Ingenieurwissenschaften und zugeordnete Tätigkeiten
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Paper des Monats
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Undetected and undesired microstructural variations in components produced by laser powder bed fusion are a major challenge, especially for safety-critical components. In this study, an in-depth analysis of the microstructural features of 316L specimens produced by laser powder bed fusion at different levels of volumetric energy density and different levels of inter layer time is reported. The study has been conducted on specimens with an application relevant build height
(>100 mm). Furthermore, the evolution of the intrinsic preheating temperature during the build-up of specimens was monitored using a thermographic in-situ monitoring set-up. By applying recently determined emissivity values of 316L powder layers, real temperatures could be quantified. Heat accumulation led to preheating temperatures of up to about 600 °C. Significant differences in the preheating temperatures were discussed with respect to the individual process parameter combinations, including the build height. A strong effect of the inter layer time on the heat accumulation was observed. A shorter inter layer time resulted in an increase of the preheating temperature by more than a factor of 2 in the upper part of the specimens compared to longer inter layer times. This, in turn, resulted in heterogeneity of the microstructure and differences in material properties within individual specimens. The resulting differences in the microstructure were analyzed using electron back scatter diffraction and scanning electron microscopy. Results from chemical analysis as well as electron back scatter diffraction measurements indicated stable conditions in terms of chemical alloy composition and austenite phase content for the used set of parameter combinations. However, an increase of the average grain size by more than a factor of 2.5 could be revealed within individual specimens. Additionally, differences in feature size of the solidification cellular substructure were examined and a trend of increasing cell sizes was observed. This trend was attributed to differences in solidification rate and thermal gradients induced by differences in scanning velocity and preheating temperature. A change of the thermal history due to intrinsic preheating could be identified as the main cause of this heterogeneity. It was induced by critical combinations of the energy input and differences in heat transfer conditions by variations of the inter layer time. The microstructural variations were directly correlated to differences in hardness.
Additive manufacturing (AM) of metals and in particular laser powder bed fusion (LPBF) enables a degree of freedom in design unparalleled by conventional subtractive methods. To ensure that the designed precision is matched by the produced LPBF parts, a full understanding of the interaction between the laser and the feedstock powder is needed. It has been shown that the laser also melts subjacent layers of material underneath. This effect plays a key role when designing small cavities or overhanging structures, because, in these cases, the material underneath is feed-stock powder. In this study, we quantify the extension of the melt pool during laser illumination of powder layers and the defect spatial distribution in a cylindrical specimen. During the LPBF process, several layers were intentionally not exposed to the laser beam at various locations, while the build process was monitored by thermography and optical tomography. The cylinder was finally scanned by X-ray computed tomography (XCT). To correlate the positions of the unmolten layers in the part, a staircase was manufactured around the cylinder for easier registration. The results show that healing among layers occurs if a scan strategy is applied, where the orientation of the hatches is changed for each subsequent layer. They also show that small pores and surface roughness of solidified material below a thick layer of unmolten material (>200 µm) serve as seeding points for larger voids. The orientation of the first two layers fully exposed after a thick layer of unmolten powder shapes the orientation of these voids, created by a lack of fusion.
Im Rahmen des Themenfeldprojektes „Process Monitoring of AM“ (ProMoAM) evaluiert die Bundesanstalt für Materialforschung und -Prüfung (BAM) gegenwärtig die Anwendbarkeit verschiedenster ZfP-Verfahren zur in-situ Prozessüberwachung in der additiven Fertigung (AM) von Metallen in Hinblick auf die Qualitätssicherung.
Einige der wichtigsten Messgrößen sind hierbei die Temperatur des Schmelzbades und die Abkühlrate, welche starken Einfluss auf das Gefüge und die Eigenspannung haben. Aufgrund der Zugänglichkeit zum Werkstück während des Bauprozesses bieten sich optische Verfahren zu Temperaturbestimmung an. Hierbei stellen jedoch u. a. die hohe Bandbreite der zu messenden Temperaturen, die Bestimmung der Emissivität und ihre Änderung bei Phasenübergängen der verwendeten Legierung große experimentelle Herausforderungen dar. Eine weitere Herausforderung stellt für die IR-Spektroskopie die Absorption durch das Schutzgas und weitere optische Elemente dar. Um diese auch in einem industriellen Umfeld kompensieren zu können, wurde eine Methode entwickelt, die das gemessene Spektrum bei der Verfestigung des Werkstoffes als Referenz nutzt. In diesem Beitrag wird die Anwendung dieser Methode für die IR-Spektrometrie als auch Thermografische Messungen beim Laser-Pulver-Auftragschweißen von 316L gezeigt, wobei beide Methoden weiterhin in Hinblick auf ihre individuellen Vor- und
Nachteile miteinander verglichen werden.
Long-time behavior of surface properties of microstructures fabricated by multiphoton lithography
(2021)
The multiphoton lithography (MPL) technique represents the future of 3D microprinting, enabling the production of complex microscale objects with high precision. Although the MPL fabrication parameters are widely evaluated and discussed, not much attention has been given to the microscopic properties of 3D objects with respect to their surface properties and time-dependent stability. These properties are of crucial importance when it comes to the safe and durable use of these structures in biomedical applications. In this work, we investigate the surface properties of the MPL-produced SZ2080 polymeric microstructures with regard to the physical aging processes during the post-production stage. The influence of aging on the polymeric microstructures was investigated by means of Atomic Force Microscopy (AFM) and X-ray Photoelectron Spectroscopy (XPS). As a result, a time-dependent change in Young’s Modulus, plastic deformation, and adhesion and their correlation to the development in chemical composition of the surface of MPL-microstructures are evaluated. The results presented here are valuable for the application of MPL-fabricated 3D objects in general, but especially in medical technology as they give detailed information of the physical and chemical time-dependent dynamic behavior of MPL-printed surfaces and thus their suitability and performance in biological systems.
To curtail flammability risks and improve material properties, flame retardants (FRs) and fillers are mixed into rubbers. High loadings of aluminum trihydroxide (ATH) and carbon black (CB) are the most used FRs and reinforcing additive, respectively, in rubbers. To reduce loading without losing mechanical properties, partial substitution of ATH as well as CB by low amounts of multilayer graphene (MLG) nanoparticles is investigated. The high aspect ratio MLG is made of ten graphene sheets. In polybutadiene/chloroprene (BR/CR) nanocomposites 3 phr MLG replaced 15 phr CB and/or 3 phr ATH. Material and mechanical properties as well as fire behavior of the nanocomposites are compared to BR/CR with 20 phr CB both with and without 50 phr ATH. MLG appears as a promising nanofiller to improve the functional properties: replacement of CB improved rheological, curing, and mechanical properties; substitution of ATH improved nanocomposite properties without affecting flame retardancy.
The built environment significantly impacts the health of individuals and populations in various ways. The health and durability of the built environment are intertwined with availability ofnaturally occurring and man-made resources and their supply chains. Therefore, resource con servation is a key to ensure sustainability of built environments. Many industrial wastes can be turned into valuable resources for reuse in construction of the built environment. For instance, biowaste (woody/ leafy biomass and animal waste) have been used to make construction adhesives (Fini et al., 2011), some urban wastes have been used in road construction (Poulikakos et al., 2017; Schmidt et al., 2021), end of life plastics and polymers have made their way to roadway construction, bio-oils and algae harvested from wastewater treatment plants has been used to make antiaging for outdoor building elements to mitigate UV aging (Kabir et al., 2021); sulfur has been used as an extender in asphalt and recycled mineral powders such as silica and alumina have been used to increase strength and durability against acidic compounds (Fini et al., 2019). These are just a few examples of recycling venues with beneficial uses in the built environment.
The construction and operation of the built environment and the traffic that it attracts or facilitates significantly contribute to the emis sion of greenhouse gasses (GHG) and cause air pollution. The direct and indirect impacts of GHG and air pollutants on the environment and so cieties have been weil established. The built environment can be used as a powerful platform not only for recycling and resource conservation but also to remove near-ground gaseous contaminants. This can be done via tailored design and engineering of adsorptive construction materials via recycling of waste materials. For instance, advanced sorbent systems can be made for removing C02, H2S, and formaldehyde from air. This re quires tailored sorbent design, topology optimization, and catalytic conversion of collected gaseous compounds to name a few.
This special issue covers innovative materials, methods, and man agement practices which aim to simultaneously address durability ofthe built environment, air quality, resource conservation, and supply chain resilience. Such innovative materials, methods, and management prac tices will transform the built environment into not only an active contributor to no waste, no pollution for healthy environment, but also a medium that converts the waste and pollution into beneficial products for use in the built environment, thereby promoting resource conser vation. Followings are examples of topics that the special issue is interested in:
• Venuses to advance resource conservation specifically via novel ap proaches in the built environment.
• Innovative construction materials for passive or active adsorption of harmful gaseous emissions to conserve air, energy, and water.
• Advanced materials, methods, and management practices to pro mote well-being of the built environment.
• Smart buildings to promote resource conservation.
• Research convergence in the built environment for zero waste, zero pollution economy.
In this work, engineered recycled mineral admixtures were obtained from four different industrial residues: basic oxygen furnace slag, iron ore tailings, quartz mining tailings and quartzite mining tailings.
The grinding performance was evaluated in two different programs and the characterization included chemical and mineralogical composition, particle morphology, and physical properties. Performance evaluations were carried out in blended pastes and mortars, including flow properties, hydration kinetics, soundness, pozzolanic activity, and compressive strength. Coarser-than-cement admixtures allowed better flow performance, greater dimensional stability and more economical production, while finer-thancementn admixtures improved mechanical performance by both filler effect and cementing activity.
Electrochemical methods offer great promise in meeting the demand for user-friendly on-site devices for Monitoring important parameters. The food industry often runs own lab procedures, for example, for mycotoxin analysis, but it is a major goal to simplify analysis, linking analytical methods with smart technologies. Enzyme-linked immunosorbent assays, with photometric detection of 3,3’,5,5’-tetramethylbenzidine (TMB),form a good basis for sensitive detection. To provide a straightforward approach for the miniaturization of the detectionstep, we have studied the pitfalls of the electrochemical TMB detection. By cyclic voltammetry it was found that the TMB electrochemistry is strongly dependent on the pH and the electrode material. A stable electrode response to TMB could be achieved at pH 1 on gold electrodes. We created a smartphonebased, electrochemical, immunomagnetic assay for the detection of ochratoxin A in real samples, providing a solid basis forsensing of further analytes.
Zeolitic imidazolate framework (ZIF) hybrid fluorescent nanoparticles and ZIF antibody conjugates have been synthesized, characterized, and employed in lateral-flow immunoassay (LFIA). The bright fluorescence of the conjugates and the possibility to tailor their mobility gives a huge potential for diagnostic assays. An enzyme-linked immunosorbent assay (ELISA) with horseradish peroxidase (HRP) as label, proved the integrity, stability, and dispersibility of the antibody conjugates, LC-MS/MS provided evidence that a covalent link was established between these metal-organic frameworks and lysine residues in IgG antibodies.