TY - JOUR A1 - Fritsch, Tobias A1 - Farahbod-Sternahl, L. A1 - Serrano Munoz, Itziar A1 - Léonard, F. A1 - Haberland, C. A1 - Bruno, Giovanni T1 - 3D Computed Tomography Quantifies the Dependence of Bulk Porosity, Surface Roughness, and Re-Entrant Features on Build Angle in Additively Manufactured IN625 Lattice Struts JF - Advanced Engineering Materials N2 - Layer-by-layer additive manufacturing (AM) by means of laser-powder bed Fusion (L-PBF) offers many prospects regarding the design of lattice structures used, for example, in gas turbines. However, defects such as bulk porosity, Surface roughness, and re-entrant features are exacerbated in nonvertical structures, such as tilted struts. The characterization and quantification of these kinds of defects are essential for the correct estimation of fracture and fatigue properties. Herein, cylindrical struts fabricated by L-PBF are investigated by means of X-ray computed tomography (XCT), with the aim of casting light on the dependence of the three kinds of defects (bulk porosity, surface roughness, and re-entrant features) on the build angle. Innovative analysis methods are proposed to correlate shape and position of pores, to determine the angular-resolved Surface roughness, and to quantify the amount of re-entrant surface features, q. A meshing of the XCT surface enables the correlation of q with the classical Surface roughness Pa. This analysis leads to the conclusion that there is a linear correlation between q and Pa. However, it is conjectured that there must be a threshold of surface roughness, below which no re-entrant features can be build. KW - Additive manufacturing KW - Laser powder bed fusion KW - Computed tomography KW - Surface roughness analysis KW - Re-entrant surface feature PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-534728 DO - https://doi.org/10.1002/adem.202100689 IS - 2100689 SP - 1 EP - 8 PB - Wiley-VCH Verlag AN - OPUS4-53472 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Thiede, Tobias A1 - Mishurova, Tatiana A1 - Evsevleev, Sergei A1 - Serrano Munoz, Itziar A1 - Gollwitzer, Christian A1 - Bruno, Giovanni T1 - 3D shape analysis of powder for laser beam melting by synchrotron X-ray CT JF - Quantum Beam Science N2 - The quality of components made by laser beam melting (LBM) additive manufacturing is naturally influenced by the quality of the powder bed. A packing density <1 and porosity inside the powder particles lead to intrinsic voids in the powder bed. Since the packing density is determined by the particle size and shape distribution, the determination of these properties is of significant interest to assess the printing process. In this work, the size and shape distribution, the amount of the particle’s intrinsic porosity, as well as the packing density of micrometric powder used for LBM, have been investigated by means of synchrotron X-ray computed tomography (CT). Two different powder batches were investigated: Ti–6Al–4V produced by plasma atomization and stainless steel 316L produced by gas atomization. Plasma atomization particles were observed to be more spherical in terms of the mean anisotropy compared to particles produced by gas atomization. The two kinds of particles were comparable in size according to the equivalent diameter. The packing density was lower (i.e., the powder bed contained more voids in between particles) for the Ti–6Al–4V particles. The comparison of the tomographic results with laser diffraction, as another particle size measurement technique, proved to be in agreement. KW - Additive manufacturing KW - Laser beam melting KW - Synchrotron computed tomography KW - Powder analysis KW - Imaging PY - 2019 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-474070 DO - https://doi.org/10.3390/qubs3010003 SN - 2412-382X VL - 3 IS - 1 SP - 3, 1 EP - 12 PB - MDPI AN - OPUS4-47407 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Metz, Christian A1 - Franz, Philipp A1 - Fischer, C. A1 - Wachtendorf, Volker A1 - Maierhofer, Christiane T1 - Active thermography for quality assurance of 3D-printed polymer structures T2 - DGZfP-Proceedings BB 167 N2 - Additively manufactured test specimens made of polyamide 12 (PA 12) by Laser Sintering (LS) as well as of acrylnitril-butadien-styrol (ABS) by Fused Layer Modeling (FLM), were tested with active thermography. For this, two different excitation methods (flash and impulse excitation) were used and compared, regarding the suitability for the detection of constructed and imprinted defects. To increase the quality of the thermograms, data processing methods like thermal signal reconstruction (TSR) and Fourier-Transformation were applied. Furthermore, the long-term stability of the probes towards environmental stress, like UV-radiation, heat, water contact and frost is being investigated in the presented project with artificial weathering tests. T2 - 14th Quantitative InfraRed Thermography Conference CY - Berlin, Germany DA - 25.06.2018 KW - Additive manufacturing KW - Active thermography KW - Artificial weathering PY - 2018 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-453919 SP - Tu.3.A.2, 1 EP - 9 AN - OPUS4-45391 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mishurova, Tatiana A1 - Cabeza, Sandra A1 - Artzt, Katia A1 - Haubrich, J. A1 - Klaus, M. A1 - Genzel, Ch. A1 - Requena, G. A1 - Bruno, Giovanni T1 - An Assessment of Subsurface Residual Stress Analysis in SLM Ti-6Al-4V JF - Materials N2 - Ti-6Al-4V bridges were additively fabricated by selective laser melting (SLM) under different scanning speed conditions, to compare the effect of process energy density on the residual stress state. Subsurface lattice strain characterization was conducted by means of synchrotron diffraction in energy dispersive mode. High tensile strain gradients were found at the frontal surface for samples in an as-built condition. The geometry of the samples promotes increasing strains towards the pillar of the bridges. We observed that the higher the laser energy density during fabrication, the lower the lattice strains. A relief of lattice strains takes place after heat treatment. KW - Selective laser melting KW - Additive manufacturing KW - Heat treatment KW - Ti-6Al-4V KW - Synchrotron X-ray diffraction KW - Residual stress PY - 2017 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-395759 DO - https://doi.org/10.3390/ma10040348 SN - 1996-1944 VL - 10 IS - 4 SP - Article 348, 1 EP - 14 AN - OPUS4-39575 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Biegler, M. A1 - Wang, J. A1 - Kaiser, L. A1 - Rethmeier, Michael T1 - Automated Tool-Path Generation for Rapid Manufacturing of Additive Manufacturing Directed Energy Deposition Geometries JF - Steel research international N2 - In additive manufacturing (AM) directed energy deposition (DED), parts are built by welding layers of powder or wire feedstock onto a substrate with applications for steel powders in the fields of forging tools, spare parts, and structural components for various industries. For large and bulky parts, the choice of toolpaths influences the build rate, the mechanical performance, and the distortions in a highly geometry-dependent manner. With weld-path lengths in the range of hundreds of meters, a reliable, automated tool-path generation is essential for the usability of DED processes. This contribution presents automated tool-path generation approaches and discusses the results for arbitrary geometries. Socalled “zig-zag” and “contour-parallel” processing strategies are investigated and the tool-paths are automatically formatted into machine-readable g-code for experimental validation to build sample geometries. The results are discussed in regard to volume-fill, microstructure, and porosity in dependence of the path planning according to photographs and metallographic cross-sections. KW - Porosity KW - Path planning KW - Mechanical properties KW - Laser metal deposition KW - Additive manufacturing PY - 2020 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-510454 DO - https://doi.org/10.1002/srin.202000017 VL - 91 IS - 11 SP - 2000017 PB - WILEY-VCH Verlag GmbH & co. KGaA CY - Weinheim AN - OPUS4-51045 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schönsee, Eric A1 - Hüsken, Götz A1 - Jeyifous, Olubunmi Anthony A1 - Mezhov, Alexander A1 - Strangfeld, Christoph T1 - Calculating rheological properties of fresh mortar for additive manufacturing based on experimental, multi-sensor data JF - Advances in science and technology N2 - Additive manufacturing of concrete structures is a novel and emerging technology. Freecontouring in civil engineering, which allows for entirely new designs, is a significant advantage. Inthe future, lower construction costs are expected with increased construction speeds and decreasingrequired materials and workers. However, architects and civil engineers rely on a certain quality ofexecution to fulfil construction standards. Although several techniques and approaches demonstratethe advantages, quality control during printing is highly challenging and rarely applied. Due to thecontinuous mixing process commonly used in 3D concrete printing, it is impossible to exclude varia-tions in the dry mixture or water content, and a test sample cannot be taken as a representative samplefor the whole structure. Although mortar properties vary only locally, a defect in one layer duringprinting could affect the entire integrity of the whole structure . Therefore, real-time process monitor-ing is required to record and document the printing process.At the Bundesanstalt für Materialforschung und -prüfung (BAM) a new test rig for the additive man-ufacturing of concrete is built. The primary purpose is measuring and monitoring the properties of amortar during the printing process.The following study investigates an approach for calculating yield stress and plastic viscosity based onexperimentally recorded pressure data. The calculations assume that fresh mortar behaves as a Bing-ham fluid and that the Buckingham-Reiner-equation is applicable. A test setup consisting of rigid pipeswith integrated pressure sensors at different positions is utilized.Monitoring the printing process with different sensors is crucial for the quality control of an ongoingprocess. T2 - Non-Traditional Cement and Concrete 2023 Conference CY - Brno, Czech Republic DA - 25.06.2023 KW - 3DCP KW - Monitoring KW - Additive manufacturing KW - Rheology KW - Bingham fluid KW - Concrete printing PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-598179 DO - https://doi.org/10.4028/p-EV4gPv SN - 1662-0356 VL - 145 SP - 131 EP - 139 PB - Trans Tech Publications CY - Baech AN - OPUS4-59817 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Merz, Benjamin A1 - Nilsson, R. A1 - Garske, C. A1 - Hilgenberg, Kai T1 - Camera-based high precision position detection for hybrid additive manufacturing with laser powder bed fusion JF - The International Journal of Advanced Manufacturing Technology (JAMT) N2 - Additive manufacturing (AM) in general and laser powder bed fusion (PBF-LB/M) in particular are becoming increasingly important in the field of production technologies. Especially the high achievable accuracies and the great freedom in design make PBF-LB/M interesting for the manufacturing and repair of gas turbine blades. Part repair involves building AM-geometries onto an existing component. To minimise the offset between component and AM-geometry, a precise knowledge of the position of the component in the PBF-LB/M machine is mandatory. However, components cannot be inserted into the PBF-LB/M machine with repeatable accuracy, so the actual position will differ for each part. For an offset-free build-up, the actual position of the component in the PBF-LB/M machine has to be determined. In this paper, a camera-based position detection system is developed considering PBF-LB/M constraints and system requirements. This includes finding an optimal camera position considering the spatial limitations of the PBF-LB/M machine and analysing the resulting process coordinate systems. In addition, a workflow is developed to align different coordinate systems and simultaneously correct the perspective distortion in the acquired camera images. Thus, position characteristics can be determined from images by image moments. For this purpose, different image segmentation algorithms are compared. The precision of the system developed is evaluated in tests with 2D objects. A precision of up to 30μm in translational direction and an angular precision of 0.021∘ is achieved. Finally, a 3D demonstrator was built using this proposed hybrid strategy. The offset between base component and AM-geometry is determined by 3D scanning and is 69μm. KW - Laser powder bed fusion KW - Additive manufacturing KW - Hybrid repair KW - Machine vision KW - Image processing KW - Position detection PY - 2023 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-568583 DO - https://doi.org/10.1007/s00170-022-10691-5 SP - 1 EP - 16 PB - Springer AN - OPUS4-56858 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Ulbricht, Alexander A1 - Mohr, Gunther A1 - Altenburg, Simon A1 - Oster, Simon A1 - Maierhofer, Christiane A1 - Bruno, Giovanni ED - Czujko, T. ED - Benedetti, M. T1 - Can Potential Defects in LPBF Be Healed from the Laser Exposure of Subsequent Layers? A Quantitative Study JF - Metals N2 - Additive manufacturing (AM) of metals and in particular laser powder bed fusion (LPBF) enables a degree of freedom in design unparalleled by conventional subtractive methods. To ensure that the designed precision is matched by the produced LPBF parts, a full understanding of the interaction between the laser and the feedstock powder is needed. It has been shown that the laser also melts subjacent layers of material underneath. This effect plays a key role when designing small cavities or overhanging structures, because, in these cases, the material underneath is feed-stock powder. In this study, we quantify the extension of the melt pool during laser illumination of powder layers and the defect spatial distribution in a cylindrical specimen. During the LPBF process, several layers were intentionally not exposed to the laser beam at various locations, while the build process was monitored by thermography and optical tomography. The cylinder was finally scanned by X-ray computed tomography (XCT). To correlate the positions of the unmolten layers in the part, a staircase was manufactured around the cylinder for easier registration. The results show that healing among layers occurs if a scan strategy is applied, where the orientation of the hatches is changed for each subsequent layer. They also show that small pores and surface roughness of solidified material below a thick layer of unmolten material (>200 µm) serve as seeding points for larger voids. The orientation of the first two layers fully exposed after a thick layer of unmolten powder shapes the orientation of these voids, created by a lack of fusion. KW - Computed tomography KW - Laser Powder Bed Fusion KW - In situ monitoring KW - infrared Thermography KW - Optical Tomography KW - Additive manufacturing KW - AISI 316L PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-528778 DO - https://doi.org/10.3390/met11071012 VL - 11 IS - 7 SP - 1012 PB - MDPI CY - Basel AN - OPUS4-52877 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - D'Accardi, E. A1 - Ulbricht, Alexander A1 - Krankenhagen, Rainer A1 - Palumbo, D. A1 - Galietti, U. T1 - Capability of active thermography to detect and localize pores in Metal Additive Manufacturing materials T2 - IOP conference series: Materials science and engineering N2 - Active thermography is a fast, contactless and non-destructive technique that can be used to detect internal defects in different types of material. Volumetric irregularities such as the presence of pores in materials produced by the Additive Manufacturing processes can strongly affect the thermophysical and the mechanical properties of the final component. In this work, an experimental investigation aimed at detecting different pores in a sample made of stainless AISI 316L produced by Laser Powder Bed Fusion (L-PBF) was carried out using pulsed thermography in reflection mode. The capability of the technique and the adopted setups in terms of geometrical and thermal resolution, acquisition frequency and energy Density of the heating source were assessed to discern two contiguous pores as well as to detect a single pore. Moreover, a quantitative indication about the minimum resolvable pore size among the available and analysed defects was provided. A powerful tool to assess the Limits and the opportunities of the pulsed technique in terms of detectability and localizability was provided by comparing active thermography results to Computed Tomography as well as a related Finite Element Analysis (FEA) to simulate the pulsed heating transfer with Comsol. T2 - 49th Italian Association for Stress Analysis Conferencee (AIAS 2020) CY - Online meeting DA - 02.09.2020 KW - Additive manufacturing KW - Laser powderbed fusion KW - Pores KW - Thermography KW - Micro-CT PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-519231 DO - https://doi.org/10.1088/1757-899X/1038/1/012018 VL - 1038 SP - 1 EP - 17 PB - Institute of Physics CY - London AN - OPUS4-51923 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 JF - Chinese Journal of Mechanical Engineering: Additive Manufacturing Frontiers 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 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-549204 DO - https://doi.org/10.1016/j.cjmeam.2022.100018 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 - CONF A1 - Altenburg, Simon A1 - Maierhofer, Christiane A1 - Straße, Anne A1 - Gumenyuk, Andrey T1 - Comparison of MWIR thermography and high-speed NIR thermography in a laser metal deposition (LMD) process T2 - Proceedings of Conference QIRT 2018 N2 - Additive manufacturing (AM) offers a range of novel applications. However, the manufacturing process is complex and the production of defect-free parts with high reliability and durability is still a challenge. Thermography is a valuable tool for process surveillance, especially in metal AM processes. The high process temperatures allow one to use cameras usually operating in the visible spectral range. Here, we compare the results of measurements during the manufacturing process of a commercial laser metal deposition setup using a mid-wavelength-IR camera with those from a visual spectrum high-speed camera with band pass filter in the near-IR range. T2 - Conference QIRT 2018 CY - Berlin, Germany DA - 25.06.2018 KW - Additive manufacturing KW - Laser metal deposition KW - ProMoAM KW - Thermography PY - 2018 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-454993 UR - http://www.qirt.org/archives/qirt2018/papers/p35.pdf DO - https://doi.org/10.21611/qirt.2018.p35 SP - 1 EP - 5 PB - QIRT Council CY - Quebec, Canada AN - OPUS4-45499 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Werner, Tiago A1 - Madia, Mauro A1 - Zerbst, Uwe T1 - Comparison of the fatigue behavior of wrought and additively manufactured AISI 316L JF - Procedia Structural Integrity N2 - Additive manufacturing (AM) is becoming increasingly important in engineering applications due to the possibility of producing components with a high geometrical complexity allowing for optimized forms with respect to the in-service functionality. Despite the promising potential, AM components are still far from being used in safety-relevant applications, mainly due to a lack of understanding of the feedstock-process-properties-performance relationship. This work aims at providing a full 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. To this purpose, a set of specimens has been produced by laser powder bed fusion (L-PBF) and subsequently heat treated at 900 °C for 1 hour for complete stress relief, whereas a second set of specimens has been machined out of hot-rolled plates. Low cycle fatigue (LCF) and high cycle fatigue (HCF) tests have been conducted for characterizing the fatigue behavior. The L-PBF material had a higher fatigue limit and better finite life performance compared to wrought material. Both, LCF and HCF-testing revealed an extensive cyclic softening. T2 - FATIGUE DESIGN 2021 CY - Online meeting DA - 17.11.2021 KW - Additive manufacturing KW - L-PBF KW - 316L KW - Fatigue KW - LCF KW - HCF PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-544952 DO - https://doi.org/10.1016/j.prostr.2022.03.056 SN - 2452-3216 VL - 38 SP - 554 EP - 563 PB - Elsevier B.V. AN - OPUS4-54495 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Dantas, A. A1 - Scalabrin, D. A1 - Farias, R. A1 - Barbosa, A. A. A1 - Ferraz, A. A1 - Wirth, Cynthia T1 - Design of highly porous hydroxyapatite scaffolds by conversion of 3D printed gypsum structures – a comparison study JF - Procedia CIRP N2 - Hydroxyapatite (HA) is a bioceramic material with excellent biological properties. However, these properties are strongly dependent of ist crystallinity degree, with high values of crystallinity associated to poor resorption rates and bioactivity. This work evaluates the properties of HA samples produced by two different free-forming conformation methods, CNC machining and 3D printing. In both cases, porous gypsum samples were produced and subsequently converted into HA in a reaction with di-ammonium hydrogen phosphate at 100°C and pH 8. A total conversion of the samples was achieved after 36 h independently of the conformation method used. The microstructure, however, before and after the conversion is showed to be dependent on the method used. After conversion the machined samples achieved a Maximum compressive strength of 3.5 MPaforporosities of circa 80%, while 3D printed samples achieved a tensile strength of 2.0 MPa by porosities of 61%. T2 - The Second CIRP Conference on Biomanufacturing CY - Manchester Conference Centre, UK DA - July 29, 2015 KW - Additive manufacturing KW - 3D printing PY - 2016 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-400831 DO - https://doi.org/10.1016/j.procir.2015.07.030 SN - 2212-8271 VL - 49 SP - 55 EP - 60 PB - Elsevier AN - OPUS4-40083 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 JF - Open 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 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-549361 DO - https://doi.org/10.1016/j.oceram.2022.100277 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 - Strobl, Dominic A1 - Unger, Jörg F. A1 - Ghnatios, C. A1 - Klawoon, Alexander A1 - Pittner, Andreas A1 - Rethmeier, Michael A1 - Robens-Radermacher, Annika T1 - Efficient bead-on-plate weld model for parameter estimation towards effective wire arc additive manufacturing simulation JF - Welding in the World N2 - Despite the advances in hardware and software techniques, standard numerical methods fail in providing real-time simulations, especially for complex processes such as additive manufacturing applications. A real-time simulation enables process control through the combination of process monitoring and automated feedback, which increases the flexibility and quality of a process. Typically, before producing a whole additive manufacturing structure, a simplified experiment in the form of a beadon-plate experiment is performed to get a first insight into the process and to set parameters suitably. In this work, a reduced order model for the transient thermal problem of the bead-on-plate weld simulation is developed, allowing an efficient model calibration and control of the process. The proposed approach applies the proper generalized decomposition (PGD) method, a popular model order reduction technique, to decrease the computational effort of each model evaluation required multiple times in parameter estimation, control, and optimization. The welding torch is modeled by a moving heat source, which leads to difficulties separating space and time, a key ingredient in PGD simulations. A novel approach for separating space and time is applied and extended to 3D problems allowing the derivation of an efficient separated representation of the temperature. The results are verified against a standard finite element model showing excellent agreement. The reduced order model is also leveraged in a Bayesian model parameter estimation setup, speeding up calibrations and ultimately leading to an optimized real-time simulation approach for welding experiment using synthetic as well as real measurement data. KW - Proper generalized decomposition KW - Model order reduction KW - Hardly separable problem KW - Additive manufacturing KW - Model calibration KW - Wire arc additive manufacturing PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-596502 DO - https://doi.org/10.1007/s40194-024-01700-0 SN - 0043-2288 SP - 1 EP - 18 PB - Springer AN - OPUS4-59650 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 JF - Scientific Data 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 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-579716 DO - https://doi.org/10.1038/s41597-023-02387-6 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 - Petrat, T. A1 - Kersting, R. A1 - Graf, B. A1 - Rethmeier, Michael T1 - Embedding electronics into additive manufactured components using laser metal deposition and selective laser melting JF - ScienceDirect - 10th CIRP Conference on Photonic Technolgies N2 - The paper deals with the integration of a light emitting diode (LED) into an additive manufactured metal component. Selective laser melting (SLM) and laser metal deposition (LMD) are used. The material used is the chrome-nickel steel 316L. The basic component is manufactured by means of SLM and consists of a solid body and an area with grid structure. The solid body includes a duct in the shape of a groove with a recess for the positioning of the power cable. The LED is embedded in the grid structure via an inlet from the solid body. In further processing, the groove is filled with LMD. Two strategies with different parameter combinations were investigated. It shows that a high energy input near the power cable leads to its destruction. By using multiple parameter combinations during the manufacturing process, this destruction can be prevented. There was a comparison of both strategies with regard to the necessary number of tracks and duration of welding time. KW - Additive manufacturing KW - Condition monitoring KW - Process chain KW - Laser-metal-deposition KW - Selektive-laser-melting KW - Embedded electronics PY - 2018 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-479469 DO - https://doi.org/10.1016/j.procir.2018.08.071 SP - 168 EP - 171 PB - Elsevier Ltd. AN - OPUS4-47946 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 JF - Advanced Materials Technologies 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 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-492190 DO - https://doi.org/10.1002/admt.201900506 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 - Cabo Rios, Alberto A1 - Mishurova, Tatiana A1 - Cordova, Laura A1 - Persson, Mats A1 - Bruno, Giovanni A1 - Olevsky, Eugene A1 - Hryha, Eduard T1 - Ex-situ characterization and simulation of density fluctuations evolution during sintering of binder jetted 316L JF - Materials & Design N2 - Efficient density evolution during sintering of the as-printed component is vital to reach full densification and required properties of binder jet (BJT) components. However, due to the high porosity and brittle nature of the green compact, analysis of the microstructure development during sintering is very difficult, resulting in lack of understanding of the densification process. Density development from green state (57 ± 1.6 %) up to full density (99 ± 0.3 %) was characterized by high-resolution synchrotron X-Ray computed tomography (SXCT) on BJT 316L samples from ex-situ interrupted sintering tests. Periodicity of density fluctuations along the building direction was revealed for the first time and was related to the layer thickness of ~ 42 μm during printing that decreased down to ~ 33 μm during sintering. Sintering simulations, utilizing a continuum sintering model developed for BJT, allowed to replicate the density evolution during sintering with a mean error of 2 % and its fluctuation evolution from green (1.66 %) to sintered (0.56 %) state. Additionally, simulation of extreme particle size segregation (1 μm to 130 μm) suggested that non-optimized printing could lead to undesirable density fluctuation amplitude rapid increase (~10 %) during sintering. This might trigger the nucleation of defects (e.g., layer delamination, cracking, or excessive residual porosity) during the sintering process. KW - Additive manufacturing KW - Synchrotron X-ray CT KW - Binder Jetting KW - Sintering KW - FEM Simulation PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-594389 DO - https://doi.org/10.1016/j.matdes.2024.112690 SN - 0264-1275 VL - 238 SP - 1 EP - 18 PB - Elsevier AN - OPUS4-59438 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mishurova, Tatiana A1 - Artzt, K. A1 - Haubrich, J. A1 - Requena, G. A1 - Bruno, Giovanni T1 - Exploring the correlation between subsurface residual stresses and manufacturing parameters in laser powder bed fused Ti-6Al-4V JF - Metals N2 - Subsurface residual stresses (RS) were investigated in Ti-6Al-4V cuboid samples by means of X-ray synchrotron diffraction. The samples were manufactured by laser powder bed fusion (LPBF) applying different processing parameters, not commonly considered in open literature, in order to assess their influence on RS state. While investigating the effect of process parameters used for the calculation of volumetric energy density (such as laser velocity, laser power and hatch distance), we observed that an increase of energy density led to a decrease of RS, although not to the same extent for every parameter variation. Additionally, the effect of support structure, sample roughness and LPBF machine effects potentially coming from Ar flow were studied. We observed no influence of support structure on subsurface RS while the orientation with respect to Ar flow showed to have an impact on RS.We conclude recommending monitoring such parameters to improve part reliability and reproducibility. KW - Additive manufacturing KW - Synchrotron X-ray diffraction KW - Residual stress KW - Ti-6Al-4V PY - 2019 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-474281 DO - https://doi.org/10.3390/met9020261 SN - 2075-4701 VL - 9 IS - 2 SP - 261, 1 EP - 13 PB - MDPI AN - OPUS4-47428 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -