TY - CONF A1 - Avila, Luis A1 - Rehmer, Birgit A1 - Skrotzki, Birgit A1 - Graf, B. A1 - Rethmeier, Michael A1 - Ulbricht, Alexander T1 - Low cycle fatigue behavior and failure mechanisms of additively manufactured Ti-6Al-4V N2 - Despite of the significant advances in AM process optimization there is still a lack of experimental results and understanding regarding the mechanical behavior and microstructural evolution of AMparts, especially in loading conditions typical for safety-relevant applications e.g. in the aerospace or power engineering. Within the scope of the presented investigations, a characterization of the fatigue behavior of additively manufactured Ti-6Al-4V in the low cycle fatigue regime was carried out in the range of 0.3 to 1.0 % strain amplitude at room temperature, 250°C and 400°C. The Ti-6Al-4V specimens are machined out of lean cylindrical rods, which were fabricated using powder laser metal deposition (LMD) with an improved build-up strategy. The improved strategy incorporates variable track overlap ratios to achieve a constant growth in the shell and core area. The low-cycle-fatigue behavior is described based on cyclic deformation curves and strain-based fatigue life curves. The lifetimes are fitted based on the Manson-Coffin-Basquin relationship. A characterization of the microstructure and the Lack-of-Fusion (LoF)-defect-structure in the as-built state is performed using optical light microscopy and high-resolution computed tomography (CT) respectively. The failure mechanism under loading is described in terms of LoF-defects-evolution and crack growth mechanism based on an interrupted LCF test with selected test parameters. After failure, scanning electron microscopy, digital and optical light microscopy and CT are used to describe the failure mechanisms both in the longitudinal direction and in the cross section of the specimens. The fatigue lives obtained are comparable with results from previous related studies and are shorter than those of traditionally manufactured (wrought) Ti-6Al-4V. In this study new experimental data and understanding of the mechanical behavior under application-relevant loading conditions (high temperature, cyclic plasticity) is gained. Furthermore, a better understanding of the role of LoFdefects and AM-typical microstructural features on the failure mechanism of LMD Ti-6Al-4V is achieved. T2 - First European Conference on Structural Integrity of Additively Manufactured Materials (ESIAM19) CY - Trondheim, Norway DA - 09.09.2019 KW - High Temperature Testing KW - Titanium KW - Ti-6Al-4V KW - Additive Manufacturing KW - Computed Tomography KW - Microstructure KW - Tensile Properties KW - Low Cycle Fatigue PY - 2019 AN - OPUS4-49492 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Avila, Luis A1 - Rehmer, Birgit A1 - Skrotzki, Birgit A1 - Graf, B. A1 - Rethmeier, Michael A1 - Ulbricht, Alexander T1 - Low cycle fatigue behavior, tensile properties and microstructural features of additively manufactured Ti-6Al-4V N2 - Despite of the significant advances in additive manufacturing (AM) process optimization there is still a lack of experimental results and understanding regarding the mechanical behavior and its relationship with the microstructural features of AM-parts, especially in loading conditions typical for safety-relevant applications. Within the scope of the presented ongoing investigations, a basic microstructural characterization, tensile tests at room and elevated temperature (400°C) as well as a characterization of the fatigue behavior of additively manufactured Ti-6Al-4V in the low cycle fatigue regime are carried out in the as-built state. After failure, different techniques are used to describe the failure mechanisms of the specimens. The AM-Specimens are provided by the Fraunhofer institute for production systems and design technology and investigated at the BAM following the philosophy of the TF-Project AGIL. T2 - Workshop on Additive Manufacturing: Process, materials, testing, simulation & implants CY - BAM, Berlin, Germany DA - 13.05.2019 KW - High Temperature Testing KW - Titanium KW - Ti-6Al-4V KW - Additive Manufacturing KW - DED-L KW - LMD KW - Computed Tomography KW - Microstructure KW - Tensile Properties KW - Low Cycle Fatigue PY - 2019 AN - OPUS4-48067 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Evans, Alexander A1 - Mohr, Gunther A1 - Hilgenberg, Kai A1 - Straße, Anne A1 - Gumenyuk, Andrey A1 - Winterkorn, René A1 - Pittner, Andreas A1 - Sommer, Konstantin A1 - Bettge, Dirk A1 - Kranzmann, Axel A1 - Nolze, Gert A1 - Avila, Luis A1 - Rehmer, Birgit A1 - Charmi, Amir A1 - Falkenberg, Rainer A1 - Skrotzki, Birgit A1 - Werner, Tiago A1 - Madia, Mauro A1 - Zerbst, Uwe A1 - Ulbricht, Alexander A1 - Sprengel, Maximilian A1 - Kromm, Arne A1 - Thiede, Tobias A1 - Bruno, Giovanni 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 - Günster, Jens A1 - Zocca, Andrea T1 - Dense Powder Beds for the Additive Manufacturing of Ceramics N2 - Many of the most successful and precise additive manufacturing (AM) technologies are based on the deposition layer-by-layer of a flowable powder. Since the first pioneering work at the end of the 1980th many developments have been introduced, greatly extending the use of different materials, improving the physical properties of the components built and enhancing the accuracy of the process. Still very important issues remain nowadays, hampering a completely autonomous production of parts and even restricting the freedom of design by means of these technologies. One of the major issues is the low density and stability of the parts during the building process, which implies the need of support structures: The powder bed surrounding the part has an essential role, since it should support the structure during building, until it’s ready for removal. Moreover, the microstructure of the powder bed is a template for the microstructure of the part produced. In this context, the use of submicron ceramic powders is still a challenge. Three approaches for the stabilization and densification of powder beds will be presented: The Layerwise Slurry Deposition process LSD, the gas flow assisted powder deposition and the Laser Induced Slipcasting (LIS) of ceramic powder compacts. T2 - 43rd International Conference and Exposition on Advanced Ceramics and Composites (ICACC 2019) CY - Daytona Beach, FL, USA DA - 27.01.2019 KW - Ceramics KW - Additive Manufacturing PY - 2019 AN - OPUS4-49627 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Günster, Jens T1 - Powder-based Additive Manufacturing at Micro-Gravity N2 - Are we ready for putting a human footprint on Mars? Obviously, it is possible to send technologically challenging missions to our earth neighbors with a high level of complexity, such as enabling autonomous planetary mobility. As humanity contemplates mounting manned missions to Mars, strategies need to be developed for the design and operation of hospitable environments safely working in space for years. Humans require water and air provided by complicated equipment. Its safe operation is a great challenge and implies being prepared for all eventualities. Instead of foreseeing and preparing for all possible scenarios of machine failures and accidents, it appears logic taking advantage of the flexibility of humans and providing essential equipment for the reaction on critical situations. The supply of spare parts for repair and replacement of lost equipment would be one key pillar of such a strategy. Bearing in mind the absolute distance and flight trajectories for manned missions to Mars, supplying spare parts from Earth is impossible. Thus, in space manufacturing remains the only option for a timely supply. With a high flexibility in design and the ability to manufacture ready to use components directly from a computer aided model, additive manufacturing technologies appear extremely attractive. For metal parts manufacturing the Laser Beam Melting process is the most widely used additive manufacturing process in industrial application. However, envisioning the handling of metal powders in the absence of gravitation is one prerequisite for its successful application in space. A gas flow throughout the powder bed has been successfully applied to compensate for missing gravitational forces in micro gravity experiments. The 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. T2 - 1st Sino-German Workshop on 3D Printing in Space CY - Beijing, China DA - 20.02.2019 KW - Zero-g KW - Additive Manufacturing KW - µ-gravity PY - 2019 AN - OPUS4-49628 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Günster, Jens T1 - Powder-based Additive Manufacturing at Micro-Gravity N2 - Are we ready for putting a human footprint on Mars? Obviously, it is possible to send technologically challenging missions to our earth neighbors with a high level of complexity, such as enabling autonomous planetary mobility. As humanity contemplates mounting manned missions to Mars, strategies need to be developed for the design and operation of hospitable environments safely working in space for years. Humans require water and air provided by complicated equipment. Its safe operation is a great challenge and implies being prepared for all eventualities. Instead of foreseeing and preparing for all possible scenarios of machine failures and accidents, it appears logic taking advantage of the flexibility of humans and providing essential equipment for the reaction on critical situations. The supply of spare parts for repair and replacement of lost equipment would be one key pillar of such a strategy. Bearing in mind the absolute distance and flight trajectories for manned missions to Mars, supplying spare parts from Earth is impossible. Thus, in space manufacturing remains the only option for a timely supply. With a high flexibility in design and the ability to manufacture ready to use components directly from a computer aided model, additive manufacturing technologies appear extremely attractive. For metal parts manufacturing the Laser Beam Melting process is the most widely used additive manufacturing process in industrial application. However, envisioning the handling of metal powders in the absence of gravitation is one prerequisite for its successful application in space. A gas flow throughout the powder bed has been successfully applied to compensate for missing gravitational forces in micro gravity experiments. The 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. T2 - 2nd Sino-German Workshop on 3D Printing in Space CY - Berlin, Germany DA - 28.10.2019 KW - µ-gravity KW - Additive Manufacturing KW - Zero-g PY - 2019 AN - OPUS4-49629 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Hilgenberg, Kai A1 - Daum, Werner A1 - Maierhofer, Christiane A1 - Altenburg, Simon A1 - Bruno, Giovanni A1 - Heckel, Thomas A1 - Skrotzki, Birgit A1 - Zerbst, Uwe A1 - Kranzmann, Axel A1 - Bettge, Dirk A1 - Sommer, Konstantin A1 - Seeger, Stefan A1 - Nitsche, Michael A1 - Günster, Jens A1 - Evans, Alexander T1 - Additive manufacturing at the BAM: We focus on Safety N2 - In Germany, the Federal Institute for Materials Research and Testing (BAM) is addressing challenges in the implementation of additive manufacturing on the industrial landscape for safety-critical applications. KW - Process development KW - Additive Manufacturing KW - In-situ Process Monitoring KW - Non-destructive Materials KW - Characterisation KW - Safety KW - Fatigue KW - Environment KW - Standardisation PY - 2019 UR - https://static.asminternational.org/amp/201910/22/ SN - 0882-7958 VL - 177 IS - 7 SP - 22 EP - 26 PB - ASM International CY - Materials Park, OH, USA AN - OPUS4-49780 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Wilbig, Janka A1 - Borges de Oliveira, F. A1 - Schwentenwein, M. A1 - Günster, Jens T1 - Quality Aspects of Additively Manufactured Medical Implants - Defect Detection in Lattice Parts N2 - Additive Manufacturing technologies are developing fast to enable a rapid and flexible production of parts. Tailoring products to individual needs is a big advantage of this technology, which makes it of special interest for the medical device industry and the direct manufacturing of final products. Due to the fast development, standards to assure reliability of the AM process and quality of the printed products are often lacking. The EU project Metrology for Additively Manufactured Medical Implants (MetAMMI) is aiming to fill this gap by investigating alternative and cost efficient non-destructive measurement methods. T2 - yCAM Forum CY - Mons, Belgium DA - 03.03.2019 KW - Additive Manufacturing KW - Metrology PY - 2019 AN - OPUS4-49141 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zocca, Andrea A1 - Lüchtenborg, Jörg A1 - Lima, P. A1 - Diener, S. A1 - Katsikis, N. A1 - Günster, Jens 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 - Zocca, Andrea A1 - Mühler, T. A1 - Lima, P. A1 - Günster, Jens A1 - Lüchtenborg, Jörg 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 -