Additive Fertigung
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This study provides insights into the properties of 316L stainless steel produced by additive manufacturing using fused filament fabrication (FFF). One key finding is particularly noteworthy: in significant contrast to cold-rolled 316L, FFF316L develops a pronounced martensite phase after fabrication. The comprehensive comparative analysis shows that FFF316L not only retains the ferrite volume content, but that this is also significantly influenced by the build-up direction. Despite the sintering process, which typically involves densification of the material, a pore volume fraction of 8.45 % remains, which influences the mechanical properties. Although FFF316L has lower elastic
modulus and tensile strength values compared to cold-rolled 316L, its ductility is still competitive. The study further reveals that deformation-induced martensite forms at the intersections of the deformation twins and ferrite islands form at the grain boundaries during the compression and sintering phases. These findings highlight the challenges associated with FFF316L in specific application fields and signal the need to continue to carefully evaluate and improve the development of manufacturing technologies.
For a deep process understanding of the laser powder bed fusion process (PBF-LB/M), recording of the occurring surface temperatures is of utmost interest and would help to pave the way for reliable process monitoring and quality assurance. A notable number of approaches for in-process monitoring of the PBF-LB/M process focus on the monitoring of thermal process signatures. However, due to the elaborate calibration effort and the lack of knowledge about the occurring spectral directional emissivity, only a few approaches attempt to measure real temperatures. In this study, to gain initial insights into occurring in the PBF-LB/M process, measurements on PBF-LB/M specimens and metal powder specimens were performed for higher temperatures up to T = 1290 °C by means of the emissivity measurement apparatus (EMMA) of the Center for Applied Energy Research (CAE, Wuerzburg, Germany). Also, measurements at ambient temperatures were performed with a suitable measurement setup. Two different materials—stainless steel 316L and aluminum AlSi10Mg—were examined. The investigated wavelength λ ranges from the visible range (λ-VIS = 0.40–0.75 µm) up to the infrared, λ = 20 µm. The influence of the following factors were investigated: azimuth angle φ, specimen temperature TS, surface texture as for PBF-LB/M surfaces with different scan angles α, and powder surfaces with different layer thicknesses t.
Multiphoton lithography (MPL), an emerging microfabrication technique, shows great potential in a variety of applications ranging from tissue engineering to soft micro-robotics. Fabricated micro-objects often are expected to undergo shape morphing or bending. Furthermore, ensuring precise property tuning becomes detrimental for the functionality of MPL microstructures. Herein, we present novel MPL materials based on interpenetrating networks (IPNs), which effectively combine the advantages of acrylate and epoxy thermoset systems. A library of 3D MPL IPN microstructures with high 3D structural stability and tailored thermal and micromechanical properties is achieved. MPL laser velocity and fabrication power can be used to tune the morphology and therefore properties of IPN. New IPN microstructures with materials Young's moduli of 4 to 6 MPa demonstrate susceptibility to deformation with high to fully elastic response. Such soft elastic materials hold immense promise within morphable microsystems, soft micro-robotics and cell engineering applications.
Fully automated and decentralized fused filament fabrication of ceramics for remote applications
(2024)
Manufacturing of ceramic components in remote (i.e., geographically isolated) settings poses significant challenges where access to conventional manufacturing facilities is limited or non-existent. Fused Filament Fabrication (FFF) enables the rapid manufacturing of ceramic components with complex geometries. Parts formed by FFF require subsequent debinding and sintering to reach full density. Debinding and sintering are typically executed in separate steps with different equipment, necessitating extensive human handling which hinders process automation and may be challenging for the operator in isolated environments. This poster presents an innovative approach: the integration of all process steps into a single, fully automated system, streamlining the process and minimizing human involvement. Our system combines a dual extrusion filament printer with a porous and heat-resistant ceramic print bed. The porous print bed enables mechanical interlocking of the first printed layers, ensuring adhesion and structural integrity during FFF. Ceramic parts are printed onto thin sacrificial rafts, which are built using an interface material with the same binder as the ceramic filament. After the print is completed, the heat-resistant print bed with all parts is transferred seamlessly with a carrier system into a high-temperature furnace for debinding and sintering. During sintering the sacrificial raft is disintegrated, allowing for unconstrained sintering of the ceramic parts and easy removal of the finished parts. In conclusion, our integrated approach enables significant advancements in the fabrication of complex ceramic components in remote environments with increased efficiency and minimal human handling.
Zirconium chloro fluoride as catalyst for C-F bond activation and HF transfer of fluoroalkanes
(2024)
In this work1, we have successfully synthesised amorphous zirconium chloro fluoride (ZCF), which exhibits medium lewis acidity. In addition to investigating the local coordination sphere around the Zr atoms and the material properties, we were able to establish a catalytic behavior of ZCF in C-F bond activation reactions. We present the first heterogeneous catalyst that performs dehydrofluorination of a fluoroalkane and consecutive hydrofluorination of an alkyne at room temperature.
Currently, mandatory requirements and recommendations for the detection of irregularities in laser beam welded joints are based on classic micrographs as set out in the standard ISO 13919-1:2019. Compared to classic micrographs, computed tomography enables a non-destructive, three-dimensional and material-independent mode of operation, which delivers much more profound results. Even in building material testing, methods with limited informative value can be checked and supplemented by CT examinations.
The European Commission has identified Advanced Manufacturing and Advanced Materials as two of six Key Enabling Technologies (KETs). By fully utilizing these KETs, advanced and sustainable economies will be created. It is considered that Metrology is a key enabler for the advancement of these KETs. EURAMET, the association of metrology institutes in Europe, has strengthened the role of Metrology for these KETs by enabling the creation of a European Metrology Network for Advanced Manufacturing. The EMN is made up of National Metrology Institutes (NMIs) and Designated Institutes (DIs) from across Europe and was formally established in October 2021. The EMN aims to provide a high-level coordination of European metrology activities for the Advanced Materials and Advanced Manufacturing community.
The EMN itself is organized in three sections representing the major stages of the manufacturing chain: 1) Advanced Materials, 2) Smart Manufacturing Systems, and 3) Manufactured Components & Products. The EMN for Advanced Manufacturing is engaging with stakeholders in the field of Advanced Manufacturing and Advanced Materials (Large companies & SMEs, industry organisations, existing networks, and academia), as well as the wider metrology community (including TCs) to provide input for the preparation of a Strategic Research Agenda (SRA) for Metrology for Advanced Manufacturing.
This presentation will describe the progress in the development of the SRA by the EMN for Advanced Manufacturing. The metrology challenges identified across the various key industrial sectors, which utilise Advanced Materials and Advanced Manufacturing will be presented.
The EMN for Advanced Manufacturing is supported by the project JNP 19NET01 AdvManuNet.
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.
Laser implantation aims at reducing friction and wear on highly stressed surfaces in forming processes. Especially the hot stamping process that is used as a resource efficient process for manufacturing geometrical complex and high-strength structures, exhibits severe wear and high friction during the forming operation. The laser implantation process addresses this problem by combining two different approaches (surface modification and surface structuring) in surface technology by creating elevated, highly wear-resistant micro-features to influence the tribological performance. Pure TiB2 implants have shown to reduce tool-sided wear significally and improve the part formability by reducing local necking in deep drawing tests. Within the scope of this work, TiB2-TiC and TiB2-TaC hard material mixtures are implanted on X38CrMoV5-3 hot work tool steel. The aim is to investigate how the implant material properties can be influenced by the application of different mixing ratios of hard material mixtures under the specific variation of the process parameters. Distinct implant formations are tested on a novel test apparatus to examine the influence on the tribological properties.
From the analyses of the implant properties by hardness measurements, light microscopic images, EDX and XRD analyses process parameter ranges are identified to produce defect-free dome- and ring-shaped implants. The specific process parameters (pulse power, pulse duration, mixing ratio and coating thickness) can be used for the determination of the implant geometry (height, width and depth). The tribological tests exhibit improved friction and wear properties. Based on these results, a tribosystem manufactured by this additive surface treatment technology shows great potential to enhance the effectiveness of the hot stamping process.
Al-Si alloys produced by Laser Powder Bed Fusion (L-PBF) techniques allow the fabrication of lightweight free-shape components. Due to the high cooling rates occurring during the building process, L-PBF AlSi10Mg alloys exhibit an ultra-fine microstructure that leads to superior mechanical properties in the as-built condition compared to conventional cast Al-Si materials. Nevertheless, L-PBF processing induces high thermal gradients, leading to deleterious residual stress. In order to relax detrimental residual stress and to increase the ductility, post-processing stress relief treatments are performed. The objective of the contribution is to investigate, under different heat treatment condition, the evolution of microstructure and residual stresses in view of optimizing the fatigue performance of the alloy. To this purpose various heat treatments in a range of temperatures between 265°C and 300°C for a duration between 15 minutes and 2 hours are performed.
Additively Manufactured (AM) parts are still far from being used in safety-relevant applications, mainly due to a lack of understanding of the feedstock-process-propertiesperformance relationship. This work aims at providing a characterization of the fatigue behavior of the additively manufactured AISI 316L austenitic stainless steel and a direct comparison with the fatigue performance of the wrought steel. A set of specimens has been produced by laser powder bed fusion (L-PBF) and a second set of specimens has been machined out of hot-rolled plates. The L-PBF material shows a higher fatigue limit and better finite life performance compared to the wrought material, accompanied by an extensive amount of cyclic softening.
Influence of the scanning strategy on the residual stress state in IN718 additive manufactured parts
(2020)
Laser Powder Bed Fusion (L-PBF) is an additive manufacturing technique enabling the design of complex geometries that are unrivalled by conventional production technologies. Nevertheless, L-PBF process is known to induce a high amount of residual stresses (RS) due to the high temperature gradients present during powder melting by laser. High tensile residual stresses are to be found the edges whereas the bulk material shows balancing compressive RS. Literature shows that the RS is highly sensitive to the process parameters. In particular, this study presents the characterization of the RS state in two L-PBF parts produced with a rastering scan vector that undergoes 90° or 67° rotation between subsequent layers.
Rapid cooling rates and steep temperature gradients are characteristic of additively manufactured parts and important factors for the residual stress formation. This study examined the influence of heat accumulation on the distribution of residual stress in two prisms produced by Laser Powder Bed Fusion (LPBF) of austenitic stainless steel 316L. The layers of the prisms were exposed using two different border fill scan strategies: one scanned from the centre to the perimeter and the other from the perimeter to the centre. The goal was to reveal the effect of different heat inputs on samples featuring the same solidification shrinkage. Residual stress was characterised in one plane perpendicular to the building direction at the mid height using Neutron and Lab X-ray diffraction. Thermography data obtained during the build process were analysed in order to correlate the cooling rates and apparent surface temperatures with the residual stress results. Optical microscopy and micro computed tomography were used to correlate defect populations with the residual stress distribution. The two scanning strategies led to residual stress distributions that were typical for additively manufactured components: compressive stresses in the bulk and tensile stresses at the surface. However, due to the different heat accumulation, the maximum residual stress levels differed. We concluded that solidification shrinkage plays a major role in determining the shape of the residual stress distribution, while the temperature gradient mechanism appears to determine the magnitude of peak residual stresses.
The understanding of process-microstructure-property-performance (PMPP) relationships in additive manufacturing (AM) of metals is highly necessary to achieve wide-spread industrial application and replace conventionally manufactured parts, especially regarding safety-relevant applications. To achieve this understanding, reliable data and knowledge regarding material’s microstructure-property relationships (e.g. the role of defects) is needed, since it represents the base for future more targeted process optimizations and more reliable calculations of performance. However, producing reliable material data and assessing the AM material behaviour is not an easy task: big challenges are e.g. the actual lack of standard testing methods for AM materials and the occasional difficulties in finding one-to-one comparable material data for the conventional counterpart.
This work aims to contribute to end this lack of reliable material data and knowledge for the low cycle fatigue behaviour of the most used titanium alloy in aerospace applications (Ti-6Al-4V). For this purpose, two sets of test specimens were investigated. The first set was manufactured from cylindrical rods produced by an optimized DED-L process and the second was manufactured from a hot formed round bar. The test specimens were cyclically loaded until failure in the low-cycle-fatigue (LCF) regime. The tests were carried out according to ISO 12106 between 0.3 to 1.0 % axial strain amplitude from room temperature up to 400°C. The LCF behaviour is described and compared between materials and with literature values based on cyclic deformation curves and strain-based fatigue life curves. Besides, the parameters of Manson-Coffin-Basquin relationship were calculated. The microstructures (initial and after failure) and fracture surfaces were comparative characterized. Thereby, the focus lied on understanding the role of grain morphology and defects on the failure mechanisms and fatigue lifetimes. For this latter characterization, optical microscopy (OM), scanning electron microscopy (SEM) and micro computed tomography (µCT) were used.
Synchrotron based absorption edge tomography for the analysis of 3D printed polymer embedded MOF
(2019)
Absorption edge tomography, also known as differential tomography at absorption edges, is a method which exploits the sudden change of the attenuation coefficient, when the photon energy crosses the absorption edge of an element. Synchrotron radiation is the best source for absorption edge tomography, because of its small bandwidth, high intensity and easily adjustable photon energy. The synchrotron beamline BAMline at the synchrotron radiation facility BESSY II in Berlin, which is operated by the Bundesanstalt für Materialforschung und -prüfung (BAM), provides a monochromatized beam in a photon energy range from 5 keV up to 80 keV with a bandwidth of 2%, when the double multilayer monochromator is used. Together with the microtomography setup, this enables differential tomography with submicron resolution at the K edge of the elements from chromium up to the lanthanides, and up to uranium, when the L edges are used as well.
In this work, metal organic frameworks (MOFs) embedded in polymer are characterized using differential tomography. MOFs are microporous structures of metal ions, coordinated by organic linker molecules, that can be used in a broad field of applications, especially in gas storage and catalysis. In this work, polymer embedded MOFs were extruded into filaments, which were subsequently used for 3d-printing to profit from the specific properties of the MOFs in polymeric materials combined with the arbitrary shapes provided by 3d-printing. For the extrusion, different polymer classes like ABS, polyester- and polyetherurethanes, as well as different MOFs (ZIF-8, ZIF-67, HKUST-1) were used to create MOF containing filaments with a nominal diameter of 3.0 mm. Differential tomography at the edges of the Zn, Co, and Cu was then used to find the distribution of the corresponding MOF in the filament and to analyze the shape of the inclusions.
During the last years Additive Manufacturing (AM) became increasingly important. That becomes clear, while looking at the advantages like a high degree of freedom concerning the geometry of the parts, low waste rates and a reduction of postprocessing, to name just three. Laser Metal Deposition (LMD) is one of those AM- methods. It can be used for different kinds of applications, e.g. repair weldings of used parts, coatings to increase the corrosion resistance or to build up new components. But for all applications, the production of defect free parts is crucial. Therefore, different kinds of non-destructive monitoring techniques were tested for the LMD-process to identify their potential to detect imperfections in-situ.
The assessment of high cycle fatigue in additive manufactured (AM) components is a challenge due to complex microstructure, anisotropic material behavior, residual stresses and porosity / lack-of-fusion defects. Due to the statistical distribution of defects, a high scatter band of S-N-curves is expected. The fracture mechanics-based fatigue assessment of additive manufactured components must consider the propagation of short cracks emanating from defects.
In this work, the fatigue crack propagation resistance in the short and large crack regimes of additive and conventionally manufactured AISI 316L stainless steel is examined experimentally based on the cyclic R-curve. However, remaining residual stresses in the AM specimen lead to unexpected and dramatic crack-growth during the pre-cracking procedure.
Using non-optimum combination of manufacturing parameters in selective laser melting (SLM) may lead to reduction of quality of component: defects generation, distortion of geometry and even cracking. Usually, the optimization of parameters is performed by changing volumetric energy density (Ev) and selecting parameters giving low porosity values. However, not only low porosity but also stable microstructure and low residual stresses will help to achieve advanced mechanical behavior of the component.
In present work, we investigated cuboid-shaped Ti-6Al-4V samples produced with different manufacturing parameters. The parameters leading to the same Ev were considered as well as parameters which are not included in Ev. Residual stresses in subsurface region were investigated by synchrotron X-ray diffraction, which allows to penetrate around 100 µm from the surface therefore overcome the problem of high roughness of SLM components without additional sample preparation. Only tensile stresses were found along the building direction, that can play critical role especially during cyclic loading. The pore shape and spatial distribution obtained by computed tomography varied for samples produced with the same Ev. However, by using some process parameters it was possible to decrease residual stresses and obtain uniform α+β Ti microstructure and relatively low porosity. Additionally, it was found that not included in Ev (e.g., base plate position, focus distance) should be considered as additional manufacturing parameters during SLM process.
Quality Aspects of Additively Manufactured Medical Implants - Defect Detection in Lattice Parts
(2019)
Additive Manufacturing technologies are developing fast to enable a rapid and flexible production of parts. Tailoring products to individual needs is a big advantage of this technology, which makes it of special interest for the medical device industry and the direct manufacturing of final products. Due to the fast development, standards to assure reliability of the AM process and quality of the printed products are often lacking. The EU project Metrology for Additively Manufactured Medical Implants (MetAMMI) is aiming to fill this gap by investigating alternative and cost efficient non-destructive measurement methods.
As a part of ProMoAM project, we are optimizing a prototype X-ray backscatter to reach NDT requirements, and thereafter to apply it for process monitoring. Moreover, we studied the capability of a radiography approach to detect artificial defects in AM components made by laser powder bed fusion (L-PBF).
The Influence of the Temperature Gradient on the Distribution of Residual Stresses in AM AISI 316L
(2019)
Steep temperature gradients and solidification shrinkage are the main contributors to the formation of residual stresses in additively manufactured metallic parts produced by laser beam melting. The aim of this work was to determine the influence of the temperature gradient.
Diffraction results show a similar pattern for both specimens, indicating the shrinkage to be more dominant for the distribution of residual stresses than the temperature gradient. Thermography results imply that a higher energy input result in higher compressive residual stresses in the bulk.
µCT is used to validate the capability of online monitoring for in-situ detection of defects during the L-PBF build process, which is a focus of the TF project ProMoAM.
Our first experiments show that online monitoring using thermography and optical tomography cameras are able to detect defects in the built part. But further research is needed to understand root cause of the correlation.
Despite of the significant advances in additive manufacturing (AM) process optimization there is still a lack of experimental results and understanding regarding the mechanical behavior and its relationship with the microstructural features of AM-parts, especially in loading conditions typical for safety-relevant applications. Within the scope of the presented ongoing investigations, a basic microstructural characterization, tensile tests at room and elevated temperature (400°C) as well as a characterization of the fatigue behavior of additively manufactured Ti-6Al-4V in the low cycle fatigue regime are carried out in the as-built state. After failure, different techniques are used to describe the failure mechanisms of the specimens. The AM-Specimens are provided by the Fraunhofer institute for production systems and design technology and investigated at the BAM following the philosophy of the TF-Project AGIL.
Virtual-lab-based determination of a macroscopic yield function for additively manufactured parts
(2019)
This work aims for a yield function description of additively manufactured parts of S316L steel at the continuum-mechanical macro-scale by means of so-called virtual experiments using a crystal plasticity (CP) model at meso-scale. Additively manufactured parts require the consideration of the specific process-related microstructure, which prevents this material to be macroscopically treated as isotropic, because of crystallographic as well as topological textures. From virtual experiments, yield loci under various loading conditions are simulated. The scale bridging from meso- to macro-scale is realised by the identification of the simulated yield loci as a modified anisotropic Barlat-type yield model representation.
Nominal-actual comparisons are routinely performed to compare a manufactured specimen to a reference specimen. X-ray Computed Tomography (CT) has brought a profound change in the way that tolerance verifications are performed in industry, by allowing the inner and outer geometries of an object to be measured, without the need for external access or destructive testing. As a results, CT is increasingly used in additive manufacturing applications, where a nominal-actual comparison performed between the digital model (CAD file), used as an input for the 3D printer, and the CT volume from the printed part, can provide invaluable information as to the accuracy of the printing process. However, the nominal-actual comparison process is somewhat different when applied to additively manufactured specimens by comparison to conventionally manufactured specimens.
In this work, the structural integrity of LBM fabricated IN625 small cylinders (d = 1 mm, h = 6 mm) was investigated regarding the porosity and the surface roughness by means of computed tomography. The measurements were carried out on a GE v|tome|x L 300/180 with a reconstructed voxel size of 2 µm. The pores were analyzed for size, shape and spatial distribution. The correlation between compactness C and spatial distribution showed that elongated pores (C < 0.2) appear exclusively within a distance of 80 µm to the sample surface. The reconstructed surface was digitally meshed and unwrapped to evaluate the mean roughness Ra. Since the gravity correlates linearly with the sine of the build angle, the influence of gravity on porosity and surface roughness was determined.
Using non-optimum combination of manufacturing parameters in selective laser melting (SLM) may lead to reduction of quality of component: defects generation, distortion of geometry and even cracking. Usually, the optimization of parameters is performed by changing volumetric energy density (Ev) and selecting parameters giving low porosity values. However, not only low porosity but also stable microstructure and low residual stresses will help to achieve advanced mechanical behavior of the component.
In present work, we investigated cuboid-shaped Ti-6Al-4V samples produced with different manufacturing parameters. The parameters leading to the same Ev were considered as well as parameters which are not included in Ev. Residual stresses in subsurface region were investigated by synchrotron X-ray diffraction, which allows to penetrate around 100 µm from the surface therefore overcome the problem of high roughness of SLM components without additional sample preparation. Only tensile stresses were found along the building direction, that can play critical role especially during cyclic loading. In parallel, using X-ray computed tomography we also observe that porosity is mainly concentrated in the contour region, except in case where the laser speed is small. However, by using some process parameters it was possible to decrease residual stresses and obtain uniform α+β Ti microstructure and relatively low porosity. Additionally, it was found that not included in Ev (e.g., base plate position, focus distance) should be considered as additional manufacturing parameters during SLM process.