Additive Fertigung
Filtern
Dokumenttyp
- Zeitschriftenartikel (55)
- Vortrag (48)
- Beitrag zu einem Tagungsband (25)
- Posterpräsentation (13)
- Forschungsbericht (3)
- Forschungsdatensatz (1)
Schlagworte
- Additive Manufacturing (34)
- Additive manufacturing (32)
- Additive Fertigung (27)
- Thermography (20)
- Laser metal deposition (18)
- Process monitoring (13)
- DED (10)
- Thermografie (10)
- Microstructure (8)
- Ti-6Al-4V (8)
- LMD (7)
- Laser Metal Deposition (7)
- Arc welding (6)
- Open science (6)
- Research data management (6)
- 3D printing (5)
- AM (5)
- Directed Energy Deposition (5)
- Hochfester Stahl (5)
- L-PBF (5)
- Mechanical properties (5)
- Quality assurance (5)
- WelDX (5)
- Widerstandspunktschweißen (5)
- 3D Druck (4)
- Additive Manufacturing (AM) (4)
- Computed Tomography (4)
- DED-Arc (4)
- Direct energy deposition (4)
- Laser Powder Bed Fusion (4)
- Laser Powder Bed Fusion (L-PBF) (4)
- Laser beam welding (4)
- Laser powder bed fusion (4)
- Liquid Metal Embrittlement (4)
- Low Cycle Fatigue (4)
- Porosity (4)
- ProMoAM (4)
- WAAM (4)
- 316L (3)
- AGIL (3)
- Artificial neural network (3)
- CT (3)
- Computed tomography (3)
- Digitalization (3)
- Dimensional accuracy (3)
- Direct Energy Deposition (3)
- Directed energy deposition (3)
- Grain refinement (3)
- Infrared thermography (3)
- Künstliche Intelligenz (3)
- Laser Pulver Auftragsschweißen (3)
- Laser beam melting (3)
- Laser-Pulver-Auftragschweißen (3)
- Mikrostruktur (3)
- Multispectral thermography (3)
- Online Process Monitoring (3)
- Prozessmonitoring (3)
- Prozessüberwachung (3)
- Residual stress (3)
- Resistance spot welding (3)
- Stainless Steel (3)
- TES (3)
- Temperature emissivity separation (3)
- Welding simulation (3)
- Aerosol measurements (2)
- AlSi10Mg (2)
- Computed tomography (CT) (2)
- Condition monitoring (2)
- Crack (2)
- DED-EB (2)
- Data fusion (2)
- Data preparation (2)
- Digital transformation (2)
- Directed Enery Deposition (2)
- Duplex AISI 2205 (2)
- EBAM (2)
- Elektronenstrahlschweißen (2)
- Embedded electronics (2)
- FGM (2)
- Fatigue (2)
- Flüssigmetallinduzierte Rissbildung (2)
- Fume (2)
- Heat treatment (2)
- High Temperature Testing (2)
- Inconel 718 (2)
- LCF (2)
- LPBF (2)
- Lack-of-fusion (2)
- Laser powder bed fusion (L-PBF) (2)
- Laserpulverauftragschweißen (2)
- Life Cycle Assessment (2)
- Liquid metal embrittlement (2)
- NDT (2)
- Neuronales Netz (2)
- Neutron Diffraction (2)
- Neutron diffraction (2)
- Nickel (2)
- Optical Tomography (2)
- Optical tomography (2)
- Optische Tomografie (2)
- Particle gas emission (2)
- Path planning (2)
- Plume (2)
- Powder Bed Fusion (2)
- Process chain (2)
- Refill friction stir spot welding (2)
- Residual Stress (2)
- Schweißnahtbewertung (2)
- Selected Laser Melting (2)
- Selective Laser Melting (SLM) (2)
- Selective laser melting (SLM) (2)
- Selektive-laser-melting (2)
- Simulation (2)
- Spatter (2)
- Submerged arc welding (2)
- Tensile Properties (2)
- Ti64 (2)
- TiAl5V4 (2)
- Time over threshold (2)
- Titan (2)
- Titanium (2)
- Welding (2)
- Wire arc additive manufacturing (2)
- Wire electron beam additive manufacturing (2)
- Wärmenachbehandlung (2)
- Zink (2)
- Zugeigenschaften (2)
- AHSS (1)
- AISI 316L (1)
- AM feature integration (1)
- Acoustic Emission (1)
- Additive manufacturing (AM) (1)
- Advanced High-Strength Steel (AHSS) (1)
- Advanced high strength steels (1)
- Advanced high-strength steel (1)
- Al-Mg-Si (1)
- Al-Mg-Si-Legierungen (1)
- AlMg0.7SiTiB filler wire (1)
- AlMgSi Legierungen (1)
- Aluminum bronze (1)
- Analytical model (1)
- Anlagen (1)
- Artificial intelligence (1)
- Auftragschweißen (1)
- Automobilindustrie (1)
- Automotive (1)
- Bending test (1)
- Build-up strategy (1)
- Calculation time (1)
- Characterisation (1)
- Cimensional Accuracy (1)
- Clad steels (1)
- Computertomografie (1)
- Convolutional neural network (1)
- Crack propagation (1)
- Crater (1)
- Creep behavior (1)
- Critical strain (1)
- Crystal Plasticity Modelling (1)
- CuSn1 (1)
- DED-L (1)
- DED-LB (1)
- DED-arc (1)
- DIC (1)
- Damage prediction (1)
- Defekte (1)
- Density measurement (1)
- Deposition rate (1)
- Design of experiments (1)
- Digital Image Correlation (1)
- Digital image correlation (1)
- Dissimilar joints (1)
- Distortion (1)
- Distortion simulation (1)
- Duktilität (1)
- Dwell-time (1)
- EBSD (1)
- Edge effects (1)
- Edge quality (1)
- Efficient modelling (1)
- Eindringprüfung (1)
- Electromagnetic support (1)
- Electron beam (1)
- Electron beam welding (1)
- Emisssivity (1)
- Energy parameters of the arc (1)
- Environment (1)
- FEM (1)
- Festigkeit (1)
- Finite Element Method (1)
- Finite element simulation (1)
- Flange width (1)
- Flüssigmetallversprödung (1)
- Formgedächtnislegierungen (1)
- Functionally Graded Materials (1)
- Funktionally Graded Material (1)
- Fusion welding (1)
- Fügequalität (1)
- Galvanized steel (1)
- Gap bridgeability (1)
- Gleeble (1)
- Hardness (1)
- Heat Input (1)
- Heat Treatment (1)
- Heat flow (1)
- Heißzug (1)
- High speed laser cladding (1)
- High strength AlMgSi aluminium alloys (1)
- High-Power Welding (1)
- High-stength aluminium alloys (1)
- High-strength fine-grained steels (1)
- Hot Cracks (1)
- Hybrid Laser-Arc Welding (1)
- Hybrid components (1)
- Hybrid laser arc welding (1)
- Hybrid laser-arc welding (1)
- IR-Spektroskopie (1)
- IR-spectroscopy (1)
- In situ Monitoring (1)
- In-situ (1)
- In-situ Monitoring (1)
- In-situ Process Monitoring (1)
- Inconel 625 (1)
- Inconel 939 (1)
- Industrial and Manufacturing Engineering (1)
- Infrared Thermography (1)
- Integrated alignment features (1)
- Inter layer time (1)
- KI (1)
- Kriechen (1)
- Körperschall (1)
- Künstliche Neuronale Netze (1)
- LPA (1)
- Laser (1)
- Laser Beam Welding (1)
- Laser Metal Deposition (LMD) (1)
- Laser beam melting (LBM) (1)
- Laser cutting (1)
- Laser powder-based directed energy deposition (1)
- Laser surfacing (1)
- Laser welding (1)
- Laser-Pulver-Auftragschweißen (LPA) (1)
- Laser-metal-deposition (1)
- Laser-metal-depositon (1)
- Laserauftragschweißen (1)
- Laserstrahlschmelzen (1)
- Liquid Metal Embrittlement (LME) (1)
- Low cycle fatigue (1)
- Low-Cycle-Fatigue (1)
- MWIR (1)
- Magnesium Alloy (1)
- Magnesium alloy (1)
- Maritime Components (1)
- Mechanical properties of the joints (1)
- Mechanisch technologische Kennwerte (1)
- Mechanische Eigenschaften (1)
- Melt pool depth (1)
- Melt pool dinamics (1)
- Metal (1)
- Micro computed tomography (1)
- Microstructure characterisation (1)
- Mikro-Computertomographie (1)
- Model calibration (1)
- Multi-materials joining (1)
- NIR (1)
- NiTi-Legierungen (1)
- Nickel-based superalloy (1)
- Non-destructive Materials (1)
- Non-destructive testing (1)
- Normen (1)
- Numerical Simulation (1)
- Numerical simulation (1)
- Numerical simulations (1)
- Oberflächenmessung (1)
- Open Data (1)
- Open source (1)
- Optical Emission Spectroscopy (1)
- Optical emission spectroscopy (1)
- Optical flow (1)
- Optische Emissionsspektroskopie (OES) (1)
- Parabolic flight (1)
- Pearlitic microstructure (1)
- Pipe Welding (1)
- Pipe weld preparation (1)
- Plasma cutting (1)
- Plastic deformation (1)
- Porosität (1)
- Powder Analysis (1)
- Ppreheating temperature (1)
- Precipitation hardening aluminum alloys (1)
- Preheatin (1)
- Process development (1)
- Prüfverfahren (1)
- Quality monitoring (1)
- Qualität (1)
- Radiological inspections (1)
- Rail tracks (1)
- Recycling (1)
- Reduced order modelling (1)
- Reference data (1)
- Research data (1)
- Resistance Spot Welding (RSW) (1)
- Ringversuch (1)
- SLM (1)
- SWIR (1)
- Safety (1)
- Schallemissionsanalyse (SEA) (1)
- Schutzgas (1)
- Schweißsimulation (1)
- Schweißstruktursimulation (1)
- Selective Laser Melting (1)
- Selective laser beam melting (1)
- Shipbuilding steel (1)
- Solidification behaviour (1)
- Solidification cracking (1)
- Stainless steels (1)
- Standardisation (1)
- Statistische Versuchsplanung (1)
- Strain fields prediction (1)
- Strain measurement (1)
- Superalloy (1)
- TIG welding (1)
- Temperature behavior (1)
- Temperature distribution (1)
- Tensile properties (1)
- Tensile resistance spot welding experiment (1)
- Tensile testing (1)
- Texture (1)
- Thermograhy (1)
- Thermographie (1)
- Thick-Walled Steel (1)
- Thick-walled steel (1)
- Titanium alloy (1)
- Turbine components (1)
- Two-run welding technique (1)
- Unterpulverschweißen (1)
- Verzug (1)
- WEBAM (1)
- Welding Current (1)
- Welding Simulation (1)
- Welding parameter (1)
- Weldx (1)
- Widerstandpunktschweißen (1)
- Wire Electron Beam Additive Manufacturing (1)
- Wire-based additive manufacturing (1)
- Wärmebehandlung (1)
- X-ray Diffraction (1)
- X-ray diffraction (1)
- Zinkbeschichtung (1)
- Zwischenlagenzeit (1)
- µ-gravity (1)
Organisationseinheit der BAM
- 9.3 Schweißtechnische Fertigungsverfahren (145) (entfernen)
Eingeladener Vortrag
- nein (48)
As industries move for ever faster development and adoption cycles of emerging new technologies in the field of welding, the meticulous and longer-winded approach of the scientific research process can feel harder to integrate. To help bridge this gap and increase the speed, quality, and adoption rate of publicly funded research, the Bundesanstalt für Materialforschung und -prüfung (BAM) continues to work towards enabling scientists with direct access to necessary software tools and - in the future – highest quality welding research reference data to further foster collaborations.
On the experimental side, the arc welding group at BAM division 9.3 “welding technologies” is continuing to expand and upgrade its capacities of robotic welding systems with integrated state of the art sensor technologies and software solutions. This allows all experiments to be recorded and measured in micro-millimeter accuracy and at sub-millisecond precision, including welding process data, complete spatial geometry and temperature measurements, process video recordings and more. The custom software-based solutions and interfaces allow scaling of the welding systems from large thick plate offshore applications to small additive repair weldments in wind turbine blades to multi-hour continuous weldments in additive manufacturing applications. In addition to the data gathered during the welding process itself, the relevant testing results and materials properties produced at BAM or externally can be integrated seamlessly. This allows detailed traceability of all results back to the actual welding process.
Regardless of the scope and application, complete datasets can be made accessible for research or industry partners in the highest resolution based on the open source WelDX (welding data exchange) file format.
Figure 1. Welding experiment representation including dynamic process data, cross-section imaging and hardness measurements from a single weldx file.
The talk will give an overview of the experimental facilities and workflows as well as current software developments with a focus on research data quality assurance, traceability, and accessibility.
Based on the integration into latest research trends and activities of the “welding technologies” division, the path to publishing reference datasets for arc welding process for various applications and materials is outlined and discussed.
Direct energy deposition additive manufacturing technologies that utilize an electric arc have great potential for generating large volume metal components. However, selecting process parameters that yield the desired near net shape design and requested mechanical component behavior is not a trivial task due to the complex relationship between all process parameters and material characteristics. This presentation exemplifies the application of a newly developed solid welding wire doped with TiB to enhance grain refinement in the deposited metal for additive manufacturing based on DED-Arc of high-strength precipitation hardening AlMgSi-aluminum alloys. It is worth noting that the solid wire is the result of our preliminary metallurgical studies on grain refinement in aluminum weld metal.
Consequently, research focuses on the correlation between process parameters and component quality to understand the underlying mechanisms. This is crucial for evaluating a robust process parameter space that yields component quality in line with corresponding standards which are mainly taken from welding technology.
Specifically, we examine component quality by analyzing pore size and distribution, as well as grain morphology. To enhance the mechanical properties of the deposited metal, a post-weld heat treatment was conducted, comprising of solution treatment, quenching, and artificial aging. The study also evaluates the effects of various heat treatment strategies on the final mechanical properties of the material.
To demonstrate the applicability of 3D metal printing of high-strength aluminium alloys, a more complex demonstrator was created. It has been shown that DED-Arc can produce high-volume aluminium parts with the same quality as the corresponding subtractive processing strategy.
Additionally, the entire additive manufacturing chain has been digitally integrated, enabling traceability of all relevant process steps, which is essential for reliable subsequent quality assessment.
Direct energy deposition additive manufacturing technologies utilizing an electric arc offer a great potential in generating large volume metal components. However, the selection of process parameters that yield the desired near net shape design as well as the requested mechanical component behavior is not a trivial task due to the complex relationship. Exemplarily for additive manufacturing of high-strength precipitation hardening AlMgSi-aluminum alloy this paper shows the application of a newly developed matching solid welding wire doped with TiB as grain refiner. The correlation between process parameters and component quality is examined analyzing the size and distribution of pores as well as the grain morphology. Furthermore, the influences of different post-weld heat treatments are evaluated to meet the reference mechanical properties of the corresponding wrought material. Finally, the digital integration of the entire additive manufacturing chain enables an overall traceability of the relevant process steps which is the basis for a reliable subsequent quality assessment.
In manufacturing, fusion welding processes use a lot of resources, which presents an opportunity to reduce environmental impact. While there is a general understanding of the environmental impact of these processes, it is difficult to quantitatively assess key parameters. This study introduces a welding-specific methodology that uses life cycle assessment (LCA) to evaluate the environmental impact of fusion welding technologies. Our approach analyses the main parameters that affect the environmental performance of different welding techniques, including traditional methods and additive manufacturing through the Direct Energy Deposition-Arc (DED-Arc) process. We integrate real-time resource usage data to offer an innovative framework for directly deriving environmental impacts. This research contributes to optimising welding processes by providing a precise and quantifiable measure of their ecological impact, facilitating the advancement of sustainable manufacturing practices.
Life cycle assessment of fusion welding processes considering upstream and downstream process steps
(2023)
In manufacturing, fusion welding processes consume significant resources, presenting a significant opportunity for reducing environmental impact. Although there is a qualitative understanding of the environmental implications of these processes, a quantitative assessment of key parameters remains complex. This study introduces a welding-specific methodology that employs life cycle assessment (LCA) to quantitatively evaluate the environmental footprint of fusion welding technologies. Our approach identifies and analyses the principal parameters affecting the environmental performance of various welding techniques, including traditional joint welding and additive manufacturing via the Direct Energy Deposition-Arc (DED-Arc) process. Real-time resource usage data is integrated to offer an innovative framework for directly deriving environmental impacts. This research contributes to optimising welding processes by providing a precise and quantifiable measure of their ecological impact. This facilitates the advancement of sustainable manufacturing practices.
Numerical and experimental assessment of liquid metal embrittlement in externally loaded spot welds
(2024)
Zinc-based surface coatings are widely applied with high-strength steels in automotive industry. Some of these base materials show an increased brittle cracking risk during loading. It is necessary to examine electrogalvanized and uncoated samples of a high strength steel susceptible to liquid metal embrittlement during spot welding with applied external load. Therefore, a newly developed tensile test method with a simultaneously applied spot weld is conducted. A fully coupled 3D electrical, thermal, metallurgical and mechanical finite element model depicting the resistant spot welding process combined with the tensile test conducted is mandatory to correct geometric influences of the sample geometry and provides insights into the sample’s time dependent local loading. With increasing external loads, the morphology of the brittle cracks formed is affected more than the crack depth. The validated finite element model applies newly developed damage indicators to predict and explain the liquid metal embrittlement cracking onset and development as well as even ductile failure.
Beim Unterpulverschweißen sind die Prozessgeräusche ein Indikator für eine gute Fügequalität. Diese Beurteilung kann i.d.R. nur von einer erfahrenen Fachkraft durchgeführt werden. Eine kürzlich entwickelte künstliche Intelligenz kann automatisch das akustische Prozesssignal anhand vortrainierter Merkmale klassifizieren und die Fügequalität anhand des Geräuschs beurteilen. Der Algorithmus, einmal richtig trainiert, kann den Prüfaufwand beim Unterpulverschweißen deutlich reduzieren.
Abstract
In the post-processing of large maritime components, a considerable amount of waste in the form of milling and grinding chips is produced. At the same time, additive manufacturing technologies have shown great potential in producing high-volume parts for maritime applications, allowing novel design approaches and short lead times. In this context, this study presents a sustainable approach to recycle and use aluminium bronze waste material, generated during post-processing of large cast ship propellers, as feedstock for laser-powder directed energy deposition. The recycling technology used to produce powder batches is inductive re-melting in combination with ultrasonic atomization. The derived metal powders are characterized using digital image analysis, powder flowability tests, scanning electron microscopy as well as energy dispersive X-ray spectroscopy. Compared to conventional metal powders produced by gas atomization, the recycled material shows excellent sphericity and a powder size distribution with a higher content of finer and coarser particles. Metallographic sections of deposited additively produced specimens show an increased hardness and reduced ductility, but also competitive densities and higher yield and ultimate tensile strength compared to cast material. The process chain shows high potential for the maritime sector to enable circular and sustainable manufacturing.
Die Additive Fertigung gewinnt zunehmend an Bedeutung für die Verarbeitung von Kupferwerkstoffen im industriellen Umfeld. Hierbei wird verstärkt auf drahtförmige Ausgangswerkstoffe gesetzt, da diese Vorteile im Handling bieten, bereits aus der Schweißtechnik bekannt sind und sich zumeist durch geringere Beschaffungskosten auszeichnen. In den letzten Jahren entwickelte sich unter den drahtbasierten Verfahren der Directed-Energy-Deposition (DED) eine Prozessvariante unter Nutzung des Elektronenstrahls zur industriellen Marktreife. Dabei zeigt die Technologie Wire Electron Beam Additive Manufacturing (DED-EB) besondere Vorteile gegenüber anderen DED-Prozessen für die Anwendung an Kupfer. Um das Verfahren einem breiten Anwenderkreis in der Industrie zugänglich zu machen, fehlen jedoch Daten zu Leistungsfähigkeit, Prozessgrenzen und Anwendungsmöglichkeit- en. Die vorliegende Untersuchung beschäftigt sich mit dieser Problemstellung am Beispiel der Legierung CuSn1MnSi. Über mehrstufige Testschweißungen werden die physikalisch möglichen Prozessgrenzen ermittelt und Rückschlüsse über die Eignung der Parameter zum additiven Aufbau gezogen. An verschiedenen additiv gefertigten Probekörpern werden anschließend Kennwerte für Aufbaurate, Härte, Mikrostruktur, Oberflächenqualität sowie mechanische Festigkeitswerte ermittelt. Es zeigt sich, dass das die durch DED-EB hergestellten Proben, trotz des groben Gefüges sowie der thermischen Belastung im Aufbauprozess, in ihren Eigenschaften gut mit den Spezifikationen des Ausgangsmaterials übereinstimmen.
Um Bauteile vor Verschleiß und Korrosion zu schützen werden Beschichtungen aus resistenteren Materialien aufgetragen. Hierzu zählen unter anderen die Legierungen auf Cobalt-Chrom Basis. Der diskrete Materialsprung ist jedoch unter thermischen und mechanischen Belastungen häufig Ursache für das Versagen der Beschichtung. In dieser Arbeit werden daher Materialgradierungen von verschiedenen Stahllegierungen zu einer Cobalt-Chrom Basislegierung untersucht. Die Ergebnissen werden dafür auch mit Resultaten zu vorangegangenen Untersuchungen verglichen. Kern der Arbeit bilden geätzte Schliffbilder der Materialpaarungen und Auswertungen mittels Farbeindringprüfung sowie die metallografische Bestimmung der Porosität. Ziel der Arbeit ist ein defektfreier Aufbau der funktional gradierten Materialpaarungen.