Ingenieurwissenschaften und zugeordnete Tätigkeiten
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- Niobium carbide (NbC) (5)
- Tungsten carbide (WC) (4)
- Cutting material (3)
- Tool wear (3)
- Additive Manufacturing (2)
- Laser powder bed fusion (2)
- Turning (2)
- Turning trials (2)
- Wear mechanisms (2)
- Aluminum (1)
Organisationseinheit der BAM
For the wide acceptance of the use of additive manufacturing (AM), it is required to provide reliable testing methods to ensure the safety of the additively manufactured parts. A possible solution could be the deployment of in-situ monitoring during the build process. However, for laser powder bed fusion using metal powders (PBF-LB/M) only a few in-situ monitoring techniques are commercially available (optical tomography, melt pool monitoring), which have not been researched to an extent that allows to guarantee the adherence to strict quality and safety standards.
In this contribution, we present results of a study of PBF-LB/M printed parts made of the nickel-based superalloy Haynes 282. The formation of defects was provoked by local variations of the process parameters and monitored by thermography, optical tomography and melt pool monitoring. Afterwards, the defects were characterized by computed tomography (CT) to identify the detection limits of the used in-situ techniques.
In line with the industrial trend of additive manufacturing, cold spray as a non-laser-based process is becoming increasingly important for many fields of application. For the evaluation of additive manufacturing of winding components made of copper for large electrical high-voltage machines, material and component properties such as electrical conductivity, mechanical load capacity and the component size that can be produced are of particular importance. In this context, the cold spray process offers advantages over laser-based additive manufacturing processes such as laser powder bed fusion (LPBF) or laser cladding by using the kinetic energy of the copper powder particles to generate particle cohesion. To investigate the electrical conductivity as well as the mechanical load capacity of cold spray parts, specimens were machined out of cold sprayed bulk copper deposits. The characteristic values were obtained with regard to the direction of deposition, which is defined by the direction of the robot’s movement. Thus, for the investigation of the component properties, specimens were provided that had been produced both longitudinally and transversely as well as orthogonally to the direction of deposition. The results of the investigations show that both the electrical conductivity and the mechanical load capacity of the specimen have a strong preferential direction of the specimen orientation with respect to the direction of deposition. Furthermore, it could be shown that by increasing the deposition height, there is an increasing oxygen content in the sample material, combined with increasingly significant defect networks. These effects have a negative impact on the electrical conductivity as well as on the mechanical load capacity. As a conclusion, further need for investigation is identified in the optimization of the process parameters as well as in the deposition strategy for the additive manufacturing of large-volume components with cold spray.
The combination of laser powder bed fusion (LPBF), known for its geometrical freedom and accuracy, and the nozzle-based laser metal deposition process (LMD), known for its high build-up rates, has great potential to reduce the additive manufacturing times for large metallic parts. For the industrial application of the LPBF-LMD hybrid process chain, it is necessary to investigate the infuence of the LMD process on the LPBF substrate. In addition, the build plate material also has a signifcant impact on the occurrence of distortion along the additive manufacturing process chain. In the literature, steel build plates are often used in laser-based additive manufacturing processes of Inconel 718, since a good metallurgical Bonding can be assured whilst reducing costs in the production and restoration of the build plates. This paper examines the distortion caused by LMD material deposition and the infuence of the build plate material along the hybrid additive manufacturing process chain. Twin cantilevers are manufactured by LPBF and an additional layer is subsequently deposited with LMD. The distortion is measured in the as-built condition as well as after heat treatment. The efect of diferent LMD hatch strategies on the distortion is determined. The experiments are conducted using the nickel-base alloy Inconel 718. The results show a signifcant infuence of LMD path strategies on distortion, with shorter tool paths leading to less distortion. The remaining distortion after heat treatment is considerably dependent on the material of the build plate.
Additive manufacturing is no longer just used for the production of prototypes but already found its way into the industrial production. However, the fabrication of massive metallic parts with high geometrical complexity is still too time-consuming to be economically viable. The combination of the powder bed-based selective laser melting process (SLM), known for its geometrical freedom and accuracy, and the nozzle-based laser metal deposition process (LMD), known for its high build-up rates, has great potential to reduce the process duration. For the industrial application of the SLM-LMD hybrid process chain it is necessary to investigate the interaction of the processes and its effect on the material properties to guarantee part quality and prevent component failure. Therefore, hybrid components are manufactured and examined before and after the heat treatment regarding the microstructure and the hardness in the SLM-LMD transition zone. The experiments are conducted using the nickel-based alloy Inconel 718.
The Federal Institute for Materials Research and Testing (BAM) and the Institute for Machine Tools and Factory Management (IWF) of the Technical University Berlin analyzed the suitability of various NbC types in comparison to tungsten carbide (WC) for use as a tool in cutting processes. The focus was placed on the optimization of the functional profile of NbC-based cutting materials with reproducible industrial production.
Evaluating innovative process technologies has become highly important within the last decades. As standard tools different Life Cycle Assessment methods have been established, which are continuously improved. While those are designed for evaluating single processes they run into difficulties when it comes to assessing environmental impacts of process innovations at macroeconomic level. In this paper we develop a multi-step evaluation framework building on multi regional inputeoutput data that allows estimating macroeconomic impacts of new process technologies, considering the network characteristics of the global economy.
Our procedure is as follows: i) we measure differences in material usage of process alternatives, ii) we identify where the standard processes are located within economic networks and virtually replace those by innovative process technologies, iii) we account for changes within economic systems and evaluate impacts on emissions.
Within this paper we exemplarily apply the methodology to two recently developed innovative technologies: longitudinal large diameter steel pipe welding and turning of high-temperature resistant materials. While we find the macroeconomic impacts of very specific process innovations to be small, its conclusions can significantly differ from traditional process based approaches. Furthermore, information gained from the methodology provides relevant additional insights for decision makers extending the picture gained from traditional process life cycle assessment.