Additive Fertigung
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Organisationseinheit der BAM
- 8 Zerstörungsfreie Prüfung (44)
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- 9.3 Schweißtechnische Fertigungsverfahren (11)
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- 9.4 Integrität von Schweißverbindungen (9)
- 6 Materialchemie (6)
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- 9.6 Additive Fertigung metallischer Komponenten (5)
LTCCs (Low-temperature co-fired ceramics) consist of three-dimensionally distributed, hermetically bonded ceramic and metallic components with structure sizes within [10; 100] µm. A non-destructive imaging technique is needed that provides 3D, sharp, high-contrast resolution of these structures, as well as porosity and defect analysis, which is made difficult by the very different X-ray absorption coefficients of the individual components of the microstructure. A HDR method is being developed that allows a combination of different tomograms, each with X-ray energies adapted to individual materials.
Al-Si alloys produced by Laser Powder Bed Fusion (PBFLB) allow the fabrication of lightweight free-shape components. Due to the extremely heterogeneous cooling and heating, PBF-LB induces high magnitude residual stress (RS) and a fine Si microstructure. As the RS can be deleterious to the fatigue resistance of engineering components, great efforts are focused on understanding their evolution in as-built state (AB) and after post-process heat treatments (HT). RS in single edge notch bending (SENB) subjected to different HT are investigated (HT1: 1h at 265°C and HT2: 2h at 300°C).
Inspired by the chemistry of mussel adhesive proteins, polydopamine (PDA) is one of the simplest and most versatile approaches to confer new functionalities to nearly any material surface. Moreover, PDA exhibits high potential for surface modification and diversified secondary reactions that makes it extremely interesting for a wide range of application including biomedical field, e.g., drug delivery, adhesives, cell adhesion, biosensing. PDA has undergone significant expansion in its applications and is one of the most attractive areas within the materials field. Nevertheless, PDA integration in microdevices is still constrained by poor spatial and temporal control of excited deposition methods.
Herein, we demonstrate a novel maskless approach for PDA micropatterning based on Direct Laser Writing (DLW) that overcomes present limitations. The pattern is formed upon exposure of the dopamine solution by light produced by tightly-focused fs NIR laser that scans substrate surface accordingly to the selected pattern design. Neither strong oxidants, metal ions nor adjusting pH to alkaline is required by this technique. Our method achieves the PDA micropatterns with the spatial resolution of 0.8 µm, at least an order of magnitude smaller than what is possible with other PDA microplanning techniques. The here introduced PDA deposition technique will uniquely unravel applications of polydopamine and other catecholamine-based mussel-inspired materials in various multifunctional systems and microdevices (e.g., MEMS elements, microfluidics).
Adjustment of MPL parameters revealed that the morphology and thickness of resulted PDA microstructures can be controlled by altering the laser power and its scanning velocity. As a result, it also enables the production of micropatterns with structural gradient.
Apart from the glass substrate, we achieved PDA patterning at surfaces of different nature such as polychlorotrifluoroethylene, polydimethylsiloxane, polyethylene terephthalate, silicon wafers, and fluorinated glass coverslips.
The chemical nature of PDA was confirmed by locally recorded vibrational and x-ray photoelectron spectra. To ensure post-modification potential of MPL deposited PDA we demonstrated one-step deposition of micropatterns with trypsin. Obtained bio-functionalised surface can be further applied as a protein sensing active microelement.
Presented in this work DLW-based microfabrication technique and the possibilities for further PDA surface post-functionalization empowers advanced applications of this material in single-molecule bioassays, sensors and other complex microdevices.
Polydopamine (PDA) is one of the simplest and most versatile approaches for forming an excellent binding exterior to confer new functionalities to nearly any material surface. Inspired by nature, it mimics the behavior of mussels and can be easily deposited on virtually all types of inorganic and organic substrates, including superhydrophobic surfaces. Moreover, PDA exhibits high potential for surface modification and diversified secondary reactions that makes it extremely interesting for a wide range of application including biomedical field, e.g., drug delivery, adhesives, cell adhesion, biosensing. PDA has undergone significant expansion in its applications and is one of the most attractive areas within the materials field. Nevertheless, PDA integration in microdevices is still constrained by poor spatial and temporal control of excited deposition methods.
Herein, we demonstrate a novel maskless approach for PDA micropatterning based on Direct Laser Writing that overcomes present limitations. The pattern is formed upon exposure of the dopamine solution by light produced by tightly-focused fs NIR laser that scans substrate surface accordingly to the selected pattern design. Neither strong oxidants, metal ions nor adjusting pH to alkaline is required by this technique to perform dopamine polymerization. Our method achieves the PDA micropatterns with the spatial resolution of 0.8 µm, at least an order of magnitude smaller than what is possible with other PDA microplanning techniques. Some examples of PDA patterns are shown in Figure 1. The here introduced PDA deposition technique will uniquely unravel applications of polydopamine and other catecholamine-based mussel-inspired materials in various multifunctional systems and microdevices (e.g., MEMS elements, microfluidics).
The chemical nature of PDA was confirmed by locally recorded vibrational and x-ray photoelectron spectra. Moreover, the morphology and thickness of PDA microstructure can be controlled by the laser power and scanning velocity revealing the possibility of fabricating the structures with gradient. In most of the applied conditions the increase of the laser intensity and decrease of the scanning velocity would lead to the thicker PDA pattern. Different morphologies from smooth and bulky-like to grain like has been obtained.
PDA was produced in the presence of tris buffer, phosphate buffer and DI water only. We also tested the effect of the solution pH applying pH 6.0, 7.0 and 8.5. Furthermore, the effect of antioxidants and purging of the solution with oxygen and nitrogen was investigated. Summarizing, we could see that the structures could be produced in all the given conditions, however their thickness and quality, morphology and roughness would differ. We did not observe negative impact of the antioxidants and nitrogen purging on the performance of PDA build up indicating that the PDA formation mechanism is different to common autooxidation. The current mechanism is based on the interaction of dopamine molecules with the photoinitiator added to solution as active to DLW laser light component.
Apart from the glass substrate, we achieved PDA patterning at surfaces of different nature such as polychlorotrifluoroethylene, polydimethylsiloxane, polyethylene terephthalate, silicon wafers, and fluorinated glass coverslips.
We also performed facile posts-modification of the PDA surface with protein enzymes like trypsin that was confirmed by XPS. Obtained bioactive pattern could be further integrated in the protein sensing devices.
Presented in this work DLW-based microfabrication technique and the possibilities for further PDA surface post-functionalization empowers advanced applications of this material in single-molecule bioassays, sensors and other complex microdevices.
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.
The availability of high-performance Al alloys in AM is limited due to difficulties in printability, requiring both the development of synergetic material and AM process to mitigate problems such as solidification cracking during laser powder bed fusion (LPBF). The goal of this work was to investigate the failure mechanism in a LPBF 7017 Aluminium alloy + 3 wt% Zr + 0.5 wt% TiC. The processing leads to different categories of Zr-rich inclusions, precipitates and defects.
Al-Si alloys produced by Laser Powder Bed Fusion (PBF-LB/M) techniques allow the fabrication of lightweight free-shape components. Due to the extremely heterogeneous cooling and heating, PBF-LB/M induces high magnitude residual stress (RS) and a fine Si microstructure. As the RS can be deleterious to the fatigue resistance of engineering components, great efforts are focused on understanding their evolution before and after post-process heat treatments (HT).
The interest to additively manufacture Nickel-based superalloys has substantially grown within the past decade both academically and industrially. More specifically, additive manufacturing processes such as laser powder bed fusion (LPBF) offer the ability to produce dense parts within a single manufacturing step. In fact, the exceptional freedom in design associated with the layer-based nature of the processes is of particular interest for the complex shapes typically required in turbine applications. In certain cases, the overall part performance can be achieved by tailoring the microstructure and the crystallographic texture to the specific application. However, these advantages must be paid at a price: the large local temperature gradients associated with the rapid melting and solidification produce parts that inherently contain large residual stress in the as-manufactured state. In addition, the presence of pores in the final part may further affect the in-service part failure. As among Nickel-based alloys Inconel 718 exhibits excellent weldability, this alloy has been widely studied in open research in the domain of LPBF. However, significant microsegregation of the heavier alloying elements such as Niobium and Molybdenum accompanied by dislocation entanglements may preclude the application of conventional heat treatment schedules. Therefore, different post processing heat treatments are required for laser powder bed fused Inconel 718 as compared to conventional variants of the same alloy.
In this study, we investigated two different heat treatment routes for LPBF Inconel 718. In a first routine, the samples were stress relieved and subsequently subjected to hot isostatic pressing (HIP) followed by a solution heat treatment and a two-step age (referred to as FHT). In a second routine, the samples were subjected to a single-step direct age post stress relieving heat treatment (referred to DA). We investigated the consequences of such heat treatment schedules on the microstructure, texture, and mechanical behavior. We show that by applying a DA heat treatment the typical columnar microstructure possessing a crystallographic texture is retained, while an equiaxed untextured microstructure prevails in case of an FHT heat treatment. We further evaluate how these heat treatments affect the mechanical behaviour on the macroscopic and microscopic scale.
The European Metrology Network (EMN) for Advanced Manufacturing has been established in June 2021. Currently nine EMNs focussing on different important topics of strategic importance for Europe exist and form an integral part of EURAMET, the European Association of National Metrology Institutes (NMI). EMNs are tasked to ▪ develop a high-level coordination of the metrology community in Europe in a close dialogue with the respective stakeholders (SH)
▪ develop a strategic research agenda (SRA) within their thematic areas
▪ provide contributions to the European Partnership on Metrology research programme Based on the analysis of existing metrology infrastructures and capabilities of NMIs, the metrology research needs for advanced manufacturing are identified in close cooperation with academic, governmental and industrial stakeholders.
Here, we report on the progress of the EMN for Advanced Manufacturing.