Additive Fertigung
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- 8 Zerstörungsfreie Prüfung (44)
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- 5 Werkstofftechnik (15)
- 9.3 Schweißtechnische Fertigungsverfahren (11)
- 9.4 Integrität von Schweißverbindungen (9)
- 8.3 Thermografische Verfahren (7)
- 6 Materialchemie (6)
- 9.6 Additive Fertigung metallischer Komponenten (6)
- 5.4 Multimateriale Fertigungsprozesse (5)
Additive manufacturing (AM) technologies are becoming increasingly important, not only for the manufacture of parts, but also as repair technology that complement existing production technologies. Powder bed fusion of metals by laser beam (PBF-LB/M) combines the freedom in design with high achievable accuracy, making it ideal as a repair approach. However, there are still challenges in adapting process for repair applications. When mounting parts inside PBF-LB/M machines, their real position within the build volume is unknown. One goal of a repair process is to minimize the offset between the base component and the additively manufactured structure to reduce additional rework. For a minimum offset between component and additively manufactured structure, the actual position of the component has to be identified with high precision within the machine coordinate system (MCS). In this work a process setup is presented that allows the actual position of a gas turbine blade to be detected inside a PBF-LB/M machine. A high resolution camera with 65 megapixel is used for this purpose. The presented setup is implemented on a SLM 280 HL PBF-LB/M machine. In addition to the setup, a novel repair workflow using PBF-LB/M is presented. The developed setup and workflow consider inaccuracies in the component and camera mounting, as well as process inaccuracies. This includes keystone distortion correction by homography. The machine setup and workflow are used to repair a real gas turbine blade. Subsequently the offset between the turbine blade and the additivley manufactured structure is validated by 3D scanning the repaired part. The maximum offset is 160 µm. The presented approach can be extended to other geometries and PBF-LB/M machine manufacturers. The high-resolution camera approach is platform independent, which facilates the market penetration of PBF-LB/M repair processes.
Text Multiphoton lithography (MPL) has recently attracted significant research interest as a versatile tool capable of producing 2D and 3D micro- and nanoscopic features with high spatial resolution. The integrity of MPL microstructures, or their ability to respond to external stimuli, is of critical importance. However, achieving the desired properties of fabricated microcomponents for a specific application remains a challenge.
In this work, we present new MPL materials based on epoxy-acrylate interpenetrating networks (IPNs). We aim at 3D microstructures, whose properties can be easily tuned by varying the ratio of the IPN components and fabrication parameters (Figure 1). The resulting library of 3D microstructures was investigated for their thermal and mechanical properties using highly-sensitive space-resolved methods. Flash scanning calorimetry revealed the influence of both, IPN composition and fabrication parameters, on glass transition temperature and material fragility. AFM force-distance curve and intermodulation methods were used to characterize the mechanical properties with a lateral resolution of 1 micron and 4 nm, respectively. The deformation, stiffness and elastic behavior are discussed in detail in relation to the morphology. Moreover, we found that some 3D IPN microstructures exhibit fully elastic behavior. Our funding encourages the further development of IPN systems as versatile and easily tunable MPL materials.
Synchrotron X-ray computed tomography (SXCT) at BAMline has been paired with in-situ tensile loading to monitor damage evolution in LPBF Metal Matrix Composite (MMC) 7017 Aluminium alloy + 3 wt% Zr + 0.5 wt% TiC. The processing of the material leads formation to different categories of Zr-rich inclusions, precipitates and defects. In-situ SXCT test disclosed the critical role of the pre-cracks in the reinforcement phases in the failure mechanisms of LPBF MMC. The damage was initiated from lack-of-fusion defects and cracks propagated through coalescence with other defects.
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.
Additively manufactured (AM) metallic sheet-based Triply Periodic Minimal Surface Structures (TPMSS) meet several requirements in both bio-medical and engineering fields: Tunable mechanical properties, low sensitivity to manufacturing defects, mechanical stability, and high energy absorption. However, they also present some challenges related to quality control. In fact, the optimization of both the AM process and the properties of TPMSS is impossible without considering structural characteristics as manufacturing accuracy, internal defects, and as well as surface topography and roughness. In this study, the quantitative non-destructive analysis of TPMSS manufactured from Ti-6Al-4V alloy by electron beam melting was performed by means of laboratory X-ray computed tomography (XCT).
Most of the Al alloys used in additive manufacturing (AM), in particular Laser Powder Bed Fusion (LPBF), do not exceed a strength of 200 MPa, whereas conventionally high-performance alloys exhibit strengths exceeding 400 MPa. The availability of such Al alloys in AM is limited due to difficulties in printability, requiring synergetic material and AM process development to satisfy harsh processing conditions during LPBF [1]. One approach is the addition of reinforcement to the based powder, allowing tailoring composition and properties of a Metal Matrix Composite (MMC) by AM. Still, the effect of the reinforcement on the resulting mechanical properties must be studied to understand the performance and limits of the newly developed material. The goal of this work was to investigate the failure mechanism of LPBF Al-based MMC material using in-situ Synchrotron X-ray Computed Tomography (SXCT) during mechanical testing.
In this work, we present the recent in-situ imaging developments at the BAMline (of synchrotron BESSY II, HZB), focused on the in-situ characterization and understanding of microstructural evolution of additively manufactured materials subjected to different environments. Two show cases are presented. In the first, X-ray refraction radiography (SXRR) was combined with in-situ heat treatment to monitor the microstructural evolution as a function of temperature in a laser powder bed fusion (LPBF) manufactured AlSi10Mg alloy. We show that SXRR allows detecting the changes in the Si-phase morphology upon heating using statistically relevant volumes. SXRR also allows observing the growth of pores (i.e., thermally induced porosity), usually studied via X-ray computed tomography (XCT), but using much smaller fields-of-view. In the second case study, XCT was combined with in-situ tensile test to investigate the damage mechanism in a LPBF Aluminum Metal Matrix Composite (MMC). In-situ SXCT test disclosed the critical role of the defects in the failure mechanism along with pre-cracks in the reinforcement phase of MMC. We found that cracks were initiated from lack-of-fusion defects and propagated through coalescence with other defects.
Additive manufacturing (AM) processes are opening new design possibilities for large scale electrical devices such as power generators. Conventional manufacturing methods use copper rods which are wrapped, vacuum impregnated, bend and welded. These processes are labor-intensive and time-consuming. The introduction of AM methods for manufacturing the copper conductor and electrical insulation can reduce the size of the generator head, the most complex part of the generator.
In this study, the electrical and dielectrical properties of additively deposited ceramic layers are investigated and compared with the properties of conventionally fabricated bulk ceramics. The ceramic layers are thermally deposited by atmospheric plasma spraying of a commercially available alumina powder. Bulk ceramics are fabricated by dry pressing and sintering of the same powder. Microstructure and porosity were analyzed by scanning electron microscopy (SEM). Electrical and dielectrical properties such as DC resistance, dielectric strength, dielectric loss, and relative permittivity were determined according to the standards.
The microstructures of sprayed and sintered alumina show significant differences with respect to grain form and porosity. The density of the bulk ceramic is lower than the density of the sprayed layer due to the coarse particle size (d50 = 33 μm). Therefore, data from dense samples of the same chemical composition but lower particle size alumina powder were used for comparison.
The insulation system of high voltage electrical devices like generators and electrical motors has to withstand thermal, electrical, ambient and mechanical influences (TEAM) during operation. Especially the dielectric properties have to satisfy the requirements also under elevated temperatures and extreme environments. To provide this high quality, the conventional fabrication process uses partly manually applied insulation tapes combined with a cost-intensive and under safety concerns at least problematic vacuum pressure impregnation step (VPI). In order to reduce process costs by increasing the degree of automation and avoiding the VPI process, additively manufactured (AM) insulations were studied. This study focuses on the fabrication of ceramic/polymer compounds via AM technique. The AM technology used a rotating screw extrusion print head with air pressure to supply the paste. Plate-like samples with dimensions of 55 mm x 55 mm x1mm thickness were produced. This work focuses on the homogeneously high viscous paste with 12.5 to 50 volume % ratio of filler particles. Three types of mica powders as ceramic filler materials with different particle sizes from micro to mm scale were evaluated. The controlled volume % ratio of particles affects the paste viscosity which enables stacking of paste layers with a viscosity close to clay pastes. The mixed pastes were cured by heating and UV light to increase mechanical properties. A TG/DTA was performed, and electrical properties were investigated. First experiments with respect to the dielectric properties such as volume resistance, permittivity and dielectric strength revealed promising results and the possibility to use AM techniques for the fabrication of high voltage insulations for electrical machines.
The manufacturing of metal parts for the use in safety-relevant applications by Laser Powder Bed Fusion (L-PBF) demands a quality assurance of both part and process. Thermography is a nondestructive testing method that allows the in-situ determination of the thermal history of the produced part which is connected to the mechanical properties and the formation of defects [1]. A wide range of commercial thermographic camera systems working in different spectral ranges is available on the market. The understanding of the applicability of these cameras for qualitative and quantitative in-situ measurements in L-PBF is of vital importance [2]. In this study, the building process of a cylindrical specimen (Inconel 718) is monitored by three camera systems simultaniously. These camera systems are sensitive in various spectral bandwidths providing information in different temperature ranges. The performance of each camera system is explored in the context of the extraction of image features for the detection of defects. It is shown that the high temporal and thermal process dynamics are limiting factors on this matter. The combination of different spectral camera systems promises the potential of an improved defect detection by data fusion.