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Effect of heat control on mechanical properties and residual stresses at the transition zone of component and substrate in hybrid DED‑arc manufacturing
- In hybrid additive manufacturing, components or semi-finished products manufactured by conventional primary forming are enhanced or modified by additive manufactured structures. However, systematic investigations focusing on the critical transition area between the specific properties of the substrate (like high-strength) and the additively manufactured component, made of specific filler material, are still lacking. The focus of the present study was to determine the influence of heat control on the Δt8/5 cooling time, the distortion, the mechanical properties, and the residual stresses in the transition area of hybrid-additive components. This contributed to the knowledge regarding the safe avoidance of cold cracking, excessive distortion, a reduction in yield stress, and the implementation of hybrid DED-arc manufacturing. The heat control was varied by means of heat input and working temperature such that the Δt8/5 cooling times corresponded to the recommended processing range. TheIn hybrid additive manufacturing, components or semi-finished products manufactured by conventional primary forming are enhanced or modified by additive manufactured structures. However, systematic investigations focusing on the critical transition area between the specific properties of the substrate (like high-strength) and the additively manufactured component, made of specific filler material, are still lacking. The focus of the present study was to determine the influence of heat control on the Δt8/5 cooling time, the distortion, the mechanical properties, and the residual stresses in the transition area of hybrid-additive components. This contributed to the knowledge regarding the safe avoidance of cold cracking, excessive distortion, a reduction in yield stress, and the implementation of hybrid DED-arc manufacturing. The heat control was varied by means of heat input and working temperature such that the Δt8/5 cooling times corresponded to the recommended processing range. The heat input has a greater influence on the cooling time in the transition area than the working temperature. Working temperature and the total energy applied per layer have a significant effect on component distortion. The lowest working temperature of 100 °C in combination with the highest total energy per layer leads to significantly greater distortion compared to manufacturing with a high working temperature of 300 °C and low total energy per layer. In addition, the longitudinal residual compressive stresses in the sensitive transition area are reduced from − 500 MPa to approx. − 200 MPa by adjusting the working temperature from 100 to 300 °C. Such complex interactions must be clarified comprehensively to provide users with easily applicable processing recommendations and standard specifications for an economical hybrid additive manufacturing of components made, for example, of high-strength steels in the transition area.…


| Autor*innen: | R. Scharf-Wildenhain, Lorenz Engelking, A. Hälsig, Dirk SchröpferORCiD, Thomas KannengießerORCiD, J. Hensel |
|---|---|
| Dokumenttyp: | Zeitschriftenartikel |
| Veröffentlichungsform: | Verlagsliteratur |
| Sprache: | Englisch |
| Titel des übergeordneten Werkes (Englisch): | Welding in the World |
| Jahr der Erstveröffentlichung: | 2025 |
| Organisationseinheit der BAM: | 9 Komponentensicherheit |
| 9 Komponentensicherheit / 9.2 Versuchsanlagen und Prüftechnik | |
| 9 Komponentensicherheit / 9.4 Integrität von Schweißverbindungen | |
| Veröffentlichende Institution: | Bundesanstalt für Materialforschung und -prüfung (BAM) |
| Verlag: | Springer |
| Erste Seite: | 1 |
| Letzte Seite: | 15 |
| DDC-Klassifikation: | Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten |
| Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Angewandte Physik | |
| Freie Schlagwörter: | DED-arc; Heat control; High-strength metals; Hybrid additive manufacturing; Residual stress |
| Themenfelder/Aktivitätsfelder der BAM: | Energie |
| Energie / Windenergie | |
| Material | |
| Material / Additive Fertigung | |
| Veranstaltung: | IIW Annual Assembly and International Conference |
| Veranstaltungsort: | Rhodes Island, Greece |
| Beginndatum der Veranstaltung: | 07.07.2024 |
| Enddatum der Veranstaltung: | 12.07.2024 |
| DOI: | 10.1007/s40194-025-02036-z |
| URN: | urn:nbn:de:kobv:b43-630415 |
| ISSN: | 1878-6669 |
| Verfügbarkeit des Dokuments: | Datei für die Öffentlichkeit verfügbar ("Open Access") |
| Lizenz (Deutsch): | Creative Commons - CC BY - Namensnennung 4.0 International |
| Datum der Freischaltung: | 07.05.2025 |
| Referierte Publikation: | Ja |
| Datum der Eintragung als referierte Publikation: | 07.05.2025 |
| Schriftenreihen ohne Nummerierung: | Wissenschaftliche Artikel der BAM |


