TY - CONF A1 - Epperlein, Martin T1 - Eine digital gestützte Qualitätssicherung für die additive Fertigung N2 - Die additive Fertigung (ugs. „3D-Druck“) ist bei der Herstellung von hochkomplexen metallischen Bauteilen, bionisch inspiriertem Leichtbau oder Prototypen nicht mehr wegzudenken. Für die konventionelle Fertigung hat sich das bestehende System der Qualitätsinfrastruktur (QI) bewährt. Die additive Fertigung vergrößert den gestalterischen Spielraum von möglichen Bauteilgeometrien und Prozessfehlern jedoch erheblich. Hier gerät die QI an ihre Grenzen, sodass die Fertigung und Zulassung sicherheitsrelevanter Bauteile sehr zeit- und kostenintensive Versuche erfordern. Eine moderne digitale QI erlaubt eine effizientere Qualitätssicherung für additiv gefertigte Bauteile. Dies erfordert eine durchgängig digitale Abbildung des physischen Materialflusses. T2 - Werner-von-Siemens Centre for Industry and Science - AM Querschnittstreffen CY - Online meeting DA - 21.06.2022 KW - Additive Fertigung KW - Qualitätssicherung KW - Digitalisierung PY - 2022 AN - OPUS4-55127 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Baer, Wolfram A1 - Wossidlo, Peter A1 - Abbasi, Behboud T1 - On the question of how to analyze and apply Charpy pendulum impact test results correctly - Shortcomings in corresponding procedures and standards JF - Journal of testing and evaluation N2 - This paper is focused on the approximation of absorbed Charpy impact energy-temperature curves (KV-T) and the management of sub-size test piece results in Charpy pendulum impact tests. Both subjects are frequently underestimated but may have a strong impact on the assessment of product quality and structural integrity. The status of related test standards, product standards, structural integrity assessment procedures and corresponding research is reviewed. It is concluded that the state of regulation is partly insufficient and wrong. There is a wide gap between the state of knowledge in the field of materials testing and the requirements of product standards and structural integrity assessment procedures. The present paper aims at boosting and supporting the necessary discussion among the parties involved to raise the level of technical safety. Correspondingly, a large experimental database was created by Charpy impact testing of popular modern structural Steels with nominal yield strength from 235 MPa to 960 MPa. KV-T data were generated using test pieces with thicknesses between 2.5 mm and 10 mm. Different strategies for KV-T curve fitting, definition of transition temperatures, as well as upper and lower shelf energy levels were followed, and different scaling procedures were applied to the sub-size test piece results. The results show that proportional scaling of sub-size to full-size test piece results in terms of KV should be disallowed because it is a wrong approach. Regulations still incorporating such procedures should be revised as soon as possible. Existing nonproportional scaling and conversion procedures were applied. The results obtained illustrate that neither an overall nor consistent conservatism nor an adequate conservatism level can be achieved. In summary, the standardizing bodies should enforce the discussion to revise relevant test standards considering more precise specifications on Charpy data fitting. Furthermore, proposals are made for an improved management of sub-size test piece results. KW - Structural integrity assessment procedure KW - Charpy pendulum impact test KW - Sub-size test piece KW - Standard test piece KW - Curve fitting KW - Conversion of results KW - Absorbed energy KW - Transition temperature KW - Steel KW - Test standard KW - Product standard PY - 2022 DO - https://doi.org/10.1520/JTE20210781 SN - 0090-3973 VL - 50 IS - 4 SP - 2268 EP - 2293 PB - American Society for Testing and Materials (ASTM) CY - West Conshohocken, PA AN - OPUS4-55172 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Simón Muzás, Juan A1 - Brunner-Schwer, C. A1 - Rethmeier, Michael A1 - Hilgenberg, Kai T1 - Mitigation of liquation cracking in laser welding of pairs of L-PBF processed and wrought plates of Inconel 718 T2 - Proceedings of IIW2022 - International Conference on Welding and Joining N2 - Laser welding is an appropriate technique for joining Laser Powder Bed Fusion (L-PBF) parts together and to conventional wrought ones. The potential consists of profiting from synergies between additive and conventional manufacturing methods and overcoming the existing limitations of both. On the one hand, L-PBF is a widely spread metal-based additive manufacturing technique suitable for generating complex parts which can present intrinsic designed cavities, conformal cooling channels, and filigree structures contributing to sustainable manufacturing and efficiency-oriented designs. On the other hand, chamber sizes for producing L-PBF parts are limited, and the process is time-consuming. Thus, its employment is not for every geometry justified. Additionally, they are in most cases individual elements of a larger assembly and need to be joined together to conventionally fabricated parts. The present research suggests laser welding parameters to adequately bond pairs of wrought and L-PBF processed plates and two L-PBF plates of Inconel 718 in butt position. L-PBF samples are printed in three different build-up orientations. Additionally, the influence of as-built L-PBF roughness qualities and usual pre-weld preparations such as edge milling are examined. The effect of normed pre-weld heat treatments is also contemplated. Identified cracks are analyzed by means of EDS in order to confirm the present phases on the areas of interest. EBSD is also employed to obtain a clear depiction of the crystallographic texture and distribution of the hot cracks. The quality of the weldment was examined according to existing standards. Substantial differences in seam geometry and microstructure across different edge’s surface qualities and build directions of stress relieved L-PBF parts have not been detected. Nevertheless, even if no other irregularities are present in the seam, variability in liquation cracking susceptibility has been confirmed. This defect is prone to happen when parts made of this nickel-based superalloy are welded together when not enough precautions are taken. It has been determined that grain size and ductility of the material before welding play a crucial role and mitigating or intensifying these imperfections. Moreover, recommendations are presented to avoid this potential welding defect. T2 - IIW 2022 International Conference on Welding and Joining CY - Tokyo, Japan DA - 17.07.2022 KW - Hybrid Part KW - Liquation Cracking KW - Build-up Orientation KW - Pre-weld Preparation KW - Heat treatment KW - Inconel 718 KW - Laser Welding KW - Laser Powder Bed Fusion KW - Selective Laser Melting KW - SLM KW - L-PBF KW - PBF-LB/M KW - LW PY - 2022 UR - www.iiw2022.com SP - 372 EP - 375 PB - The International Institute of Welding (IIW) CY - Tokyo, Japan AN - OPUS4-56066 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Epperlein, Martin T1 - Eine digital gestützte Qualitätssicherung für die additive Fertigung N2 - Die Digitalisierung der Qualitätsinfrastruktur (QI) am Beispiel der Additiven Fertigung. Der Vortrag erörtert, wie die Elemente einer digitalen QI zur Qualitätssicherung und Zertifizierung in der Additiven Fertigung beitragen können. T2 - Treffen der Arbeitsgemeinschaft Additive Fertigung des VDMA CY - Coburg, Germany DA - 27.10.2022 KW - Qualitätsinfrastruktur KW - Additive Fertigung KW - Digitalisierung PY - 2022 AN - OPUS4-56165 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Braun, T. A1 - Jäger, M. A1 - Rauch, H. A1 - Brach, K. A1 - Singh, R. A1 - Kondas, J. A1 - Uhlmann, E. A1 - Häcker, Ralf T1 - Evaluation of electric conductivity and mechanical load capacity of copper deposits for application in large winding components for electrical high-voltage machines made with cold spray additive manufacturing N2 - In line with the industrial trend of additive manufacturing, cold spray as a non-laser-based process is becoming increasingly important for many fields of application. For the evaluation of additive manufacturing of winding components made of copper for large electrical high-voltage machines, material and component properties such as electrical conductivity, mechanical load capacity and the component size that can be produced are of particular importance. In this context, the cold spray process offers advantages over laser-based additive manufacturing processes such as laser powder bed fusion (LPBF) or laser cladding by using the kinetic energy of the copper powder particles to generate particle cohesion. To investigate the electrical conductivity as well as the mechanical load capacity of cold spray parts, specimens were machined out of cold sprayed bulk copper deposits. The characteristic values were obtained with regard to the direction of deposition, which is defined by the direction of the robot’s movement. Thus, for the investigation of the component properties, specimens were provided that had been produced both longitudinally and transversely as well as orthogonally to the direction of deposition. The results of the investigations show that both the electrical conductivity and the mechanical load capacity of the specimen have a strong preferential direction of the specimen orientation with respect to the direction of deposition. Furthermore, it could be shown that by increasing the deposition height, there is an increasing oxygen content in the sample material, combined with increasingly significant defect networks. These effects have a negative impact on the electrical conductivity as well as on the mechanical load capacity. As a conclusion, further need for investigation is identified in the optimization of the process parameters as well as in the deposition strategy for the additive manufacturing of large-volume components with cold spray. T2 - ITSC 2022 CY - Vienna, Austria DA - 04.05.2022 KW - Cold Spray KW - Copper powder particles KW - Electrical conductivity KW - Large electrical high-voltage machine PY - 2022 AN - OPUS4-56127 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Braun, T. A1 - Uhlmann, E. A1 - Häcker, Ralf A1 - Jäger, M. A1 - Rauch, H. A1 - Kondas, J. A1 - Brach, K. A1 - Singh, R. T1 - Evaluation of electric conductivity and mechanical load capacity of copper deposits for application in large winding components for electrical high-voltage machines made with cold spray additive manufacturing N2 - In line with the industrial trend of additive manufacturing, cold spray as a non-laser-based process is becoming increasingly important for many fields of application. For the evaluation of additive manufacturing of winding components made of copper for large electrical high-voltage machines, material and component properties such as electrical conductivity, mechanical load capacity and the component size that can be produced are of particular importance. In this context, the cold spray process offers advantages over laser-based additive manufacturing processes such as laser powder bed fusion (LPBF) or laser cladding by using the kinetic energy of the copper powder particles to generate particle cohesion. To investigate the electrical conductivity as well as the mechanical load capacity of cold spray parts, specimens were machined out of cold sprayed bulk copper deposits. The characteristic values were obtained with regard to the direction of deposition, which is defined by the direction of the robot’s movement. Thus, for the investigation of the component properties, specimens were provided that had been produced both longitudinally and transversely as well as orthogonally to the direction of deposition. The results of the investigations show that both the electrical conductivity and the mechanical load capacity of the specimen have a strong preferential direction of the specimen orientation with respect to the direction of deposition. Furthermore, it could be shown that by increasing the deposition height, there is an increasing oxygen content in the sample material, combined with increasingly significant defect networks. These effects have a negative impact on the electrical conductivity as well as on the mechanical load capacity. As a conclusion, further need for investigation is identified in the optimization of the process parameters as well as in the deposition strategy for the additive manufacturing of large-volume components with cold spray. T2 - ITSC 2022 CY - Wien, Austria DA - 04.05.2022 KW - Cold Spray KW - Electrical conductivity KW - Copper powder particles KW - Large electrical high-voltage machine PY - 2022 SP - 1 EP - 7 AN - OPUS4-56108 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Heßmann, Jennifer A1 - Hilgenberg, Kai T1 - New approach for multi material design: combination of laser beam and electromagnetic melt pool displacement by induced lorentz forces N2 - Multi-material structures are a promising solution to reduce vehicle weight and save fuel or electric energy in automotive design. However, thermal joining of steel and aluminum alloys is a challenge to overcome due to different material properties and the formation of brittle intermetallic phases. In this study, a new joining approach for producing overlap line-shaped joints is presented. The lower joining partner (EN AW 5754) is melted by a laser beam and this melt is displaced into a line-shaped cavity of the upper joining partner (1.0330) by induced Lorentz forces. The melt solidifies in the cavity to a material and form-fitting joint. This approach needs no auxiliary joining elements or filler materials. Previous investigation to produce spot-shaped joints by using this approach showed that quality and reproducibility were limited by known melt pool dynamics of aluminum alloys (keyhole collapses). For line-shaped joints, the melt displacement can take place behind the keyhole. This allows the displacement process to be spatial uncoupled from the influence of the keyhole collapses. The study shows that this improved the process stability and the quality of the joint. The created line-shaped joints were microstructurally characterized by transversal sections. Intermetallic phases were identified by electron backscatter diffraction (EBSD) and EDX-Analysis. The detected intermetallic phases consist of a 5 µm - 6 µm compact phase seam of Al5.6Fe2 and a needle shaped phase of Al13Fe4. Tensile shear tests were carried out to quantify the load capacity. It was possible to create a joint with a load capacity of about 2 kN. T2 - ICALEO Orlando 2022 CY - Orlando, Florida, USA DA - 17.10.2022 KW - Electromagnetic forces KW - Joining dissimilar materials KW - Laser beam welding KW - Steel and aluminium PY - 2022 AN - OPUS4-56149 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Heßmann, Jennifer A1 - Hilgenberg, Kai T1 - New approach for multi-material design: Combination of laser beam and electromagnetic melt pool displacement by induced Lorentz forces JF - Journal of Laser Applications N2 - Multimaterial structures are a promising solution to reduce vehicle weight and save fuel or electric energy in automotive design. However, thermal joining of steel and aluminum alloys is a challenge to overcome due to different material properties and the formation of brittle intermetallic phases. In this study, a new joining approach for producing overlap line-shaped joints is presented. The lower joining partner (EN AW 5754) is melted by a laser beam, and this melt is displaced into a line-shaped cavity of the upper joining partner (1.0330) by induced Lorentz forces. The melt solidifies in the cavity to a material and form-fitting joint. This approach needs no auxiliary joining elements or filler materials. Previous investigation to produce spot-shaped joints by using this approach showed that quality and reproducibility were limited by known melt pool dynamics of aluminum alloys (keyhole collapses). For line-shaped joints, the melt displacement can take place behind the keyhole. This allows the displacement process to be spatially uncoupled from the influence of keyhole collapses. The study shows that this improved the process stability and the quality of the joint. The created line-shaped joints were microstructurally characterized by transversal sections. Intermetallic phases were identified by electron backscatter diffraction and EDX analysis. The detected intermetallic phases consist of a 5–6 μm compact phase seam of Al5.6Fe2 and a needle-shaped phase of Al13Fe4. Tensile shear tests were carried out to quantify the load capacity. It was possible to create a joint with a load capacity of about 2 kN. KW - Electromagnetic forces KW - Joining dissimilar materials KW - Laser beam welding KW - Steel and aluminium KW - Lorentz forces PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-564840 DO - https://doi.org/10.2351/7.0000763 SN - 1042-346X VL - 35 IS - 1 SP - 1 EP - 8 PB - Laser Institute of America CY - Orlando, Fla. AN - OPUS4-56484 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hilgenberg, Kai T1 - Herausforderungen in der additiven Fertigung sicherheitsrelevanter Komponenten N2 - Der Vortrag stellt nach einer kurzen allgemeinen Einleitung zur additiven Fertigung und des Laser Powder Bed Fusion Verfahrens einige Herausforderungen vor, die derzeitig den Einsatz von AM-Komponenten in sicherheitsrelevanten Anwendungen erschweren. Abschließend werden zwei Beispiele von Arbeiten der BAM gezeigt, die zur Überwindung dieser Herausforderungen beitragen können. T2 - Anwendertreffen des Laserverbundes Berlin-Brandenburg CY - Berlin, Germany DA - 25.11.2022 KW - Additive Fertigung KW - Laser Powder Bed Fusion PY - 2022 AN - OPUS4-56435 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Schneider, M. A1 - Schlingmann, T. A1 - Schmidt, J. A1 - Bettge, Dirk A1 - Hilgenberg, Kai A1 - Binder, M. A1 - Klöden, B. T1 - A Round Robin Test To Investigate The Printing Quality Of PBF LB/M Processed AlSi10Mg N2 - When it comes to higher accuracies, new technologies and real applications in additive manufacturing, there is one topic which cannot be avoided: The material response on the chosen processing parameters and its agreement and correspondence with literature data of the wrought material grade counterpart. In industrial Additive Manufacturing (AM) standards in terms of printing parameters, protection gas atmospheres or powder handling instructions are not obligatory. Therefore, the question must be answered whether the AM process is reproducible and reliable over different printing companies. This was the motivation to realize a round robin test between 8 European printing companies and academic partners. The consortium had printed and tested fatigue and tensile testing bars under plant-specific conditions. A commonly used cast aluminum alloy, AlSi10Mg, was chosen as test material for the PBF-LB/M process. Differences of the results between the partners and the scatter itself were discussed in detail. T2 - World PM2022 CY - Lyon, France DA - 09.10.2022 KW - Additive manufacturing KW - AlSi10Mg KW - Laser powder bed fusion KW - Round robin KW - Reproducibility PY - 2022 AN - OPUS4-56303 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -