TY - CONF A1 - Thiede, Tobias T1 - Computed Tomography of SLM Produced IN625 Parts: From Powder Grains to Lattice Structures N2 - The layer-by-layer Additive Manufacturing (AM) by means of Selective Laser Melting (SLM) offers many prospects regarding the design of a part used in aeroplane components and gas turbines. However, structural deviations from the nominal morphology are unavoidable. The cooling of the finished part leads to shrinkage and a high surface roughness is induced by attached powder particles affecting the part volume too. The integrity and load-bearing capacity of a SLM produced lattice structure has been investigated by means of in-situ X-ray computed tomography during compression. The lattice structure was compressed by 10 % in height with an applied maximum force of 5 kN. Additionally, a single strut has been investigated ex-situ as a component of the lattice structure. With the higher resolution achieved on the single strut, the pore distribution (size and location) as well as the surface roughness were assessed. The particle and pore size distribution of the raw powder have been investigated, too. One of the main results coming from the in-situ analysis was that the nodes were identified as the weakest points in the lattice structure. T2 - Inno Testing CY - Wildau, Germany DA - 22.02.2018 KW - Additive Manufacturing KW - Selective Laser Melting KW - Computed Tomography KW - Lattice Structures KW - Porosity PY - 2018 AN - OPUS4-44515 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Werner, Tiago T1 - Comparison of the fatigue behavior of wrought and additively manufactured AISI 316L N2 - Additively Manufactured (AM) parts are still far from being used in safety-relevant applications, mainly due to a lack of understanding of the feedstock-process-propertiesperformance relationship. This work aims at providing a characterization of the fatigue behavior of the additively manufactured AISI 316L austenitic stainless steel and a direct comparison with the fatigue performance of the wrought steel. A set of specimens has been produced by laser powder bed fusion (L-PBF) and a second set of specimens has been machined out of hot-rolled plates. The L-PBF material shows a higher fatigue limit and better finite life performance compared to the wrought material, accompanied by an extensive amount of cyclic softening. T2 - Fatigue Design 2021 CY - Online meeting DA - 17.11.2021 KW - Additive Manufacturing KW - AM KW - 316L KW - Fatigue KW - High Cycle Fatigue KW - Low Cycle Fatigue PY - 2021 AN - OPUS4-53780 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hébrard, Louis T1 - Comparison of Room and High Temperature Fatigue Behavior of a New LPBF VDM 780 Alloy N2 - The actual environmental challenges require a huge effort from all industrial sectors to reduce their emissions of greenhouse gasses and pollutants. In this context, aeronautics is deeply concerned as one of the most emissive industrial sectors (cf. EU Green Deal). The answer to this pressing challenge is complex and involves new fuels and engine concepts, new aerostructures with higher weight-savings, as well as new, energy-efficient, and sustainable manufacturing technologies and materials. Two technologies may contribute particularly to achieving the goals: (i) new and more energy-efficient processes such as additive manufacturing (AM) can be used for part production; (ii) the engine efficiency of airplanes can be significantly improved to save fuel and reduce gas emissions. The latter can be achieved by increasing the engine thermal efficiency, i.e., increasing the turbine inlet temperature. Currently, only single-crystalline cast materials are available to be used for the thermally highest-loaded parts in the gas turbine engine, i.e., the turbine blades in the high-pressure turbine just behind the combustion chamber. These materials rely on a special casting technology, although they lose these original material performances when additive manufactured. In addition, current materials suitable for metal additive manufacturing have a limited range of temperature application. Therefore, the focus is on the development of new materials targeting higher in-service operation temperatures and durability. Recently, a new Ni-based superalloy (VDM 780) has been developed to ensure microstructural stability up to 800 °C. The goal of this work is to provide a deeper understanding of the high temperature fatigue properties of this alloy. This will enable the identification of the maximum operating temperature of this alloy and assess its performance in order to establish its potential in view of a new generation of more efficient aero-engines. T2 - 11th Edition of Fatigue Design International Conference CY - Senlis, France DA - 19.11.2025 KW - Fatigue KW - Additive Manufacturing KW - Ni-based superalloy KW - High Temperature PY - 2025 AN - OPUS4-64992 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Breese, Philipp Peter T1 - Comparison of NIR and SWIR thermography for defect detection in laser powder bed fusion N2 - Since laser powder bed fusion (PBF-LB/M) is prone to the formation of defects during the building process, a fundamental requirement for widespread application is to find ways to assure safety and reliability of the additively manufactured parts. A possible solution for this problem lies in the usage of in-situ thermographic monitoring for defect detection. In this contribution we investigate possibilities and limitations of the VIS/NIR wavelength range for defect detection. A VIS/NIR camera can be based on conventional silicon-based sensors which typically have much higher spatial and temporal resolution in the same price range but are more limited in the detectable temperature range than infrared sensors designed for longer wavelengths. To investigate the influence, we compared the thermographic signatures during the creation of artificially provoked defects by local parameter variations in test specimens made of a nickel alloy (UNS N07208) for two different wavelength ranges (~980 nm and ~1600 nm). T2 - 13th CIRP Conference on Photonic Technologies - LANE 2024 CY - Fürth, Germany DA - 15.09.2024 KW - Additive Manufacturing KW - Laser Powder Bed Fusion KW - Nondestructive Testing KW - Defect Detection KW - Thermography PY - 2024 AN - OPUS4-61285 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Scheuschner, Nils T1 - Comparison of in-situ OES and Thermography in the LMD process N2 - In this talk optical emission spectroscopy (OES) and thermographic measurements of the Laser Metal Deposition Process (LMD) are presented. T2 - Workshop on Additive Manufacturing: Process, materials, simulation & implants CY - BAM, Berlin, Germany DA - 13.05.2019 KW - Additive Manufacturing KW - Infrared Thermography PY - 2019 AN - OPUS4-48054 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Mohr, Gunther T1 - Comparability issues of test specimens in laser powder bed fusion - how to consider differences in thermal history of complex components and primitive test specimens N2 - The capability to produce complexly and individually shaped metallic parts is one of the main advantages of the laser powder bed fusion (PBF-LB/M) process. However, the thermal history during additive manufacturing of complex components can differ significantly from the thermal history of geometrically primitive test specimens. This can result in divergent microstructures and resulting mechanical properties. It drastically limits the comparability of different built parts and requires expensive full component testing. Moreover, the thermal history as the spatiotemporal temperature distribution has been identified as a major cause for flaw formation. Therefore, it can be hypothesized that a similar thermal history between components and test specimens enhances their comparability. In this talk, the concept of representative test specimens is introduced, which enables the transfer of thermal histories from complex geometries to simple geometries, which can lead to better comparability of material properties. T2 - 4th Asia-Pacific International Conference on Additive Manufacturing (APICAM) CY - Melbourne, Australia DA - 30.06.2025 KW - Additive Manufacturing PY - 2025 AN - OPUS4-64527 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Sprengel, Maximilian T1 - Combining diffraction methods to non-destructively characterize through thickness residual stress gradients in L-PBF IN718 N2 - Laser based Powder Bed Fusion (L-PBF) is an additive manufacturing technique that has been continuously developed in the past years. It offers unparalleled design freedom and the resulting mechanical properties match, in some cases even exceed, those of materials processed by conventional manufacturing techniques. Nonetheless the process is prone to create Residual Stresses (RS) resulting from the sequential melting and solidification of the material. RS can reduce load bearing capacity and generate unwanted distortions thus diminishing the potential of L-PBF. This research activity aimed at characterizing the RS state in Inconel 718 L-PBF specimens using multiple diffraction methods. The microstructure as well as the surface and bulk residual stresses were investigated. The RS analysis was performed using X-ray, synchrotron and neutron diffraction methods to provide information at different depths within the specimen. The measurements were performed at the Bundesanstalt für Materialforschung und –prüfung (BAM), the EDDI beamline at BESSY II synchrotron and E3 line at BER II neutron reactor of the Helmholtz-Zentrum für Materialien und Energie (HZB) Berlin. The results revealed a depth depending RS state. The longitudinal and transverse stress components measured by X-ray and synchrotron at the surface agree well, exhibiting stress values around the yield strength of the material. In addition, synchrotron mapping showed gradients along the width and length of the sample for the longitudinal and transverse stress components. Lower RS values compared to surface RS were measured in the bulk of the material using neutron diffraction. The longitudinal stress component in the bulk was tensile and gradually decreased towards the edge of the specimen. The normal component however did not change significantly along the specimen dimensions and was of compressive nature. The transversal component was almost negligible. The results indicate that a stress re-distribution takes place during the deposition of the consecutive layers, which has to be further investigated. T2 - First European Conference on Structural Integrity of Additively Manufactured Materials CY - Trondheim, Norway DA - 09.09.2019 KW - Additive Manufacturing KW - Residual Stress KW - Diffraction PY - 2019 AN - OPUS4-49804 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zocca, Andrea T1 - Combination of layerwise slurry deposition and binder jetting (lsd-print) for the additive manufacturing of advanced ceramic materials N2 - Powder bed technologies are amongst the most successful Additive Manufacturing (AM) techniques. Powder bed fusion and binder jetting especially are leading AM technologies for metals and polymers, thanks to their high productivity and scalability. The application of these techniques to most ceramics has been difficult so far, because of the challenges related to the deposition of homogeneous powder layers when using fine powders. In this context, the “layerwise slurry deposition” (LSD) has been developed as a layer deposition method which enables the use of powder bed AM technologies also for advanced ceramic materials. The layerwise slurry deposition consists of the layer-by-layer deposition of a ceramic slurry by means of a doctor blade, in which the slurry is deposited and dried to achieve a highly packed powder layer. This offers high flexibility in the ceramic feedstock used, especially concerning material and particle size. The LSD technology can be combined with binder jetting to develop the so-called “LSDprint” process for the additive manufacturing of ceramics. The LSDprint technology combines the high-speed printing of binder jetting with the possibility of producing a variety of high-quality ceramics with properties comparable to those achieved by traditional processing. In this presentation, the LSD process will be introduced and several examples of application ranging from silicate to high-performance ceramics will be shown. Recent developments towards the scale-up and industrialization of this process will be discussed, alongside future perspectives for the multi-material additive manufacturing. T2 - Shaping 8 CY - Dübendorf, Switzerland DA - 14.09.2022 KW - Additive Manufacturing KW - 3D printing KW - Ceramics PY - 2022 AN - OPUS4-56523 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Meinel, Dietmar T1 - Classic Materials Testing in the Light of CT N2 - Currently, mandatory requirements and recommendations for the detection of irregularities in laser beam welded joints are based on classic micrographs as set out in the standard ISO 13919-1:2019. Compared to classic micrographs, computed tomography enables a non-destructive, three-dimensional and material-independent mode of operation, which delivers much more profound results. Even in building material testing, methods with limited informative value can be checked and supplemented by CT examinations. T2 - 13th International Conference on Industrial Computed Tomography (iCT2024) CY - Wels, Austria DA - 06.02.2024 KW - Computed Tomography KW - Additive Manufacturing KW - Machine-Learning Segmentation KW - Air Void System PY - 2024 AN - OPUS4-59568 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bruno, Giovanni T1 - Characterization of Additive Manufacturing Materials at BAM N2 - The combination of tomographic, microstructural data with other experimental techniques and with modeling is paramount, if we want to extract the maximum amount of information on material and component properties. In particular, quantitative image analysis, statistical approaches, direct discretization of tomographic reconstructions represent concrete possibilities to extend the power of the tomographic 3D representation to insights into the material and component performance. This logic thread equally holds for industrial and academic research and valorizes expensive experiments such as those carried out at synchrotron sources, which cannot be daily repeated. I will show a few examples of possible use of X-ray tomographic data for quantitative assessment of damage evolution and microstructural properties, as well as for non-destructive testing. Examples of micro-structured inhomogeneous materials will be given, such as Composites, Ceramics, Concrete, and Additively manufactured parts. I will also show how X-ray refraction computed tomography (CT) can be highly complementary to classic absorption CT, being sensitive to internal interfaces. Additionally, I will show how Neutron Diffraction, which is extremely well suited to the study of internal stresses, both residual and under external load, can well be coupled to the microstructural framework gained by CT, allowing understanding the microstructure-property relationships in materials. Finally, I will show that BAM is very active in standardization and certification, including production of Reference Materials and Methods. T2 - Skoltech Determination of the microscopic residual stress CY - Moscow, Russia DA - 20.11.2019 KW - Additive Manufacturing KW - Computed Tomography KW - Neutron Diffraction KW - X-ray refraction techniques KW - Composites PY - 2019 AN - OPUS4-49929 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - D'Accardi, E. T1 - Capability of active thermography to detect and localize pores in Metal Additive Manufacturing materials N2 - A powerful tool to understand, demonstrate and explain the limits of the pulsed technique in terms of detectability and localizability of AM keyhole pores has been assessed by comparing the active thermographic approach (both experimental and FEM simulations) to Computed Tomography results; ✓ µCT results demonstrate that the intended defect geometry is not achieved; indeed a network of voids (microdefects consisting of small sharp-edged hollows with a complicated, almost fractal, inner surface) was found; ✓ both Exp-PT and FEM results explains clearly why no indication of defect related to the thermal contrasts could be found during the investigation of an uncoated surface. However, the application of further data evaluations focusing on the thermal behavior and emissivity evaluation (PPT post data processing) enable the detection of some defects; ✓ coating facilitates a closer inspection of inner defects, but inhomogeneities of the coating could impair the spatial resolution and lead to the emergence of hotspots (the FEM simulation reached its limit with this extreme geometry where a 25 µm thin disc is considered at a 1 cm thick specimen in millisecond time resolution); ✓ both Exp-PT and FEM results allow the conclusion that very short pulses of 200 ms or shorter should be sufficient to detect these defects below, but near the surface; besides a short duration of the thermal phenomenon it should be emphasized, about 0.04 s (high frame rate camera); T2 - Convegno AIAS 2020 CY - Online meeting DA - 02.09.2020 KW - Additive Manufacturing KW - Laser powderbed fusion KW - Pores KW - Thermography PY - 2020 AN - OPUS4-51922 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bruno, Giovanni T1 - Capabilities at BAM, division 8.5- X-ray Imaging N2 - The X-ray computed tomography capabilities at BAM (especially in Division 8.5) are shown. It is also shown that the group possesses X-ray refraction radiography techniques, which are complementary to absorption radiography, and uses diffraction for residual stress analysis. Examples of applications in the field of Additive Manufacturing ale also shown. T2 - DGM AK XCT CY - Berlin, Germany DA - 27.11.2024 KW - X-ray Computed tomography KW - Defects KW - X-ray refraction radiography KW - Additive Manufacturing PY - 2024 AN - OPUS4-62046 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Schönsee, Eric T1 - Calculating rheological properties of fresh mortar for additive manufacturing based on experimental, multi sensor data N2 - Additive manufacturing of concrete structures is a novel and emerging technology. Free contouring in civil engineering, which allows for entirely new designs, is a significant advantage. In the future, lower construction costs are expected with increased construction speeds and decreasing required materials and workers. However, architects and civil engineers rely on a certain quality of execution to fulfil construction standards. Although several techniques and approaches demonstrate the advantages, quality control during printing is highly challenging and rarely applied. Due to the continuous mixing process commonly used in 3D concrete printing, it is impossible to exclude variations in the dry mixture or water content, and a test sample cannot be taken as a representative sample for the whole structure. Although mortar properties vary only locally, a defect in one layer during printing could affect the entire integrity of the whole structure . Therefore, real-time process monitoring is required to record and document the printing process. At the Bundesanstalt für Materialforschung und -prüfung (BAM) a new test rig for the additive manufacturing of concrete is built. The primary purpose is measuring and monitoring the properties of a mortar during the printing process. The following study investigates an approach for calculating yield stress and plastic viscosity based on experimentally recorded pressure data. The calculations assume that fresh mortar behaves as a Bingham fluid and that the Buckingham-Reiner-equation is applicable. A test setup consisting of rigid pipes with integrated pressure sensors at different positions is utilized. Monitoring the printing process with different sensors is crucial for the quality control of an ongoing process. T2 - Non-Tradijtional Cement and Concrete CY - Brno, Czech Republic DA - 25.06.2023 KW - 3DCP KW - Monitoring KW - Additive Manufacturing KW - Rheology KW - Bingham Fluid PY - 2023 AN - OPUS4-58144 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Günster, Jens T1 - Binder Jetting of Advanced Ceramics N2 - The Binder Jetting BJ process is one of the most versatile additive manufacturing technologies in use. In this process a binder is locally jetted into a powder bed for the consolidation of a 3D structure, layer by layer. Basically, all materials which can be provided as a flowable powder and, thus, spreadable to a thin layer, can be processed. Metals, ceramics and polymers are processable, but also materials from nature, such as sand, wood sawdust and insect frass. Moreover, the BJ technology is adapted to large building volumes of some cubic meters easily. Besides these striking advantages, the manufacture of ceramic parts by BJ is still challenging, as the packing density of the powder bed is generally too low and the particle size of a flowable powder too large for a successful densification of printed parts in a subsequent sintering step to an advanced ceramic product. After an introduction of binder jetting in general and highlighting some examples, strategies for obtaining dense ceramic parts by BJ will be introduced. T2 - yCAM 2022 CY - Barcelona, Spain DA - 08.11.2022 KW - Additive Manufacturing KW - Ceramics PY - 2022 AN - OPUS4-59887 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bruno, Giovanni T1 - BAM Characterization on Capabilities in Additive Manufacturing N2 - Quantitative image analysis, statistical approaches, direct discretization of tomographic reconstructions represent concrete possibilities to extend the power of the tomographic 3D representation to insights into the material and component performance. I will show a few examples of possible use of X-ray tomographic data for quantitative assessment of damage evolution and microstructural properties, as well as for non-destructive testing, with particular focus on additively manufactured materials. I will also show how X-ray refraction computed tomography (CT) and Neutron diffraction can be highly complementary to classic absorption CT, being sensitive to internal interfaces and residual stress analysis, respectively. T2 - Treffen des Konsortium AeroMatForAM CY - Köln, Germany DA - 16.03.2017 KW - Neutronenbeugung KW - Eigenspannungen KW - Additive Fertigung KW - Computertomographie KW - Röntgenrefraktion KW - X-ray Refraction KW - Additive Manufacturing KW - Computed Tomography KW - Residual Stress analysis KW - Neutron Diffraction PY - 2017 AN - OPUS4-39657 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bruno, Giovanni T1 - Avoid living dangerously: non-destructive characterization of AM parts from powder to end-of-life N2 - The freeform and the revolutionary design possibilities offered by additive manufacturing have skyrocketed the amount of optimization studies in the realm of engineering, and metallic additive manufactured parts are becoming a reality in industry. Not surprisingly, this has not been paralleled by a similar enthusiastic wave in the realm of materials science, and still very little is known about AM materials properties. This has the consequence that, typically, conventional materials properties are still used in design and even in simulations. lt is necessary to dig a lot deeper than at present, in order to understand these new materials classes, and in particular their microstructure and their intemal stresses, largely different from their cast or wrought companions. T2 - ISAM Konferenz 2019 CY - Dresden, Germany DA - 29.01.2019 KW - Computed Tomography KW - Microstructure KW - Metals KW - Additive Manufacturing PY - 2019 AN - OPUS4-47331 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Winkler, Michael T1 - Automated Repair of Gas Turbine Blades Using DED-Arc N2 - Gas turbine blades are critical components in aerospace and power generation, often subject to wear, erosion, and fatigue-induced damage. Traditional repair methods are labor-intensive, costly, prone to inconsistencies, and not rapidly adaptable. This work presents an automated approach for repairing gas turbine blade tips using Wire and Arc Directed Energy Deposition (DED-Arc) in combination with a high-precision point to point registration technique of laser line triangulation (LLT) 3D scans. The proposed workflow begins with affixation of the milled down turbine blade to a work piece manipulator using a 3D printed clamping mechanism and a rough alignment of the turbine tip. Subsequently, the turbine blade’s geometry is acquired using a fully integrated 3D laser triangulation sensor, transforming, and aggregating the captured 2D line data into a 3D scan in the working user coordinate system using live feedback data from a finely calibrated industry robot. This point cloud representation of the real-world turbine blade is then used as the target during an advanced point-to-point shape registration technique transforming the digital representation of the repair process containing all relevant tool path and geometry data into the coordinate system of the real-world turbine blade. Afterwards, the turbine tip is then iteratively repaired whereby the turbine tip geometry is divided into differentiated sections, each with its own optimized process parameter set. A key innovation in this approach is the adaptability of the repair process through a closed-loop monitoring system. After each DED-Arc deposition, a 3D scan is performed to document the deposited geometry, to detect the interaction of the different process parameter sets, to activate an intervention if necessary, and calculate subsequent tool paths based on current geometry data. The results indicate that the combination of precise 3D scan registration with DED-Arc is a viable solution for the industrial-scale repair of gas turbine blades leading to significant reduction in labor, tooling, process, and time related cost. T2 - IIW Assembly CY - Genoa, Italy DA - 22.06.2025 KW - DED-Arc KW - Additive Manufacturing KW - Repair KW - Turbine Blade KW - Automation PY - 2025 AN - OPUS4-63624 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Chaurasia, Prashant Kumar T1 - Automated In-situ Monitoring and Analysis of Process Signatures and Build Profile During Arc-based Directed Energy Deposition N2 - Automated in-situ synchronous monitoring and analysis of key process signatures during arc-based directed energy deposition (DED) process are the key challenges for layer-by-layer printing of large-scale parts. An attempt is presented here for real-time monitoring of process transients, deposit profile, and quantitative assessment of arc power, energy input and its influence on deposit dimensions. The workflow including setup, job generation and data analysis is fully automated in Python to allow large scale experiments with fast analysis results. T2 - 2nd Online Young Welding Professional International Conference CY - Online meeting DA - 06.02.2025 KW - Additive Manufacturing KW - Arc welding KW - DED-arc KW - Monitoring KW - Deposition profile PY - 2025 AN - OPUS4-62663 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Chaurasia, Prashant Kumar A1 - Cagtay, Fabry A1 - Andreas, Pittner A1 - Rethmeier, Michael T1 - Automated in situ monitoring and analysis of process signatures and build profiles during wire arc directed energy deposition N2 - Wire arc directed energy deposition (DED-Arc) is an emerging metal additive manufacturing process to build near-net shaped metallic parts in a layer-by-layer with minimal material wastage. Automated in situ monitoring and fast-responsive analyses of process signatures and deposit profiles during DED-Arc are in ever demand to print dimensionally consistent parts and reduce post-deposition machining. A comprehensive experimental investigation is presented here involving real-time synchronous measurement of arc current, voltage, and the deposit profile using a novel multi-sensor monitoring framework integrated with the DED-Arc set-up. The recorded current–voltage transients are used to estimate the time-averaged arc power, and energy input in real time for an insight of the influence of wire feed rate and printing travel speed on the deposit characteristics. A unique attempt is made to represent the geometric profiles of the single-track deposits in a generalized mathematical form corresponding to a segmented ellipse, which has exhibited the minimum root-mean-square error of 0.03 mm. The dimensional inconsistency of multi-track deposits is evaluated quantitatively in terms of waviness using build profile monitoring and automated estimation, which is found to increase with an increase in step-over ratio and energy input. For the multi-track mild steel deposits, the suitable range of step-over ratio for the minimum surface waviness is observed to lie between 0.6 and 0.65. Collectively, the proposed framework of synchronized process monitoring and real-time analysis provides a pathway to achieve dimensionally consistent and defect-free parts, and highlights the potential for closed-loop control systems for a wider industrial application of DED-Arc. T2 - IIW Annual Assembly 2025 CY - Genova, Italy DA - 23.06.2025 KW - Additive Manufacturing KW - Arc welding KW - Real-time monitoring and control KW - Dimensional inconsistency KW - DED-arc PY - 2025 AN - OPUS4-65231 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Waske, Anja T1 - Anwendungsaspekte magnetischer Funktionsmaterialien: Untersuchungen mit Computertomographie N2 - In diesem Vortrag wird am Beispiel magnetischer Werkstoffe zur Energiewandlung gezeigt, wie röntgentomographische Untersuchungen zur Strukturaufklärung in Kompositen und Massivproben beitragen können. Die Bauteile werden zerstörungsfrei geprüft, um Risse, Poren und andere Defekte und ihren Einfluss auf die funktionellen Eigenschaften dreidimensional und rechtzeitig im Lebenszyklus des Werkstoffs zu charakterisieren. Kombiniert man Mikrotomographie mit anderen Methoden der magnetischen Werkstoffcharakterisierung, lassen sich einzigartige Aussagen über den Aufbau und die funktionellen Eigenschaften treffen. T2 - Werkstoffwoche CY - Dresden, Germany DA - 18.09.2019 KW - X-Ray Imaging KW - Additive Manufacturing KW - Magnetocaloric KW - Material Science KW - Non-Destructive testing PY - 2019 AN - OPUS4-50175 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zocca, Andrea T1 - An overview of ceramic AM with focus on bioceramics and powder bed technologies N2 - The presentation will start with an overview of ceramic additive manufacturing (AM) technologies and will discuss the potential of AM in the field of bioceramics. The presentation will then focus on two possible use cases of binder jetting technologies. In the first example, standard powder-based binder jetting is used to manufacture a porous implant design for large scale bone defects. The related challenges in the process chain will be discussed, from powder synthesis to sintering and characterization of the printed part. In the second example, the LSD-print slurry-based binder jetting technology is presented as a possibility to adapt powder-bed AM to produce dense ceramic parts. The use case will focus on an application in the field of dental ceramics, specifically for the manufacturing of patient individualized single tooth restorations (veneers, crowns) with a high throughput process chain. T2 - BioCAM - Additive Manufacturing Applied to Bioceramics CY - Mons, Belgium DA - 06.12.2023 KW - Additive Manufacturing KW - Bioceramic KW - Binder Jetting PY - 2023 AN - OPUS4-60053 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Thiel, Erik T1 - AM activities at BAM with focus on process monitoring N2 - The presentation gives an overview of current projects in additive manufacturing at BAM. In particular, the results of the ProMoAm project were presented. T2 - VAMAS - Materials Issues in Additive Manufacturing CY - Berlin, Germany DA - 25.06.2018 KW - Additive Manufacturing KW - Laser Metal Deposition KW - Thermography KW - Data Fusion KW - In-situ monitoring PY - 2018 AN - OPUS4-45620 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Breese, Philipp Peter T1 - Aktive Laserthermografie im L-PBF-Prozess zur in-situ Detektion von Defekten N2 - Die zerstörungsfreie Prüfung von metallischen Bauteilen hergestellt mit additiver Fertigung (Additive Manufacturing - AM) gewinnt zunehmend an industrieller Bedeutung. Grund dafür ist die Feststellung von Qualität, Reproduzierbarkeit und damit auch Sicherheit für Bauteile, die mittels AM gefertigt wurden. Jedoch wird noch immer ex-situ geprüft, wobei Defekte (z.B. Poren, Risse etc.) erst nach Prozessabschluss entdeckt werden. Übersteigen Anzahl und/oder Abmessung die vorgegebenen Grenzwerte für diese Defekte, so kommt es zu Ausschuss, was angesichts sehr langer Bauprozessdauern äußerst unrentabel ist. Eine Schwierigkeit ist dabei, dass manche Defekte sich erst zeitverzögert zum eigentlichen Materialauftrag bilden, z.B. durch thermische Spannungen oder Schmelzbadaktivitäten. Dementsprechend sind reine Monitoringansätze zur Detektion ggf. nicht ausreichend. Daher wird in dieser Arbeit ein Verfahren zur aktiven Thermografie an dem AM-Prozess Laser Powder Bed Fusion (L-PBF) untersucht. Das Bauteil wird mit Hilfe des defokussierten Prozesslasers bei geringer Laserleistung zwischen den einzelnen gefertigten Lagen unabhängig vom eigentlichen Bauprozess erwärmt. Die entstehende Wärmesignatur wird ort- und zeitaufgelöst durch eine Infrarotkamera erfasst. Durch diese der Lagenfertigung nachgelagerte Prüfung werden auch zum Bauprozess zeitversetzte Defektbildungen nachweisbar. In dieser Arbeit finden die Untersuchungen als Proof-of-Concept, losgelöst vom AM-Prozess, an einem typischen metallischen Testkörper statt. Dieser besitzt eine Nut als oberflächlichen Defekt. Die durchgeführten Messungen finden an einer eigens entwickelten L-PBF-Forschungsanlage innerhalb der Prozesskammer statt. Damit wird ein neuartiger Ansatz zur aktiven Thermografie für L-PBF erforscht, der eine größere Bandbreite an Defektarten auffindbar macht. Der Ansatz wird validiert und Genauigkeit sowie Auflösungsvermögen geprüft. Eine Anwendung am AM-Prozess wird damit direkt forciert und die dafür benötigten Zusammenhänge werden präsentiert. T2 - DGZfP-Jahrestagung 2022 CY - Kassel, Germany DA - 23.05.2022 KW - Additive Manufacturing KW - Laser Powder Bed Fusion KW - Thermografie KW - Zerstörungsfreie Prüfung KW - Aktive Laserthermografie PY - 2022 AN - OPUS4-55040 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Evans, Alexander T1 - Ageing in additively manufactured metallic components: from powder to mechanical failure” an overview of the project agil N2 - An overview of the BAM funed Focus Area Materials Project "AGIL" will be presented. AGIL focussed on the stdiy of the ageing characteristics of additively manufactured austenitic stainless steel with a "powder to mechanical failure" Approach. Recent Highlights are presented and a perspective for future studies. T2 - Workshop on Additive Manufacturing CY - BAM, Berlin, Germany DA - 13.05.2019 KW - Residual stress KW - Additive Manufacturing KW - Non-destructive testing KW - Microstructure characterisation KW - Tensile testing KW - Fatigue KW - Crystal Plasticity Modelling KW - Crack propagation PY - 2019 AN - OPUS4-49823 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zocca, Andrea T1 - Advanced ceramics by powder bed 3D printing N2 - Powder bed -based technologies are amongst the most successful Additive Manufacturing (AM) techniques. "Selective laser sintering/melting" (SLS/SLM) and "binder jetting 3D printing" (3DP) especially are leading AM technologies for metals and polymers, thanks to their high productivity and scalability. However, the flowability of the powder used in these processes is essential to achieve defect-free and densely packed powder layers. For standard powder bed AM technologies, this limits the use of many raw materials which are too fine or too cohesive. This presentation will discuss the possibilities to either optimize the powder raw material to adapt it to the specific AM process, or to develop novel AM technologies which are able to process powders in a wider range of conditions. In this context, the "layerwise slurry deposition" (LSD) has been developed as a layer deposition method which enables the use of very fine ceramic particles. Another technology, the Gas Flow Assisted Powder Deposition, can increase the stability of the powder bed and the packing density, even in extreme conditions such as in absence of gravitational forces. T2 - yCAM 2019 - young Ceramists Additive Manufacturing Forum CY - Mons, Belgium DA - 03.04.2019 KW - Additive Manufacturing KW - Flowability KW - Ceramic KW - Powder PY - 2019 AN - OPUS4-47867 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zocca, Andrea T1 - Advanced ceramics by powder bed 3D printing N2 - Powder bed -based technologies are amongst the most successful Additive Manufacturing (AM) techniques. "Selective laser sintering/melting" (SLS/SLM) and "binder jetting 3D printing" (3DP) especially are leading AM technologies for metals and polymers, thanks to their high productivity and scalability. However, the flowability of the powder used in these processes is essential to achieve defect-free and densely packed powder layers. For standard powder bed AM technologies, this limits the use of many raw materials which are too fine or too cohesive. This presentation will discuss the possibilities to either optimize the powder raw material to adapt it to the specific AM process, or to develop novel AM technologies which are able to process powders in a wider range of conditions. In this context, the "layerwise slurry deposition" (LSD) has been developed as a layer deposition method which enables the use of very fine ceramic particles. T2 - Smart Made CY - Osaka, Japan DA - 01.09.2019 KW - Additive Manufacturing KW - Ceramic KW - Powder KW - Layerwise slurry deposition KW - 3D printing PY - 2019 AN - OPUS4-49221 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zocca, Andrea T1 - Additive Manufacturing of Silicon Carbide by LSD-print N2 - The layerwise slurry deposition (LSD) has been established in the recent years as a method for the deposition of ceramic powder layers. The LSD consists in the layer-by-layer deposition of a ceramic slurry by means of a doctor blade; each layer is sequentially deposited and dried to achieve a highly packed powder layer. The combination of binder jetting and LSD was introduced as a novel technology named LSD-print. The LSD-print takes advantage of the speed of binder jetting to print large areas, parallel to the flexibility of the LSD, which allows the deposition of highly packed powder layers with a variety of ceramic materials. The working principle and history of the LSD technology will be shortly discussed. A theoretical background will be also discussed, highlighting advantages and drawbacks of the LSD compared to the deposition of a dry powder. The last part of the talk will be dedicated to highlight recent results on the LSD-print of SiSiC of geometrically complex components, in collaboration between BAM and HC Starck Ceramics GmbH. Density, microstructure and mechanical properties of LSD-printed and isostatic pressed samples will be discussed and compared. T2 - XVI ECerS CONFERENCE CY - Torino, Italy DA - 16.06.2019 KW - Additive Manufacturing KW - Silicon Carbide KW - 3D printing KW - Layerwise Slurry Deposition PY - 2019 AN - OPUS4-49220 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Lüchtenborg, Jörg T1 - Additive Manufacturing of Dense Ceramics with Laser Induced Slip Casting (LIS) N2 - Most additive manufacturing processes which produce dense ceramics are nowadays limited in size because of inevitable post-processing steps like for example binder removal in stereolithography. The additive manufacturing of voluminous ceramic parts is realized by powder bed based processes which, however, generate parts with residual porosity. Via infiltration these parts can be processed to dense parts like for example SiC but this is not possible for all ceramics like for example Si3N4. There is a lack of methods for the additive manufacturing of dense voluminous parts for most ceramics. We have developed a new additive manufacturing technology, the Laser Induced Slip casting (LIS), based on the layerwise deposition of slurries and their local drying by laser radiation. Laser Induced Slip casting generates ceramic green bodies which can be sintered to dense ceramic components like traditional formed ceramic powder compacts. We will introduce the LIS technology, green bodies and sintered parts will be shown and their microstructure and mechanical properties will be discussed. T2 - CIMTEC 2018 14th Ceramics Congress CY - Perugia, Italy DA - 04.06.2018 KW - Additive Manufacturing PY - 2018 AN - OPUS4-45781 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Lüchtenborg, Jörg T1 - Additive Manufacturing of Dense Ceramics with Laser Induced Slip Casting (LIS) N2 - The possibility to produce dense monolithic ceramic parts with additive manufacturing is at the moment restricted to small parts with low wall thickness. Up to now, the additive manufacturing of voluminous ceramic parts is realized by powder bed based processes which, however, generate parts with residual porosity. Via infiltration these parts can be processed to dense parts like for example SiC but this is not possible for all ceramics like for example Si3N4. There is a lack of methods for the additive manufacturing of dense voluminous parts for most ceramics. We have developed a new additive manufacturing technology, the Laser Induced Slip casting (LIS), based on the layerwise deposition of slurries and their local drying by laser radiation. Laser Induced Slip casting generates ceramic green bodies which can be sintered to dense ceramic components like traditional formed ceramic powder compacts. We will introduce the LIS technology, green bodies and sintered parts will be shown and their microstructure and mechanical properties will be discussed. T2 - 42nd International Conference and Expo on Advanced Ceramics and Composites CY - Daytona Beach, FL, USA DA - 21.01.2018 KW - Additive Manufacturing KW - Ceramics PY - 2018 AN - OPUS4-44182 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zocca, Andrea T1 - Additive manufacturing of ceramics from water-based feedstocks with low binder content N2 - A major challenge in the current ceramic additive manufacturing is the debinding of the printed parts, which is often associated with long process times and limitations in size and wall thickness. Binder jetting, a powder-based AM technology, can in principle generate thick-walled parts with a low amount of organics and with high productivity. However, this technology is often not capable of handling the fine powders required as raw materials for most technical ceramics. In this context, the "layerwise slurry deposition" (LSD-print) has been developed as a layer deposition method using water-based ceramic slurry feedstocks, enabling binder jetting also for advanced ceramic materials. LSD-print thus combines the high-speed printing of binder jetting with the possibility of producing a variety of high-quality technical ceramics. Perspectives and limitations of the LSD-print will be presented, with focus on achieving short debinding cycles and high productivity. T2 - MS&T CY - Pittsburgh, PA, USA DA - 06.10.2024 KW - Additive Manufacturing KW - Ceramic KW - Binder KW - Slurry KW - Water-based PY - 2024 AN - OPUS4-61882 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zocca, Andrea T1 - Additive Manufacturing of Ceramic Materials N2 - Powder bed -based technologies are amongst the most successful Additive Manufacturing (AM) techniques. "Selective laser sintering/melting" (SLS/SLM) and "binder jetting 3D printing" (3DP) especially are leading AM technologies for metals and polymers, thanks to their high productivity and scalability. In this context, the "layerwise slurry deposition" (LSD) has been developed as a layer deposition method which enables the use of SLS/SLM and 3DP technologies for advanced ceramic materials. LSD consists in the layer-by-layer deposition of a ceramic slurry by means of a doctor blade. Each layer is deposited and dried to achieve a highly packed powder layer, which can be used for SLM or for 3DP. This technique offers high flexibility in the ceramic feedstock used, especially concerning material and particle size, and is capable of producing parts with physical and mechanical properties comparable to traditionally shaped parts. In this presentation, the LSD technique will be introduced and several examples of application to porcelain, SiC and alumina products will be reported. T2 - First Sino-German Workshop on 3D Printing in Space CY - Beijin, China DA - 20.02.2019 KW - Additive Manufacturing KW - Ceramic KW - Layerwise PY - 2019 AN - OPUS4-47868 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zocca, Andrea T1 - Additive Manufacturing of advanced ceramics by layerwise slurry deposition and binder jetting (LSD-print) N2 - Powder bed technologies are amongst the most successful Additive Manufacturing (AM) techniques. Powder bed fusion and binder jetting especially are leading AM technologies for metals and polymers, thanks to their high productivity and scalability. The application of these techniques to most ceramics has been difficult so far, because of the challenges related to the deposition of homogeneous powder layers when using fine powders. In this context, the "layerwise slurry deposition" (LSD) has been developed as a layer deposition method which enables the use of powder bed AM technologies also for advanced ceramic materials. The layerwise slurry deposition consists of the layer-by-layer deposition of a ceramic slurry by means of a doctor blade, in which the slurry is deposited and dried to achieve a highly packed powder layer. This offers high flexibility in the ceramic feedstock used, especially concerning material and particle size. The LSD technology can be combined with binder jetting to develop the so-called “LSDprint” process for the additive manufacturing of ceramics. The LSDprint technology combines the high-speed printing of binder jetting with the possibility of producing a variety of high-quality ceramics with properties comparable to those achieved by traditional processing. In this presentation, the LSD process will be introduced and several examples of application ranging from silicate to high-performance ceramics will be shown. Recent developments towards the scale-up and industrialization of this process will be discussed, alongside future perspectives for the multi-material additive manufacturing. T2 - Ceramics in Europe 2022 CY - Krakow, Poland DA - 10.07.2022 KW - Layerwise slurry deposition KW - Laser induced slipcasting KW - Additive Manufacturing KW - Ceramics PY - 2022 AN - OPUS4-55543 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zocca, Andrea T1 - Additive Manufacturing for dental restorations by layerwise slurry deposition (LSD-print) technology N2 - The growing market of custom-made dental restorations offers a major potential for an application of ceramic additive manufacturing (AM). The possibility to individualize patient specific design and to establish new efficient workflows, from model generation to manufacturing, can be fully exploited by AM technologies. However, for mass customization to be truly envisioned, ceramic AM needs to achieve a level of maturity, aesthetic quality, and productivity comparable to established manufacturing processes. In this presentation, the potential of the “layerwise slurry deposition” LSD-print technology for dental applications will be explored. It has been shown in the past years that the LSD-print can be applied to advanced ceramic materials such as alumina and silicon-infiltrated silicon carbide. For these materials, the LSD-print technology combines the high-speed printing of binder jetting with the possibility of producing a variety of high-quality ceramics. The current development deals with the challenges of applying this technology to a feldspar dental material, comparing the quality of AM restorations with the equivalent material for an established CAD/CAM workflow. Preliminary results not only indicate that the AM material produced by LSD-print can be competitive in terms of mechanical properties, but also that aesthetically satisfactory restorations can be manufactured for veneers, inlays and onlays as well as single unit fixed dental prostheses (FDPs). The presentation focuses on the material and technological challenges alongside the process chain, from the printing process, to debinding, firing and finishing the restorations. T2 - XVIIIth Conference of the European Ceramic Society CY - Lyon, France DA - 02.07.2023 KW - Additive Manufacturing KW - Layerwise slurry deposition KW - dental KW - ceramic PY - 2023 AN - OPUS4-58469 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Schnieder, Verena T1 - Additive Fertigung von Nickel-Titan-Formgedächtnislegierungen aus den Elementpulvern mittels Laserpulverauftragschweißen N2 - Additive Fertigungsverfahren gewinnen aufgrund der schnellen, flexiblen und kostengünstigen Fertigung von Bauteilen zunehmend an Bedeutung. Das Laserpulverauftragschweißen (LPA) wurde anfangs hauptsächlich als Beschichtungsverfahren eingesetzt. Diese Technologie bewerkstelligt aber auch das Reparieren von verschlissenen Bauteilen, sodass diese zeitsparend und ressourcenschonend erneuert werden können. Die hohe Aufbaurate, die flexible Pulverzusammensetzung sowie die hohe Endkonturnähe ermöglichen die Entwicklung und additive Fertigung von neuen Materialien. Im Rahmen dieses Beitrages wurde das Verfahren des Laserpulverauftragschweißens zur additiven Fertigung von Nickel-Titan-Formgedächtnislegierungen angewandt. Diese Legierungsgruppe ist aufgrund der Eigenschaft der Gestalterinnerung ein äußerst interessantes Legierungssystem mit unterschiedlichen Anwendungsbereichen, wie zum Beispiel in der Luft- und Raumfahrttechnik sowie in der Medizintechnik. Zur Erzeugung einer äquiatomaren NiTi-Legierung wurden die Elementpulver in einem Verhältnis von 55,9 wt.% Nickel und 44,1 wt.% Titan miteinander vermischt. Das Auftragen von Einzelspuren, Schichten und dreidimensionalen Körpern erfolgte auf unterschiedlichen Substratplatten aus Titan-, Nickel- und Nickeltitanlegierungen. Die metallographischen Untersuchungen zeigten, dass sich in Abhängigkeit des Substratmaterials unterschiedliche Phasen ausbilden und Risse vom Substrat durch den additiven Aufbau auftreten. Bei mehrlagigem Aufbau kam es sogar zur Ablösung des additiven Aufbaus von der Substratplatte. Der artgleiche additive Aufbau, sprich NiTi-Legierung auf einem NiTi-Substrat (Ni50,8Ti49,2 in at.%), führte zur keiner Materialablösung. Das Gefüge sowie die Phasenzusammensetzungen bieten in diesem Bereich noch viel Forschungsbedarf. T2 - 39. Assistentenseminar CY - Eupen, Belgium DA - 12.09.2018 KW - Additive Fertigung KW - Additive Manufacturing KW - Laserpulverauftragschweißen KW - Formgedächtnislegierungen KW - NiTi-Legierungen PY - 2018 AN - OPUS4-46092 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bruno, Giovanni T1 - Absorption and refraction tomography: Characterization and Non-destructive Testing of Micro-structured Materials N2 - The combination of tomographic, microstructural data with other experimental techniques and with modeling is paramount, if we want to extract the maximum amount of information on material and component properties. In particular, quantitative image analysis, statistical approaches, direct discretization of tomographic reconstructions represent concrete possibilities to extend the power of the tomographic 3D representation to insights into the material and component performance. This logic thread equally holds for industrial and academic research, and valorizes expensive experiments such as those carried out at synchrotron sources, which cannot be daily repeated. I will show a few examples of possible use of X-ray tomographic data for quantitative assessment of damage evolution and microstructural properties, as well as for non-destructive testing. Examples of micro-structured inhomogeneous materials will be given, such as Composites, Ceramics, Concrete, and Additively manufactured parts. I will also show how X-ray refraction computed tomography (CT) can be highly complementary to classic absorption CT, being sensitive to internal interfaces. Additionally, I will present a new technique in our portfolio, Neutron Diffraction, which is extremely well suited to the study of internal stresses, both residual and under external load. T2 - Seminare der EMPA CY - EMPA, Dubenddorf, Switzerland DA - 10.10.2017 KW - Computed Tomography KW - X-ray Refraction KW - Neutron Diffraction KW - Additive Manufacturing KW - Image Analysis PY - 2017 AN - OPUS4-42699 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Waske, Anja T1 - A unique authenticator for additively manufactured parts derived from their microstructure N2 - Components produced using additive manufacturing can be marked for unique identification and secure authentication [1,2]. Serial numbers and machine-readable codes can be used to identify the component, and link digital product-related data (i.e., a digital product passport) to the actual components. The most prevailing solution consists of local process manipulation, such as printing a quick response (QR) code [3] or a set of blind holes on the surface of the internal cavity of hollow components. However, local manipulation of components may alter the properties, and external tagging features can be altered or even removed by post-processing treatments. This work therefore aims to provide a new methodology for identification, authentication, and traceability of additively manufactured (AM) components using microstructural features that are unique to each part. X-ray computed tomography (XCT) was employed to image the microstructural features of AlSi10Mg parts. Based on size and geometry, the most prominent features were selected to create a unique digital authenticator. We implemented a framework in Python using open-access modules that can successfully create a digital object authenticator using the segmented microstructure information from XCT. The authenticator is stored as a QR code, along with the 3D information of the selected features. T2 - MRS Spring Meeting Seattle CY - Seattle, WA, USA DA - 07.04.2025 KW - Additive Manufacturing KW - Fingerprint KW - Non-destructive testing PY - 2025 AN - OPUS4-65199 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Waske, Anja T1 - A unique authenticator for additively manufactured parts derived from their microstructure N2 - In the field of additive manufacturing, the ability to uniquely identify and authenticate parts is crucial for certification, logistics, and anti-counterfeiting efforts. This study introduces a novel methodology that leverages the intrinsic microstructural features of additively manufactured components for their identification, authentication, and traceability. Unlike traditional tagging methods, such as embedding QR codes on the surface [1] or within the volume of parts, this approach requires no alteration to the printing process, as it utilizes naturally occurring microstructural characteristics. The proposed workflow [2] involves the analysis of 3D micro-computed tomography data to identify specific voids that meet predefined identification criteria. This method is demonstrated on a batch of 20 parts manufactured with identical process parameters, proving capable of achieving unambiguous identification and authentication. By establishing a tamper-proof link between the physical part and its digital counterpart, this methodology effectively bridges the physical and digital realms. This not only enhances the traceability of additively manufactured parts but also provides a robust tool for integrating digital materials, parts databases, and product passports with their physical counterparts. T2 - Artificial Intelligence in MSE CY - Bochum, Germany DA - 18.11.2025 KW - Authentication KW - Additive Manufacturing KW - Non-destructive testing PY - 2025 AN - OPUS4-65204 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Waske, Anja T1 - A unique authenticator for additively manufactured parts derived from 3D microstructural information N2 - Additive manufacturing (AM) is rapidly emerging from rapid prototyping to industrial production [1]. Thus, providing AM parts with a tagging feature that allows identification, like a fingerprint, can be crucial for logistics, certification, and anti-counterfeiting purposes since nearly any geometry can be produced by AM with stolen data or reverse engineering of an original product. However, the mechanical and functional properties of the replicated part may not be identical to the original ones and pose a safety risk [2]. Several methods are already available, which range from encasing a detector to leveraging the stochastic defects of AM parts for the identification, authentication, and traceability of AM components. The most prevailing solution consists of local process manipulation, such as printing a quick response (QR) code [3] or a set of blind holes on the surface of the internal cavity of hollow components. Local manipulation of components may alter the properties. The external tagging features can be altered or even removed by post-processing treatments. Integrating electronic systems [4] in AM parts can be used to identify and authenticate components with complex or customized geometries. However, metal-based AM, especially in powder bed fusion (PBF-LB/M) techniques, has a strong shielding effect that interferes with the communication between the reader and the transponder. Our work suggests a methodology for the identification, authentication, and traceability of AM components using microstructural features in AM components. We will show a workflow that includes analysing 3D micro computed tomography data and selecting a set number of voids that fulfil the identification criteria. We will show the results this workflow produces for a series of 20 Al-based cuboid samples with identical processing parameters and discuss their prospects and limitations. The workflow can help to establish a non-tamperable connection between an additively manufactured part and its digital data and hence link the physical and the digital world. T2 - MSE Konferenz CY - Darmstadt, Germany DA - 24.09.2024 KW - Additive Manufacturing KW - Fingerprint KW - Computed tomography PY - 2024 AN - OPUS4-62288 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Oster, Simon T1 - A comparison of machine learning approaches for porosity prediction in PBF-LB/M based on thermography N2 - Metal-based additive manufacturing processes are increasingly used in industry to produce complex-shaped components. In this regard, the laser-based Powder Bed Fusion process (PBF-LB/M) is one of the key technologies due to its capability to produce components in high spatial accuracy. The formation of porosity during manufacturing poses a serious risk to the safety of the printed parts. For quality assessment, in-situ monitoring technologies such as thermography can be used to capture the thermal history during production. It was shown that discontinuities within the thermal history can be correlated with the probability of porosity or defect formation. In this context, Machine Learning (ML) algorithms have achieved promising results for the task of porosity prediction based on thermographic in-situ monitoring data. One important technique is the use of thermogram features for porosity prediction that are extracted from the raw data (e.g., features related to the melt pool geometry or spatter generation). However, the reduction from large thermogram data to discrete features holds the risk of losing potentially important thermal information and, thereby, introducing bias in the model. Therefore, we present a raw data-based deep learning approach that uses thermographic image sequences for the prediction of local porosity. The model takes advantage of the self-attention mechanism that considers not only the thermogram information but also its positional context within the sequence. The model is used to predict porosity in the form of a many-to-one regression. It is trained and tested on a dataset retrieved from the manufacturing of HAYNES282 cuboid specimens. The model results are compared against state-of-the-art thermogram feature-based ML models and artificial neural networks. The raw data model outperforms its feature-based counterparts in terms of prediction scores and, therefore, seems to make better use of the information available in the thermogram data. T2 - 4th Symposium on Materials and Additive Manufacturing CY - Berlin, Germany DA - 12.06.2024 KW - PBF-LB/M KW - In situ monitoring KW - Thermography KW - Additive Manufacturing KW - Machine learning KW - Porosity prediction PY - 2024 AN - OPUS4-62472 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zocca, Andrea T1 - A comparison of layerwise slurry deposition and (LSD-print) laser induced slip casting (LIS) for the additive manufacturing of advanced ceramics N2 - The presentation gives an overview of two slurry-based additive manufacturing (AM) technologies specifically developed for advanced ceramic materials. The “Layerwise Slurry Deposition” (LSD-print) is a modification of Binder Jetting making use of a ceramic slurry instead of a dry powder as a feedstock. In this process, a slurry is deposited layer-by-layer by means of a doctor blade and dried to achieve a highly packed powder layer, which is then printed by jetting a binder. The LSD-print technology combines the high-speed printing of binder jetting with the possibility of producing a variety of high-quality ceramics with properties comparable to those achieved by traditional processing. The Laser Induced Slip casting (LIS) technology follows a novel working principle by locally drying and selectively consolidating layer-by-layer a ceramic green body in a vat of slurry, using a laser as energy source. LIS combines elements of Vat Photopolymerization with the use of water-based feedstocks containing a minimal amount of organic additives. The resulting technology can be directly integrated into a traditional ceramic process chain by manufacturing green bodies that are sintered without the need of a dedicated debinding. Both technologies offer high flexibility in the ceramic feedstock used, especially concerning material and particle size. Advantages and disadvantages are briefly described to outline the specific features of LSD-print and LIS depending on the targeted application. T2 - AM Ceramics CY - Vienna, Austria DA - 27.09.2023 KW - Additive Manufacturing KW - Dental KW - Ceramics KW - Feldspar PY - 2023 AN - OPUS4-58468 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -