TY - JOUR A1 - Spranger, Felix A1 - Graf, B. A1 - Schuch, M. A1 - Hilgenberg, Kai A1 - Rethmeier, Michael T1 - Build-up strategies for additive manufacturing of three dimensional Ti-6Al-4V-parts produced by laser metal deposition N2 - Laser metal deposition (LMD) has been applied as a coating technology for many years. Today, the technologies capacity to produce 3D depositions leads to a new field of application as additive manufacturing method. In this paper, 3D laser metal deposition of titanium alloy Ti-6Al-4V is studied with special regard to the demands of additive manufacturing. Therefore, only the coaxial LMD powder nozzle is used to create the shielding gas atmosphere, which ensures high geometric flexibility. Furthermore, specimen with high aspect ratio and hundreds of layers are manufactured, which represent typical features in additive manufacturing. The presented study contains the following steps: First, cylindrical specimens are manufactured with a standard shell-core build-up strategy and mechanical properties as well as fracture mechanisms are determined. Based on the results, experiments are conducted to improve the build-up strategy and new tensile test specimens are built with the improved strategy. The improved strategy incorporates variable track overlap ratios to achieve a constant growth in the shell and core area. As blanks, lean cylinders comprising more than 240 layers and a height of more than 120mm are manufactured. The specimens are analyzed by X-ray inspection for material defects. Fractured surfaces are observed via scanning electron microscopy and the composition of the surfaces is determined using energy dispersive X-ray spectroscopy. The tensile test results prove mechanical properties close to ASTM F1108 specification for wrought material. KW - Laser metal deposition KW - Ti-6Al-4V KW - Additive manufacturing KW - Titanium alloy KW - Turbine components PY - 2018 DO - https://doi.org/10.2351/1.4997852 SN - 1938-1387 SN - 1042-346X VL - 30 IS - 2 SP - UNSP 022001, 1 EP - 13 PB - Laser Institute of America AN - OPUS4-44655 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Thiel, Erik A1 - Altenburg, Simon A1 - Myrach, P. A1 - Mohr, Gunther A1 - Gumenyuk, Andrey T1 - Crack detection in metal additive manufacturing with laser thermography N2 - BAM ensures and represents high standards for safety in technology and chemistry. Additive manufacturing (AM) changes the requirements for conventional non-destructive testing (NDT) as new processes of defect creation occur. Especially in safety critical areas, such as aerospace and automotive, new manufacturing processes and materials always require reliability tests and new standards which is a big challenge for NDT. T2 - Internationales Laser- und Fügesymposium CY - Dresden, Germany DA - 27.02.2018 KW - Laser Beam Melting KW - Laser Metal Deposition KW - Thermography KW - In-situ monitoring PY - 2018 AN - OPUS4-45619 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Seeger, Stefan A1 - Brödner, Doris A1 - Jacobi, T. A1 - Rasch, Fabian A1 - Rothhardt, Monika A1 - Wilke, Olaf T1 - Emissions of fine and ultrafine particles and volatile organic compounds from different filament materials operated on a low-cost 3D printer T1 - Emissionen feiner und ultrafeiner Partikel sowie flüchtiger organischer Verbindungen beim Einsatz verschiedener Filamentmaterialien in einem „low-cost“-3D-Drucker N2 - 3D-printing or additive manufacturing has many promising and unique advantages. Especially low cost molten polymer Deposition Printers are increasingly populär in the private and educational sector. Their environmental friendliness can be questioned due to recently reported ultrafine particle and suspected VOC emissions, To further investigate 3D-printing as a potential indoor air pollution source we characterized fine and ultrafine particle emissions from a molten polymer deposition printer producing a 3D object with ten marketable polymer filament materials under controlled conditions in a test chamber. VOC emissions from the filaments have also been compared. Using a straightforward emission model time dependent and averaged particle emission rates were determined. The results indicate that under comparable conditions some filament materials produce mainly ultrafine particles up to an average rate of 1013 per minute. This value is in the upper ränge of typical indoor ultrafine particle sources (e.g. Smoking, frying, candle light, laser printer). The observed material-specific rates differ by five Orders of magnitude. Filament-specific gaseous emissions of organic compounds such as bisphenol A, styrene and others were also detected. Our results suggest a detailed evaluation of related risks and considering protective measures such as housing and filtering. N2 - 3D-Druck oder additive Herstellungsverfahren haben eine Menge vielversprechender und einzigartiger Vorteile. Insbesondere günstige 3D-Drucker für Polymere werden im privaten und ausbildenden Bereich zunehmend beliebter. Ihre Umweltfreundlichkeit kann aufgrund jüngst berichteter Emissionen ultrafeiner Partikel und vermuteter VOC-Emissionen infrage gestellt werden. Um 3D-Drucker für Polymere als mögliche Quelle von Innenraumluftverunreinigungen weiter zu untersuchen, charakterisierten wir die Emissionen feiner und ultrafeiner Partikel bei der Herstellung eines 3D-Objekts unter Verwendung zehn marktgängiger Polymerfilamente unter kontrollierten Bedingungen in einer Emissionsprüfkammer. Die VOC-Emissionen der verschiedenen Filamente wurden ebenfalls verglichen. Die zeitabhängigen und gemittelten Partikelemissionsraten wurden durch Anwendung eines einfachen Emissionsmodells bestimmt. Die Ergebnisse zeigen, dass unter vergleichbaren Bedingungen einige Filamente mit einer mittleren Rate von 10 KW - Emission KW - Ultrafine particles KW - VOC KW - 3D printer PY - 2018 SN - 0949-8036 SN - 0039-0771 VL - 78 IS - 3 SP - 79 EP - 87 PB - Springer-VDI-Verl. CY - Düsseldorf AN - OPUS4-44954 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 A1 - Mohr, Gunther A1 - Hilgenberg, Kai T1 - Thermography in metal AM: Comparison of high-speed NIR thermography and MWIR thermography N2 - Additive manufacturing (AM) opens the route to a range of novel applications.However, the complexity of the manufacturing process poses a challenge for the production of defect-free parts with a high reliability. Since process dynamics and resulting microstructures of AM parts are strongly influenced by the involved temperature fields, thermography is a valuable tool for process surveillance. The high process temperatures in metal AM processes allow one to use cameras usually operating in the visible spectral range to detect the thermally emitted radiation from the process. In our work, we compare the results of first measurements during the manufacturing processes of a commercial laser metal deposition (LMD) setup and a laser beam melting (LBM) setup using a MWIR camera with those from a VIS high-speed camera with band pass filter in the NIR range. T2 - Additive Manufacturing Benchmarks 2018 CY - Gaithersburg, MA, USA DA - 18.06.2018 KW - Thermography KW - Additive manufacturing KW - Laser metal deposition KW - Laser beam melting KW - ProMoAM PY - 2018 AN - OPUS4-45401 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Saadeh, Qais A1 - Pauw, Brian Richard A1 - Thünemann, Andreas A1 - Günster, Jens T1 - In-Situ SAXS Techniques N2 - Our project's aim is to enhance the capabilities of additive manufacturing techniques, where enabling a Two-Photon-Polymerization (TPP) 3D printer of producing arrays of precisely aligned nanoparticles is of an enormous value. As heterogeneous functional nanostructures with arrays of oriented nanoparticles are very promising in many fields; electrochemistry, energy storage, nanoelectronics among other vital fields. The feasibility and the convenience of orienting nanoparticles using magnetic, electric fields and ultrasonic vibrations will be systematically investigated, using Small Angle X-ray Scattering (SAXS), since SAXS can provide detailed information about the orientation characteristics of nano-Ensembles. Corresponding to our prerequisites, a set ad hoc functional sample holders, sample stages and other In-Situ SAXS solutions were developed, and incorporated to be compatible with a state-of-the-arts SAXS machine, called Multi-scale Analyzer for Ultrafine Structures (MAUS). The MAUS has been customized and engineered to serve as a miniaturized synchrotron, and that is exactly what we need. Experiments attempting to orient superparamagnetic nanoparticles will be discussed, where the outcomes will not only help in understanding the mechanics of field-particle interactions, it will also help in further developing the adequate needed set of corrections to the SAXS data, that is especially regards oriented samples. T2 - XVII International Small Angle Scattering Conference – SAS 2018 CY - Traverse City, Michigan, USA DA - 07.10.2018 KW - In-Situ Techniques KW - SAXS KW - Magnetic nano-particles PY - 2018 AN - OPUS4-46443 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - GEN A1 - Bäßler, Ralph T1 - Additive manufacturing of metals – From fundamental technology to rocket nozzles, medical implants, and custom jewelry (Book review) N2 - This book fulfills its intention to provide a comprehensive overview on 3D-printing of metals. The interested reader can get a lot of information about the topics one should deal with when working with additively manufactured metallic parts. It gives a general roadmap where to start, what to learn and how it fits together. KW - Additive manufacturing KW - Alloys KW - Cladding KW - 3D-Metal-Printing PY - 2018 DO - https://doi.org/10.1002/maco.201870124 SN - 0947-5117 VL - 69 IS - 12 SP - 1881 PB - WILEY-VCH Verlag GmbH & Co. KGaA CY - Weinheim AN - OPUS4-46902 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -