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In situ Prozessüberwachung und Qualitätskontrolle bei der additiven Fertigung von Betonbauteilen
(2024)
In der additiven Fertigung von Beton wird kontinuierlich Material gemischt und verarbeitet. Dies erfordert eine kontinuierliche in situ Prozessüberwachung und Qualitätskontrolle. An der BAM wurde ein 3D-Betondrucker aufgebaut, der eine umfängliche Prozessüberwachung ermöglicht. Druck-, Temperatur- und Feuchtesensoren in der Pumpe und im Fördersystem erlauben ein kontinuierliches Monitoring des Frischbetons, während ein Laserlinienscanner am Druckkopf unmittelbar die gedruckte Ist-Kontur verfolgt. Die so gewonnenen Daten können Grundlage für die Erarbeitung von Normen für die additive Fertigung von Betonbauteilen sein und somit deren Standsicherheit gewährleisten.
Die additive Fertigung von Betonbauteilen, auch bekannt als 3D-Betondruck, ist eine Technologie, die im letzten Jahrzehnt aufgrund ihrer finanziellen und ökologischen Vorteile als nachhaltige Fertigungstechnologie viel Aufmerksamkeit erhalten hat. Obwohl die Vorteile der additiven Fertigung bereits durch zahlreiche Forschungs- und Demonstrationsprojekte gezeigt wurden, ist die Qualitätskontrolle während des Druckens äußerst anspruchsvoll und wird auch aufgrund fehlender harmonisierter Normen kaum angewendet. Aufgrund des kontinuierlichen Mischprozesses beim 3D-Betondruck ist es unmöglich Schwankungen des Trockenmörtels oder des Wassergehalts auszuschließen. Daher ist eine einzelne Stichprobe nicht mehr repräsentativ für das gesamte Bauteil und ein während des Druckens in einer Schicht auftretender Fehler kann die Integrität der gesamten Struktur beeinträchtigen. In diesem Beitrag werden die Ergebnisse eines als Fachwerkstruktur konzipierten Bogens, der unter vergleichbaren Randbedingungen mehrmals mit einem 3D-Betonextrusionsdrucker gedruckt wurde, vorgestellt. Jeder Bogen wurde auf seine mechanische Festigkeit und sein Tragverhalten geprüft. Die Ergebnisse der mechanischen Prüfungen der gedruckten Bögen werden mit Materialdaten aus klassischen Materialprüfungen verglichen und hinsichtlich ihrer statistischen Signifikanz diskutiert.
Extrusion based 3D concrete printing (3DCP) is a growing technology because of its high potential for automating construction and the new possibilities of design. In conventional construction methods, a sample is taken to be representative for one material batch. However, in 3DCP continuous mixing is used which results in variations during the mixing process. Therefore, one sample is not representative for the entire structure. This leads to the necessity of continuous and real-time process monitoring.
This study focuses on the variations of pressure and temperature which are caused by changes in the material due to the ongoing mixing process. Changes in material, which is transported downstream, are influencing sensor signals in different positions with a time delay. In the following, the data is analysed to investigate if the changing material and the so caused change in pressure can be used to calculate volume flow.
Additive manufacturing of concrete structures, also known as 3D concrete printing, is a technology that received a lot of attention over the past decade due to its financial an ecological advantage as sustainable construction technology. Although several techniques and approaches demonstrate these advantages, quality control during printing is highly challenging and rarely applied and harmonized standards are not existing. Due to the continuous mixing process used in 3D concrete printing, it is impossible to exclude variations in the dry mixture or water content, and a single test sample is insufficient to be representative for the whole structure. A defect in one layer during the printing can affect the entire integrity of the whole structure. This study shows the results of an arch designed as framework structure that was printed multiple times under the same boundary conditions using an extrusion-based 3D concrete printer. Each arch was tested for its mechanical strength and load bearing behavior. The results of the mechanical testing of the printed arches are compared with material data obtained by classical tests and discussed regarding their statistical significance.
Extrusion based 3D concrete printing (3DCP) is a growing technology because of its high potential for automating construction and the new possibilities of design. In conventional construction methods, a sample is taken to be representative for one material batch. However, in 3DCP continuous mixing is used which results in variations during the mixing process. Therefore, one sample is not representative for the entire structure. This leads to the necessity of continuous and real-time process monitoring.
This study focuses on the variations of pressure and temperature which are caused by changes in the material due to the ongoing mixing process. Changes in material, which is transported downstream, are influencing sensor signals in different positions with a time delay. In the following, the data is analysed to investigate if the changing material and the so caused change in pressure can be used to calculate volume flow.
Extrusion based 3D concrete printing (3DCP) is a growing technology because of its high potential for automating construction and the new possibilities of de-sign. In conventional construction methods, a sample is taken to be representative for one material batch. However, in 3DCP continuous mixing is used which re-sults in variations during the mixing process. Therefore, one sample is not repre-sentative for the entire structure. This leads to the necessity of continuous and re-al-time process monitoring.
At the Bundesanstalt für Materialforschung und -prüfung (BAM), Berlin, a test rig is developed to allow for comprehensive monitoring of the printing process. For this purpose, sensors for torque, temperature, pressure and moisture are in-stalled into the pipe. A laser scanner is installed at the nozzle to acquire infor-mation about the geometry of the extruded material.
This study focuses on the variations of pressure and temperature which are caused by changes in the material due to the ongoing mixing process. Preliminary results indicate that changes in the material properties cause changes in the sensor signals as well. These changes can be observed in various sensors with a delay, caused by material which is carried downstream. In the following, the data is ana-lysed to investigate if the changing material and the so caused change in pressure can be used to calculate volume flow.
Additive manufacturing of concrete structures is a novel and emerging tech-nology. Free contouring in civil engineering, which allows for entirely new designs, is a significant advantage. Although several techniques and ap-proaches demonstrate these advantages, quality control during printing is highly challenging and rarely applied. Due to the continuous mixing process used in 3D concrete printing, it is impossible to exclude variations in the dry mixture or water content, and a single test sample is insufficient to represent the whole structure. A defect in one layer during printing can affect the in-tegrity of the entire structure. Therefore, continuous and real-time process monitoring is required to record and document the printing process.
At the Bundesanstalt für Materialforschung und -prüfung (BAM), a test rig for 3D concrete printing was developed to monitor the properties during the printing process. This study investigates the relationship between geometric accuracy and process parameters (pressure, pump torque, print speed, layer height, water content) in extrusion-based 3D concrete printing. Using a high-precision laser scanner, the geometric measurements of printed concrete ele-ments are evaluated in real-time. The concrete elements are printed under controlled conditions with varied process parameters. Preliminary findings indicate a significant correlation between process variables and geometric ac-curacy.
In den vergangenen Jahren ist die Entwicklung additiver Fertigungsverfahren branchenübergreifend fortgeschritten. In der Industrie ist die Verarbeitung von Polymeren wie z. B. Polylactide (PLA) oder Acrylnitril-Butadien-Styrol-Copolymer (ABS) am weitesten verbreitet, aber auch die Verarbeitung von Metallen nimmt zu. Umfragen des Fraunhofer-Institut für Produktionstechnik und Automatisierung IPA aus dem Jahr 2016 verdeutlichen, wie hoch das Potential additiver Fertigungsverfahren eingeschätzt wird und auch die Anzahl der jährlich angemeldeten Patente im Bereich des 3D-Drucks hat sich in den letzten Jahren vervielfacht.
Additive manufacturing of concrete structures is an innovative and rapidly advancing technology. One of its key advantages is the ability to achieve freeform designs in civil engineering, enabling entirely new architectural possibilities. However, despite the demonstrated benefits of this technology, maintaining consistent print quality during the printing process remains a significant challenge and is seldom implemented. The continuous mixing process inherent in 3D concrete printing introduces potential variations in the dry mix composition or water content, making a single test sample insufficient to represent the entire structure. Moreover, defects in a single layer can compromise the integrity of the whole structure. This underscores the need for continuous, real-time monitoring to document and ensure the quality of the printing process.
At the Bundesanstalt für Materialforschung und prüfung (BAM), a 3D concrete printer was developed to enable real-time non-destructive monitoring of material properties during the printing process. This study examines the impact of rheological variations, influenced by water content variations, on the geometric characteristics of printed elements. Geometric measurements are captured in real time using a high-precision laser scanner. Concrete elements are printed under controlled conditions with systematically varied process parameters. Preliminary results reveal a strong correlation between rheological behaviour and the geometric properties of the printed components.
The growing interest of 3D Concrete Printing (3DCP) arises new challenges for quality control. A major challenge lies in evaluation of the interlayer bond strength. An optical approach is developed to monitor the surface properties of the printed layer. Commercial laser profile scanners are utilised to record the reflection intensity of the mortar’s surface. To be applicable in the printing process, the reflection intensity needs to be characterised for each material within the printable region and further effects, like geometry and environmental light, need to be considered. The presented work aims to provide a framework for implementing the laser reflection intensity to 3DCP monitoring.
