth name of Wirth, Cynthia: Gomes, C. M. VL - 2014 SP - 491581-1 - 491581-6 PB - Hindawi Publishing Corporation CY - New York, NY ; Cairo AN - OPUS4-31424 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Zocca, Andrea A1 - Colombo, P. A1 - Günster, Jens A1 - Mühler, T. A1 - Heinrich, J.G. T1 - Selective laser densification of lithium aluminosilicate glass ceramic tapes N2 - Tapes, cast by blade deposition of a lithium aluminosilicate glass slurry, were sintered using a YAG-fiber laser, with the aim of finding suitable parameters for an additive manufacturing process based on layer-wise slurry deposition and selective laser densification. The influence of the laser parameters (output power and scan velocity) on the sintering was evaluated, by scanning electron microscopy and by X-ray diffraction, on the basis of the quality of the processed layer. Well densified samples could be obtained only in a small window of values for the output power and the scan velocity. The measurement of the width of a set of single scanned lines allowed also to estimate the minimum resolution of the system along the layer plane. KW - Selective laser sintering (SLS) KW - Laserwise-slurry-deposition (LSD) KW - Glass-ceramic KW - LAS PY - 2013 UR - http://ac.els-cdn.com/S0169433212020168/1-s2.0-S0169433212020168-main.pdf?_tid=4ba0c92c-31d4-11e4-84f1-00000aab0f02&acdnat=1409575040_15d5256291262aca99cc5321374ab879 U6 - https://doi.org/10.1016/j.apsusc.2012.11.058 SN - 0169-4332 SN - 1873-5584 VL - 265 SP - 610 EP - 614 PB - North-Holland CY - Amsterdam AN - OPUS4-31283 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mühler, T. A1 - Heinrich, J. A1 - Wirth, Cynthia A1 - Günster, Jens T1 - Slurry-based additive manufacturing of ceramics N2 - Most additive manufacturing (AM) techniques have in common that material is spread out as thin layers of a dried powder/granulate by a roller or a shaker system. These layers are mostly characterized by a low packing rate. On the other hand, appreciable densities can be reached by the use of ceramic slurries. In this context, the layer-wise slurry deposition (LSD) has been developed. Specific features of the LSD process are reflected on the basis of already existing additive manufacturing technologies. The microstructure of laser-sintered bodies will be discussed, and strategies for an improved microstructure during sintering will be introduced. KW - Additive manufacturing KW - Ceramic KW - Selective laser sintering PY - 2015 U6 - https://doi.org/10.1111/ijac.12113 SN - 1546-542X SN - 1744-7402 N1 - Geburtsname von Wirth, Cynthia: Gomes, C. M. - Birth name of Wirth, Cynthia: Gomes, C. M. VL - 12 IS - 1 SP - 18 EP - 25 PB - American Ceramic Soc. CY - Westerville, Ohio AN - OPUS4-29937 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mühler, T. A1 - Wirth, Cynthia A1 - Ascheri, Mary A1 - Nicolaides, Dagmar A1 - Heinrich, J. A1 - Günster, Jens T1 - Slurry-based powder beds for the selective laser sintering of silicate ceramics N2 - Selective laser sintering of ceramic powders is a promising technique for the additive manufacturing of complex- and delicate-shaped ceramic parts. Most techniques have in common that the powder to be sintered is spread to a thin layer as a dry powder by means of a roller or shaker system. These layers have a relatively low density. On the other hand, appreciable densities can be reached with the use of ceramic slurries as the starting material. Therefore, the layer-wise slurry deposition (LSD) process has been developed. Layer stacks, i.e. powder beds, built up by employing the LSD technology exhibit a density comparable to ceramic powder compacts processed by means of conventional forming technologies. Writing the layer information with a focused laser beam in these dense ceramic powder compacts enables the manufacture of ceramic bodies with a high density and precision in contour. KW - Additive Fertigung KW - Keramik PY - 2015 U6 - https://doi.org/10.4416/JCST2015-0007 SN - 2190-9385 VL - 6 IS - 2 SP - 113 EP - 118 PB - Göller CY - Baden-Baden AN - OPUS4-34962 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mühler, T. A1 - Helsch, G. A1 - Heinrich, J.G. A1 - Yao, Dongxu A1 - Gräf, S. A1 - Müller, F.A. A1 - Günster, Jens T1 - Strategies for the selective volume sintering of ceramics N2 - The present study is dealing with the basic physics for a novel way to generate a free-formed ceramic body, not like common layer by layer, but directly by Selective Volume Sintering (SVS) in a compact block of ceramic powder. To penetrate with laser light into the volume of a ceramic powder compact it is necessary to investigate the light scattering properties of ceramic powders. Compared with polymers and metals, ceramic materials are unique as they offer a wide optical window of transparency. The optical window typically ranges from below 0.3 up to 5 µm wave length. In the present study thin layers of quartz glass (SiO2) particles have been prepared. As a function of layer thickness and the particle size, transmission and reflection spectra in a wave length range between 0.5 and 2.5 µm have been recorded. Depending on the respective particle size and by choosing a proper relation between particle size and wave length of the incident laser radiation, it is found that light can penetrate a powder compact up to a depth of a few millimeters. With an adjustment of the light absorption properties of the compact the initiation of sintering in the volume of the compact is possible. KW - Additive Manufacturing PY - 2014 U6 - https://doi.org/10.1557/jmr.2014.174 SN - 0884-2914 VL - 29 IS - 17 SP - 2095 EP - 2099 PB - Materials Research Society CY - Warrendale, Pa. AN - OPUS4-32544 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Wirth, Cynthia A1 - Müller, Ralf A1 - Günster, Jens A1 - Mühler, T. A1 - Görke, R. A1 - Heinrich, J.G. T1 - Submicrometer silica spheres generated by laser fuming N2 - The production of agglomerate-free SiO2 particles exhibiting a monomodal distribution of particle sizes of around 300 nm by means of direct laser fuming of micrometric SiO2 powders has been successfully demonstrated. With a 12 kW cw CO2 laser system, a production rate of up to 1 kilogram powder per hour was achieved. Almost ideal spherical amorphous SiO2 particles in a broad particle size distribution between 10 nm and several 100 nm (d50 ≈ 300 nm) were synthesized. Several observations suggest weak agglomeration forces between the particles. A temperature reduction of 200 °C for sintering powder compacts was observed. KW - Laser KW - SiO2 KW - Nanopowder PY - 2013 U6 - https://doi.org/10.4416/JCST2012-00033 SN - 2190-9385 N1 - Geburtsname von Wirth, Cynthia: Gomes, C. M. - Birth name of Wirth, Cynthia: Gomes, C. M. VL - 4 IS - 1 SP - 11 EP - 18 PB - Göller CY - Baden-Baden AN - OPUS4-31423 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -