TY - JOUR A1 - Ginés-Palomares, Juan Carlos A1 - Fateri, Miranda A1 - Kalhöfer, Eckhard A1 - Schubert, Tim A1 - Meyer, Lena A1 - Kolsch, Nico A1 - Brandic Lipinska, Monica A1 - Davenport, Robert A1 - Imhof, Barbara A1 - Waclavicek, René A1 - Sperl, Matthias A1 - Makaya, Advenit A1 - Günster, Jens T1 - Laser melting manufacturing of large elements of lunar regolith simulant for paving on the Moon N2 - The next steps for the expansion of the human presence in the solar system will be taken on the Moon. However, due to the low lunar gravity, the suspended dust generated when lunar rovers move across the lunar soil is a significant risk for lunar missions as it can affect the systems of the exploration vehicles. One solution to mitigate this problem is the construction of roads and landing pads on the Moon. In addition, to increase the sustainability of future lunar missions, in-situ resource utilization (ISRU) techniques must be developed. In this paper, the use of concentrated light for paving on the Moon by melting the lunar regolith is investigated. As a substitute of the concentrated sunlight, a high-power CO2 laser is used in the experiments. With this set-up, a maximum laser spot diameter of 100 mm can be achieved, which translates in high thicknesses of the consolidated layers. Furthermore, the lunar regolith simulant EAC-1A is used as a substitute of the actual lunar soil. At the end of the study, large samples (approximately 250 × 250 mm) with interlocking capabilities were fabricated by melting the lunar simulant with the laser directly on the powder bed. Large areas of lunar soil can be covered with these samples and serve as roads and landing pads, decreasing the propagation of lunar dust. These manufactured samples were analysed regarding their ineralogical composition, internal structure and mechanical properties. KW - Regolith KW - ISRU KW - Moon KW - Laser KW - Additive manufacturing PY - 2023 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-585985 SN - 2045-2322 VL - 13 SP - 1 EP - 10 PB - Springer AN - OPUS4-58598 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schröder, Jakob A1 - Evans, Alexander A1 - Luzin, V. A1 - Abreu Faria, G. A1 - Degener, Sebastian A1 - Polatidis, E. A1 - Čapek, J. A1 - Kromm, Arne A1 - Dovzhenko, G. A1 - Bruno, Giovanni T1 - Texture-based residual stress analysis of laser powder bed fused Inconel 718 parts N2 - Although layer-based additive manufacturing methods such as laser powder bed fusion (PBF-LB) offer an immense geometrical freedom in design, they are typically subject to a build-up of internal stress (i.e. thermal stress) during manufacturing. As a consequence, significant residual stress (RS) is retained in the final part as a footprint of these internal stresses. Furthermore, localized melting and solidification inherently induce columnar-type grain growth accompanied by crystallographic texture. Although diffraction-based methods are commonly used to determine the RS distribution in PBF-LB parts, such features pose metrological challenges in their application. In theory, preferred grain orientation invalidates the hypothesis of isotropic material behavior underlying the common methods to determine RS. In this work, more refined methods are employed to determine RS in PBF-LB/M/IN718 prisms, based on crystallographic texture data. In fact, the employment of direction-dependent elastic constants (i.e. stress factors) for the calculation of RS results in insignificant differences from conventional approaches based on the hypothesis of isotropic mechanical properties. It can be concluded that this result is directly linked to the fact that the {311} lattice planes typically used for RS analysis in nickel-based alloys have high multiplicity and less strong texture intensities compared with other lattice planes. It is also found that the length of the laser scan vectors determines the surface RS distribution in prisms prior to their removal from the baseplate. On removal from the baseplate the surface RS considerably relaxes and/or redistributes; a combination of the geometry and the scanning strategy dictates the sub-surface RS distribution. KW - Additive manufacturing KW - Electron backscattered diffraction KW - Principal stress KW - Residual stress PY - 2023 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-578331 SN - 1600-5767 VL - 56 IS - Pt 4 SP - 1076 EP - 1090 AN - OPUS4-57833 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Rehmer, Birgit A1 - Bayram, Faruk A1 - Ávila Calderon, Luis Alexander A1 - Mohr, Gunther A1 - Skrotzki, Birgit T1 - Elastic modulus data for additively and conventionally manufactured variants of Ti-6Al-4V, IN718 and AISI 316 L N2 - This article reports temperature-dependent elastic properties (Young’s modulus, shear modulus) of three alloys measured by the dynamic resonance method. The alloys Ti-6Al-4V, Inconel IN718, and AISI 316 L were each investigated in a variant produced by an additive manufacturing processing route and by a conventional manufacturing processing route. The datasets include information on processing routes and parameters, heat treatments, grain size, specimen dimensions, and weight, as well as Young’s and shear modulus along with their measurement uncertainty. The process routes and methods are described in detail. The datasets were generated in an accredited testing lab, audited as BAM reference data, and are hosted in the open data repository Zenodo. Possible data usages include the verification of the correctness of the test setup via Young’s modulus comparison in low-cycle fatigue (LCF) or thermo-mechanical fatigue (TMF) testing campaigns, the design auf VHCF specimens and the use as input data for simulation purposes. KW - Elastic modulus KW - Young's modulus KW - Shear modulus KW - Additive manufacturing KW - AISI 316L KW - IN 718 KW - Ti-6Al-4V KW - Reference data KW - Temperature dependence PY - 2023 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-579716 VL - 10 IS - 1 SP - 1 EP - 9 PB - Springer Nature AN - OPUS4-57971 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Franchin, G. A1 - Zocca, Andrea A1 - Karl, D. A1 - Yun, H. A1 - Tian, X. T1 - Editorial: Advances in additive manufacturing of ceramics N2 - Recently, additive manufacturing of ceramics has achieved the maturity to be transferred from scientific laboratories to industrial applications. At the same time, research is progressing to expand the boundaries of this field into the territory of novel materials and applications. This feature issue addresses current progress in all aspects of additive manufacturing of ceramics, from parts design to feedstock selection, from technological development to characterization of printed components. KW - Additive manufacturing KW - Ceramic PY - 2022 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-549361 SN - 2666-5395 VL - 10 SP - 1 EP - 2 PB - Elsevier CY - Amsterdam AN - OPUS4-54936 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Zocca, Andrea A1 - Wilbig, Janka A1 - Waske, Anja A1 - Günster, Jens A1 - Widjaja, Martinus A1 - Neumann, C. A1 - Clozel, M. A1 - Meyer, A. A1 - Ding, J. A1 - Zhou, Z. A1 - Tian, X. T1 - Challenges in the Technology Development for Additive Manufacturing in Space N2 - Instead of foreseeing and preparing for all possible scenarios of machine failures, accidents, and other challenges arising in space missions, it appears logical to take advantage of the flexibility of additive manufacturing for “in-space manufacturing” (ISM). Manned missions into space rely on complicated equipment, and their safe operation is a great challenge. Bearing in mind the absolute distance for manned missions to the Moon and Mars, the supply of spare parts for the repair and replacement of lost equipment via shipment from Earth would require too much time. With the high flexibility in design and the ability to manufacture ready-to-use components directly from a computer-aided model, additive manufacturing technologies appear to be extremely attractive in this context. Moreover, appropriate technologies are required for the manufacture of building habitats for extended stays of astronauts on the Moon and Mars, as well as material/feedstock. The capacities for sending equipment and material into space are not only very limited and costly, but also raise concerns regarding environmental issues on Earth. Accordingly, not all materials can be sent from Earth, and strategies for the use of in-situ resources, i.e., in-situ resource utilization (ISRU), are being envisioned. For the manufacturing of both complex parts and equipment, as well as for large infrastructure, appropriate technologies for material processing in space need to be developed. KW - Additive manufacturing KW - Space KW - Process PY - 2022 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-549204 SN - 2772-6657 VL - 1 IS - 1 SP - 1 EP - 13 PB - Elsevier Ltd. AN - OPUS4-54920 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schneider, M. A1 - Bettge, Dirk A1 - Hilgenberg, Kai A1 - Binder, M. A1 - Dollmeier, K. A1 - Dreyer, M. A1 - Klöden, B. A1 - Schlingmann, T. A1 - Schmidt, J. T1 - Reproducibility and Scattering in Additive Manufacturing: Results from a Round Robin on PBF-LB/M AlSi10Mg Alloy T1 - Reproduzierbarkeit und Streuung bei der additiven Fertigung: Ergebnisse eines Ringversuchs mit einer PBF-LB/M AlSi10Mg-Legierung N2 - The round robin test investigated the reliability users can expect for AlSi10Mg additive manufactured specimens by laser powder bed fusion through examining powder quality, process parameter, microstructure defects, strength and fatigue. Besides for one outlier, expected static material properties could be found. Optical microstructure inspection was beneficial to determine true porosity and porosity types to explain the occurring scatter in properties. Fractographic analyses reveal that the fatigue crack propagation starts at the rough as-built surface for all specimens. Statistical analysis of the scatter in fatigue using statistical derived safety factors concludes that at a stress of 36.87 MPa the fatigue limit of 107 cycles could be reached for all specimen with a survival probability of 99.999 %. N2 - Im Rahmen eines Ringversuchs wurde durch die Untersuchung der Pulverqualität, der Prozessparameter, der Gefügefehler, der Festigkeit und der Ermüdung die Zuverlässigkeit bestimmt, die Nutzer von AlSi10Mg-Proben erwarten können, die mit pulverbettbasiertes Schmelzen mittels Laser (engl. Laser Powder Bed Fusion) gefertigt worden sind. Abgesehen von einem Ausreißer wurden die erwarteten statischen Materialeigenschaften erreicht. Eine optische Gefügeprüfung diente dazu, die tatsächliche Porosität und Arten von Porosität zu ermitteln, um die bei den Eigenschaften auftretende Streuung zu erklären. Fraktographische Unterschungen zeigen eine bei allen Proben von der rauen Oberfläche im As-built-Zustand ausgehende Ermüdungsrissausbreitung. Aus der statistischen Analyse der Streuung bezüglich der Ermüdung unter Anwendung von statistischen abgeleiteten Sicherheitsfaktoren geht hervor, dass alle Proben die Dauerfestigkeit von 107 Zyklen bei einer Spannung von 36,87 MPa mit einer Überlebenswahrscheinlichkeit von 99,999 % erreichten. KW - Additive manufacturing KW - Reproducibility KW - Reliability PY - 2022 U6 - https://doi.org/10.1515/pm-2022-1018 SN - 2195-8599 VL - 59 IS - 10 SP - 580 EP - 614 PB - De Gruyter AN - OPUS4-55935 LA - mul AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Sommer, Konstantin A1 - Agudo Jácome, Leonardo A1 - Hesse, René A1 - Bettge, Dirk T1 - Revealing the nature of melt pool boundaries in additively manufactured stainless steel by nano-sized modulation N2 - In the current study, the 3D nature of the melt pool boundaries (MPBs) in a 316 L austenitic steel additively manufactured by laser-based powder bed fusion (L-PBF) is investigated. The change of the cell growth direction and its relationship to the MPBs is investigated by transmission electron microscopy. A hitherto unreported modulated substructure with a periodicity of 21 nm is further discovered within the cell cores of the cellular substructure, which results from a partial transformation of the austenite, which is induced by a Ga+ focused ion beam. While the cell cores show the modulated substructure, cell boundaries do not. The diffraction pattern of the modulated substructure is exploited to show a thickness ≥200 nm for the MPB. At MPBs, the cell walls are suppressed, leading to continuously connecting cell cores across the MPB. This continuous MPB is described either as overlapping regions of cells of different growing directions when a new melt pool solidifies or as a narrow planar growth preceding the new melt pool. KW - Additive manufacturing KW - Austenitic steel 316L KW - Melt pool boundary KW - Microstructural characterization KW - Transmission electron microscopy PY - 2022 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-547295 SN - 1527-2648 VL - 24 IS - 6 SP - 1 EP - 11 PB - Wiley-VCH CY - Weinheim AN - OPUS4-54729 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schröder, Jakob A1 - Evans, Alexander A1 - Polatidis, E. A1 - Čapek, J. A1 - Mohr, Gunther A1 - Serrano Munoz, Itziar A1 - Bruno, Giovanni T1 - Understanding the impact of texture on the micromechanical anisotropy of laser powder bed fused Inconel 718 N2 - The manufacturability of metallic alloys using laser-based additive manufacturing methods such as laser powder bed fusion has substantially improved within the last decade. However, local melting and solidification cause hierarchically structured and crystallographically textured microstructures possessing large residual stress. Such microstructures are not only the origin of mechanical anisotropy but also pose metrological challenges for the diffraction-based residual stress determination. Here we demonstrate the influence of the build orientation and the texture on the microstructure and consequently the mechanical anisotropy of as-built Inconel 718. For this purpose, we manufactured specimens with [001]/[011]-, [001]- and [011]/[111]-type textures along their loading direction. In addition to changes in the Young’s moduli, the differences in the crystallographic textures result in variations of the yield and ultimate tensile strengths. With this in mind, we studied the anisotropy on the micromechanical scale by subjecting the specimens to tensile loads along the different texture directions during in situ neutron diffraction experiments. In this context, the response of multiple lattice planes up to a tensile strain of 10% displayed differences in the load partitioning and the residual strain accumulation for the specimen with [011]/[111]-type texture. However, the relative behavior of the specimens possessing an [001]/[011]- and [001]-type texture remained qualitatively similar. The consequences on the metrology of residual stress determination methods are discussed. KW - Laser powder bed fusion KW - Additive manufacturing KW - Electron backscatter diffraction KW - Tensile testing KW - Diffraction PY - 2022 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-555840 SN - 1573-4803 VL - 2022 IS - 57 SP - 15036 EP - 15058 PB - Springer Science + Business Media B.V. CY - Dordrecht AN - OPUS4-55584 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Hildebrand, G. A1 - Sänger, Johanna Christiane A1 - Schirmer, U. A1 - Mantei, W. A1 - Dupuis, Y. A1 - Houbertz, R. A1 - Liefeith, K. T1 - Process Development for Additive Manufacturing of Alumina Toughened Zirconia for 3D Structures by Means of Two-Photon Absorption Technique N2 - Additive manufacturing is well established for plastics and metals, and it gets more and more implemented in a variety of industrial processes. Beside these well-established material platforms, additive manufacturing processes are highly interesting for ceramics, especially regarding resource conservation and for the production of complex three-dimensional shapes and structures with specific feature sizes in the µm and mm range with high accuracy. The usage of ceramics in 3D printing is, however, just at the beginning of a technical implementation in a continuously and fast rising field of research and development. The flexible fabrication of highly complex and precise 3D structures by means of light-induced photopolymerization that are difficult to realize using traditional ceramic fabrication methods such as casting and machining is of high importance. Generally, slurry-based ceramic 3D printing technologies involve liquid or semi-liquid polymeric systems dispersed with ceramic particles as feedstock (inks or pastes), depending on the solid loading and viscosity of the system. This paper includes all types of photo-curable polymer-ceramic-mixtures (feedstock), while demonstrating our own work on 3D printed alumina toughened zirconia based ceramic slurries with light induced polymerization on the basis of two-photon absorption (TPA) for the first time. As a proven exemplary on cuboids with varying edge length and double pyramids in the µm-range we state that real 3D micro-stereolithographic fabrication of ceramic products will be generally possible in the near future by means of TPA. This technology enables the fabrication of 3D structures with high accuracy in comparison to ceramic technologies that apply single-photon excitation. In sum, our work is intended to contribute to the fundamental development of this technology for the representation of oxide-ceramic components (proof-of-principle) and helps to exploit the high potential of additive processes in the field of bio-ceramics in the medium to long-term future. KW - Additive manufacturing KW - Ceramics 3D printing KW - Two-photon adsorption KW - Polymer-ceramic mixtures KW - Bio-ceramic engineering PY - 2021 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-526672 VL - 4 IS - 2 SP - 224 EP - 239 PB - MDPI CY - Basel AN - OPUS4-52667 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Sprengel, Maximilian A1 - Ulbricht, Alexander A1 - Evans, Alexander A1 - Kromm, Arne A1 - Sommer, Konstantin A1 - Werner, Tiago A1 - Kelleher, J. A1 - Bruno, Giovanni A1 - Kannengießer, Thomas T1 - Towards the optimization of post-laser powder bed fusion stress-relieve treatments of stainless steel 316L N2 - This study reports on the stress relaxation potential of stress-relieving heat treatments for laser powder bed fused 316L. The residual stress is monitored non-destructively using neutron diffraction before and after the heat treatment. Moreover, the evolution of the microstructure is analysed using scanning electron microscopy. The results show, that a strong relaxation of the residual stress is obtained when applying a heat treatment temperature at 900°C. However, the loss of the cellular substructure needs to be considered when applying this heat treatment strategy. KW - Residual stress KW - Additive manufacturing KW - Neutron diffraction KW - Projekt AGIL - Alterung additiv gefertigter metallischer Materialien und Komponenten PY - 2021 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-536045 SN - 1543-1940 VL - 52 IS - 12 SP - 5342 EP - 5356 PB - Springer CY - Boston AN - OPUS4-53604 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -