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Electrical drives in automotive applications require new brake concepts, e.g. to allow recuperation mode. One approach for these are brake-by-wire systems, which are utilized in electrical motorsports. Based on the design freedom of Additive Manufacturing (AM), in particular laser-based powder bed fusion, a function-integrated hydraulic housing for such brake-by-wire systems is developed. The hydraulic housing is a core component of the brake system, as it holds all electric and hydraulic devices and a complex channel system to link the hydraulic devices. Thus, it must fulfill mechanical and hydraulic requirements, as well as a lightweight design in general. Based on a morphological box, which integrates already existing technical approaches and bionic solution principles, two prototypes were developed: One is derived from a current, conventionally manufactured hydraulic housing, and another one, utilizing the AM-capabilities to full extent. Both designs were developed utilizing three CAD tools, in particular Creo Parametric™ for the design itself, Inspire™ for topology optimisation and FEM calculation, and nTopology to generate ripples and lattices, like Voronoi structures. To develop a complex AM-design utilizing different software tools required several manual process steps. Thereby, insufficient software integration was identified as a hindrance to generate complex designs. Finally, both prototypes were manufactured by laser-based powder bed fusion from the aluminum alloy AlSi10Mg. Further optimisation potential exists, but could not be exploited due to insufficient material models for the mechanical design, e.g. fatigue data. Availability of calculation methods for lifetime prediction was identified as another limitation in the design process.
Modeling framework for planning and operation of multi-modal energy systems in the case of Germany
(2019)
Integrated Planning and Evaluation of Multi-Modal Energy Systems for Decarbonization of Germany
(2019)
For a successful realization of the energy transition and a reduction of greenhouse gas emissions, an integrated view of multiple energy sectors (electricity, heat and mobility) is necessary. The coupling of different energy sectors is seen as an option to achieve the climate goals in a cost-effective way. In this paper, a methodical approach for multi-modal energy system planning and technology impact evaluation is presented. A key feature of the model is a coupled consideration of sectors electricity, heat and mobility. Energy demands, conversion and storage technologies in households, the Commerce, Trade and Services (CTS) area and the industry are modelled employing a bottom-up modelling approach. The model can be used for the calculation of a detailed transition pathway of energy systems taking into account politically defined climate goals. Based on these calculations, in-depth analyses of energy markets as well as transmission and distribution grids can be performed.
Carbon Particle In-Situ Alloying of the Case-Hardening Steel 16MnCr5 in Laser Powder Bed Fusion
(2021)
The carbon content of steel affects many of its essential properties, e.g., hardness and mechanical strength. In the powder bed fusion process of metals using a laser beam (PBF-LB/M), usually, pre-alloyed metal powder is solidified layer-by-layer using a laser beam to create parts. A reduction of the carbon content in steels is observed during this process. This study examines adding carbon particles to the metal powder and in situ alloying in the PBF-LB/M process as a countermeasure. Suitable carbon particles are selected and their effect on the particle size distribution and homogeneity of the mixtures is analysed. The workability in PBF-LB is then shown. This is followed by an evaluation of the resulting mechanical properties (hardness and mechanical strength) and microstructure in the as-built state and the state after heat treatment. Furthermore, potential use cases like multi-material or functionally graded parts are discussed.