TY - JOUR A1 - Simon, Sebastian A1 - Gluth, Gregor ED - Rossignol, S. ED - Gluth, Gregor T1 - Unraveling the hardening mechanism during laser-induced slip casting of lithium aluminate-microsilica slurry N2 - Additive manufacturing (AM) of alkali-activated materials is a promising method for producing ceramic precursors, construction elements and other parts. A recently introduced AM process is laser-induced slip casting of lithium aluminate/microsilica slurries, which yields parts with excellent mechanical strengths. To clarify the underlying mechanisms, μ-Raman spectroscopy was applied to parts produced by the process, and the dissolution and hydration of lithium aluminate was studied inter alia using conventional and in-situ X-ray diffraction. The results show that significant dissolution of lithium aluminate occurs, particularly at increased temperatures during laser interaction, which leads to an increase of pH and precipitation of an akopovaite-like Li-Al-CO3 layered double hydroxide. The increase of the pH is likely to induce dissolution of the microsilica and possibly formation of a hydrous lithium aluminosilicate gel. These observations explain the strength evolution of the studied parts and can also aid the development and improvement of related AM methods. KW - Alkali-activated materials KW - Additive manufacturing KW - Laser-induced slip casting KW - Lithium KW - Layered double hydroxide PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-520557 DO - https://doi.org/10.1016/j.oceram.2021.100060 SN - 2666-5395 VL - 5 IS - Special issue: Alkali-activated materials and geopolymers in ceramics and beyond SP - 1 EP - 7 PB - Elsevier CY - Amsterdam AN - OPUS4-52055 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Tamsen, Erik T1 - Towards an automatic optimization framework for performance oriented precast concrete design N2 - Concrete has a long history in the construction industry and is currently one of the most widely used building materials. Especially precast concrete elements are frequently utilized in construction projects for standardized applications, increasing the quality of the composite material, as well as reducing the required building time. Despite the accumulated knowledge, continuous research and development in this field is essential due to the complexity of the composite combined with the ever-growing number of applications and requirements. Especially in view of global climate change, design aspects as CO2 emissions and resource efficiency require new mix designs and optimization strategies. A result of the material’s high complexity and heterogeneity on multiple scales is that utilizing the full potential with changing demands is highly challenging, even for the established industry. We propose a framework based on an ontology, which automatically combines experimental data with numerical simulations. This not only simplifies experimental knowledge transfer, but allows the model calibration and the resulting simulation predictions to be reproducible and interpretable. This research shows a way towards a more performance oriented material design. Within this talk we present our workflow for an automated simulation of a precast element, demonstrating the interaction of the ontology and the finite element simulation. We show the automatic calibration of our early-age concrete model [1, 2], to improve the prediction of the optimal time for the removal of the form work. T2 - The 8th European Congress on Computational Methods in Applied Sciences and Engineering (ECCOMAS) 2022 CY - Oslo, Norway DA - 05.06.2022 KW - Performance oriented concrete design KW - Early-age concrete KW - Precast concrete KW - Ontology KW - Optimization workflow PY - 2022 AN - OPUS4-55302 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Simon, Sebastian A1 - Bertmer, M. A1 - Gluth, Gregor T1 - Sol–gel synthesis and characterization of lithium aluminate (L–A–H) and lithium aluminosilicate (L–A–S–H) gels N2 - Hydrous lithium aluminosilicate (L–A–S–H) and lithium aluminate (L–A–H) gels are candidate precursors for glass-ceramics and ceramics with potential advantages over conventional processing routes. However, their structure before calcination remained largely unknown, despite the importance of precursor structure on the properties of the resulting materials. In the present study, it is demonstrated that L–A–S–H and L–A–H gels with Li/Al ≤ 1 can be produced via an organic steric entrapment route, while higher Li/Al ratios lead to crystallization of gibbsite or nordstrandite. The composition and the structure of the gels was studied by thermogravimetric analysis, X-ray diffraction, 27Al and 29Si magic-angle spinning nuclear magnetic resonance, and Raman spectroscopy. Aluminium was found to be almost exclusively in six-fold coordination in both the L–A–H and the L–A–S–H gels. Silicon in the L–A–S–H gels was mainly in Q4 sites and to a lesser extent in Q3 sites (four-fold coordination with no Si–O–Al bonds). The results thus indicate that silica-rich and aluminium-rich domains formed in these gels. KW - Lithium aluminosilicates KW - Raman spectroscopy KW - Sol-gel PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-558756 DO - https://doi.org/10.1111/ijac.14187 SN - 1546-542X VL - 19 IS - 6 SP - 3179 EP - 3190 PB - Wiley AN - OPUS4-55875 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Silvestro, L. A1 - Ruviaro, A. S. A1 - Lima, G. A1 - Durlo Tambara, Luís Urbano A1 - Feys, D. A1 - Kirchheim, A. P. T1 - Rotational rheometry test of Portland cement-based materials - A systematic literature review N2 - This study systematically reviews 62 papers on the use of rotational rheometry to assess the fresh state behavior of Portland cement-based materials. The research highlights the wide variation in test methods and aims to provide a comprehensive overview. Findings reveal that 50.0% of studies employed vane geometry, despite its limitations in providing transformation equations. Regarding dynamic shearing tests, 67.0% followed a consensus using a pre-shearing step and a step-wise routine with stabilization times ≥ 10 s. While the Bingham model is commonly used, the study emphasizes the importance of considering shear-thinning behavior in cementitious materials. Models like Herschel-Bulkley and modified Bingham may be more appropriate. This review offers insights into testing conditions for rotational rheometry of cementitious materials, serving as a foundation for future research in the field. KW - Review KW - Rheology KW - Rheometry KW - Rotational KW - Cement PY - 2024 DO - https://doi.org/10.1016/j.conbuildmat.2024.136667 SN - 0950-0618 VL - 432 SP - 1 EP - 14 PB - Elsevier Ltd. CY - Amsterdam AN - OPUS4-60075 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Bäßler, Ralph T1 - Review: Science, Technology and Applications of Metals in Additive Manufacturing N2 - Often 3D‐printing and additive manufacturing are mentioned as the 3rd industrial revolution. In this conjunction this book provides a brief overview on additively manufactured metal pieces. This book fulfills its intension to serve as an educational guide, providing a holistic picture encompassing science, technology and applications for the real‐life use of Metal Additive Manufacturing. KW - Additive manufacturing KW - Corrosion KW - Material properties PY - 2020 DO - https://doi.org/10.1002/maco.202070114 SN - 1521-4176 SN - 0947-5117 VL - 71 IS - 11 SP - 1929 EP - 1930 PB - WILEY‐VCH Verlag GmbH & Co. KGaA CY - Weinheim AN - OPUS4-51514 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Strobl, Domninic T1 - Reduced order model for temperature field simulation of wire arc additive manufacturing N2 - Additive manufacturing (AM) has revolutionized the manufacturing industry, offering a new paradigm to produce complex geometries and parts with customized properties. Among the different AM techniques, the wire arc additive manufacturing (WAAM) process has gained significant attention due to its high deposition rate and low equipment cost. However, the process is characterized by a complex thermal history making it challenging to simulate it in real-time for online process control and optimization. In this context, a reduced order model (ROM) using the proper generalized decomposition (PGD) method [1] is proposed as a powerful tool to overcome the limitations of conventional numerical methods and enable the real-time simulation of the temperature field of WAAM processes. These simulations use a moving heat source leading to a hardly separable parametric problem, which is handled by applying a novel mapping approach [2]. This procedure makes it possible to create a separated representation of the model, which is required to apply the PGD method, allowing a simulation of multiple layers. In this contribution, a PGD model is derived for the temperature field simulation of the WAAM process. A layer-by-layer simulation in combination with a compression of the PGD modes, without influencing the approximation error, is shown. The compression is an essential step since the modes sum up quickly over the layers and thus a reduction of the number of modes is needed. Furthermore, using an element birth technique leads usually to an update of the mesh or a new mesh in each time step. Though, this is not the case applying the mapping approach, where only a single nonchanging mesh is required to simulate the deposition of a whole layer. T2 - ECCOMAS Congress 2024 CY - Lisbon, Portugal DA - 03.06.2024 KW - Reduced Order Model KW - Proper Generalized Decomposition KW - Thermal transient problem KW - Additive manufacturing PY - 2024 AN - OPUS4-62231 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Strobl, Dominic T1 - Real-time Bead-on-Plate weld Simulation for Wire Arc Additive Manufacturing using Reduced Order modelling coupled with stochastic model Calibration N2 - Numerical simulations are essential in predicting the behavior of systems in many engineering fields and industrial sectors. The development of accurate virtual representations of actual physical products or processes (also known as digital twins) allows huge savings in cost and resources. In fact, digital twins would allow reducing the number of real, physical prototypes, tests, and experiments, thus also increasing the sustainability of production processes and products’ lifetime. Standard numerical methods fail in providing real time simulations, especially for complex processes such as additive manufacturing applications. This work aims to use a reduced order model for efficient wire arc additive manufacturing simulations, calibrations and real-time process control. Model reduction, e.g. the proper generalized decomposition [1,2] method, is a popular concept to decrease the computational effort. A new mapping approach [3] was applied to simulate a moving heat source with the proper generalized decomposition. Using this procedure even complex models can be simulated in real-time. The physical model is later on calibrated with the use of a stochastic model updating process and the reduced order model, leading to an optimized real-time simulation. In this contribution, a proper generalized decomposition model for a bead-on-plate wire arc additive manufacturing is presented. It is also coupled with a stochastic model updating process identifying the heat source characteristics as well as the boundary conditions of the transient thermal problem, whereas the heat source shape is simulated using a Goldak heat source T2 - 15th World Congress on Computational Mechanics (WCCM-XV) CY - Yokohama, Japan DA - 31.07.2022 KW - Wire arc additive manufacturing KW - Reduced order modelling KW - Model calibration PY - 2022 AN - OPUS4-55576 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - GEN A1 - Strobl, Domninic T1 - PGD in thermal transient problems with a moving heat source – a sensitivity study on factors affecting accuracy and efficiency N2 - Thermal transient problems, essential in applications like welding and additive metal manufacturing, are characterized by a dynamic evolution of temperature. Accurately simulating these phenomena is often computationally expensive, thus limiting the application, e. g. for model parameter estimation or online process control. Model order reduction, a solution to preserve accuracy while reducing complexity, is explored. This paper addresses challenges in developing a reduced model using the Proper Generalized Decomposition (PGD) for transient thermal problems with a specific treatment of the moving heat source within the reduced model. Factors affecting accuracy, convergence, and computational cost, such as discretization methods (finite element and finite difference), a dimensionless formulation, the size of the heat source, and the inclusion of material parameters as additional PGD variables are examined across progressively complex examples. The results demonstrate the influence of these factors on the PGD model's performance and emphasize the importance of their consideration when implementing such models. For thermal examples it is demonstrated that a PGD model with a finite difference discretization in time, a dimensionless representation, a mapping for a moving heat source, and a spatial domain non-separation yields the best approximation to the full order model. KW - Additive manufacturing KW - Mapping for unseparable load KW - Model order reduction KW - Proper generalized decomposition KW - Sensitivity analysis KW - Thermal transient problem PY - 2024 DO - https://doi.org/10.5281/zenodo.10102489 PB - Zenodo CY - Geneva AN - OPUS4-62235 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Ginés-Palomares, J.-C. A1 - Fateri, M. A1 - Schubert, T. A1 - de Peindray d’Ambelle, L. A1 - Simon, Sebastian A1 - Gluth, Gregor A1 - Günster, Jens A1 - Zocca, Andrea T1 - Material aspects of sintering of EAC-1A lunar regolith simulant N2 - Future lunar exploration will be based on in-situ resource utilization (ISRU) techniques. The most abundant raw material on the Moon is lunar regolith, which, however, is very scarce on Earth, making the study of simulants a necessity. The objective of this study is to characterize and investigate the sintering behavior of EAC-1A lunar regolith simulant. The characterization of the simulant included the determination of the phase assemblage, characteristic temperatures determination and water content analysis. The results are discussed in the context of sintering experiments of EAC-1A simulant, which showed that the material can be sintered to a relative density close to 90%, but only within a very narrow range of temperatures (20–30 °C). Sintering experiments were performed for sieved and unsieved, as well as for dried and non-dried specimens of EAC-1A. In addition, an analysis of the densification and mechanical properties of the sintered specimens was done. The sintering experiments at different temperatures showed that the finest fraction of sieved simulant can reach a higher maximum sintering temperature, and consequently a higher densification and biaxial strength. The non-dried powder exhibited higher densification and biaxial strength after sintering compared to the dried specimen. This difference was explained with a higher green density of the non-dried powder during pressing, rather than due to an actual influence on the sintering mechanism. Nevertheless, drying the powder prior to sintering is important to avoid the overestimation of the strength of specimens to be fabricated on the Moon. KW - Lunar regolith KW - Ceramics KW - Microstructure KW - Sintering KW - Softening temperature PY - 2023 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-592668 DO - https://doi.org/10.1038/s41598-023-50391-y SN - 2045-2322 VL - 13 SP - 1 EP - 14 PB - Springer Nature AN - OPUS4-59266 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Erning, Johann Wilhelm T1 - Hygienische Eigenschaften von additiv gefertigtem 1.4404 in Trinkwasser N2 - Elektrochemische Messungen zur hygienischen Bewertung additiv gefertigter Bauteile werden diskutiert. Die Bewertung und Details des Werkstoffs werden beschrieben, Anwendungsbeispiele gezeigt. T2 - 3. Fachtagung Werkstoffe und Additive Fertigung CY - Dresden, Germany DA - 11.05.2022 KW - Korrosion KW - Trinkwasser KW - Hygiene KW - Additive Fertigung PY - 2022 AN - OPUS4-54829 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -