@article{GradZentgrafSchultheissetal., author = {Grad, Marius and Zentgraf, Jan and Schultheiss, Ulrich and Esper, Lukas and Diemar, Andreas and Noster, Ulf and Spiess, Lothar}, title = {Effect of Carbon Content on the Phase Composition, Microstructure and Mechanical Properties of the TiC Layer Formed in Hot-Pressed Titanium-Steel Composites}, series = {Metals}, volume = {14}, journal = {Metals}, number = {9}, publisher = {MDPI AG}, issn = {2075-4701}, doi = {10.3390/met14090959}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:898-opus4-74617}, abstract = {During the hot pressing of pure titanium and different carbon steels in a temperature range of ϑ = 950-1050 °C, a compound layer up to dL≈10 μm thick is formed at the titanium-steel interface. With a higher carbon content of the used steel, the layer thickness increases. The carbon concentration within the layer is in the range of stoichiometry for TiC. Apart from TiC, no other phases can be detected by X-ray diffraction (XRD) measurements inside the formed layer. The calculation of the activation energy for the TiC layer formation is Q = 126.5-136.7 kJ mol-1 and is independent of the carbon content of the steel. The resulting microstructure has a grain size gradient, wherein the mechanical properties, such as hardness and Young's modulus, are almost constant. Statistical analysis using Response Surface Methodology (RSM) indicates that the carbon content of the steel has the most significant influence on layer thickness, followed by annealing temperature and annealing time. By selecting the appropriate carbon steel and the subsequent removal of the steel, it is possible to produce targeted TiC layers on titanium substrates, which holds enormous potential for this material in wear-intensive applications.}, language = {en} } @article{BartschBurgerGradetal., author = {Bartsch, Alexander and Burger, Moritz and Grad, Marius and Esper, Lukas and Schultheiß, Ulrich and Noster, Ulf and Schratzenstaller, Thomas}, title = {Enhancement of laser cut edge quality of ultra-thin titanium grade 2 sheets by applying an in-process approach using modulated Yb:YAG continuous wave fiber laser}, series = {Discover Mechanical Engineering}, journal = {Discover Mechanical Engineering}, number = {10}, publisher = {Springer}, doi = {10.1007/s44245-023-00018-3}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:898-opus4-65647}, pages = {9}, abstract = {Titanium is used in many areas due to its excellent mechanical, biological and corrosion-resistant properties. Implants often have thin and filigree structures, providing an ideal application for fine cutting with laser. In the literature, the main focus is primarily on investigating and optimizing the parameters for titanium sheets with thicknesses greater than 1 mm. Hence, in this study, the basic manufacturing parameters of laser power, cutting speed and laser pulse of a 200 W modulated fiber laser are investigated for 0.15 mm thick grade 2 titanium sheets. A reproducible, continuous cut could be achieved using 90 W laser-power and 2 mm/s cutting-speed. Pulse pause variations between 85 and 335 μs in 50 μs steps and a fixed pulse width of 50 μs show that a minimum kerf width of 23.4 μm, as well as a minimum cut edge roughness Rz of 3.59 μm, is achieved at the lowest pulse pause duration. An increase in roughness towards the laser exit side, independent of the laser pulse pause duration, was found and discussed. The results provide initial process parameters for cutting thin titanium sheets and thus provide the basis for further investigations, such as the influence of cutting gas pressure and composition on the cut edge.}, language = {en} } @unpublished{GradHaagHahnetal., author = {Grad, Marius and Haag, Lydia and Hahn, Konstantin and Schultheiß, Ulrich and Esper, Lukas and Noster, Ulf}, title = {Influence of carbon content on the formation of TiC at diffusion bonded titanium-steel interface}, publisher = {Elsevier}, doi = {10.2139/ssrn.4261928}, abstract = {Hot pressing of pure Ti and various carbon steels in a temperature range of 950 - 1050 °C creates an up to 9 μm thick compound layer of TiC at the Ti/ steel interface. The calculation of the activation energy for layer formation is 126.5 - 136.7 kJ/mol, independent of the steels carbon content. As the carbon content of the steel increases, the layer thickness also increases, which provides enormous potential for the surface modification of Ti/ Ti-alloys.}, language = {en} } @unpublished{BurgerBartschGradetal., author = {Burger, Moritz and Bartsch, Alexander and Grad, Marius and Esper, Lukas and Schultheiß, Ulrich and Noster, Ulf and Schratzenstaller, Thomas}, title = {Enhancement of laser cut edge quality of ultra-thin titanium grade 2 sheets by applying in-process approach using modulated Yb:YAG continuous wave fibre laser}, doi = {10.21203/rs.3.rs-2520041/v1}, abstract = {Titanium is used in many areas due to its excellent mechanical, biological and corrosion-resistant properties. Implants often have thin and filigree structures, providing an ideal application for laser fine cutting. In literature, the main focus is primarily on investigating and optimizing the parameters for titanium sheet thicknesses greater than 1 mm. Hence, in this study, the basic manufacturing parameters of laser power, cutting speed and laser pulsing of a 200 W modulated fibre laser are investigated for 0.15 mm thick titanium grade 2 sheets. A reproducible, continuous cut could be achieved using 90 W laserpower and 2 cutting-speed. Pulse pause variations between 85-335 μs in 50 μs steps and fixed pulse duration of 50 μs show that a minimum kerf width of 23.4 μm, as well as a minimum cut edge roughness Rz of 3.59 μm, is achieved at the lowest pulse pause. An increase in roughness towards the laser exit side, independent of the laser pulse pause, was found and discussed. The results provide initial process parameters for cutting thin titanium sheets and thus provide the basis for further investigations, such as the influence of cutting gas pressure and composition on the cut edge.}, language = {en} } @misc{EsperNosterSchultheissetal., author = {Esper, Lukas and Noster, Ulf and Schultheiss, Ulrich and Bund, Andreas}, title = {Quasi-in-Situ Analysis of Electropolished Additively Manufactured Stainless Steel Surfaces}, series = {ECS Meeting Abstracts, F01: Advances in Industrial Electrochemistry and Electrochemical Engineering}, volume = {MA2023-02}, journal = {ECS Meeting Abstracts, F01: Advances in Industrial Electrochemistry and Electrochemical Engineering}, publisher = {The Electrochemical Society}, issn = {2151-2043}, doi = {10.1149/MA2023-02241342mtgabs}, pages = {1342 -- 1342}, abstract = {Progress in additive manufacturing is leading to the emergence of new areas of application. Laser Powder Bed Fusion (L-PBF) is increasingly used for the development of metallic medical implants, but for high-risk implants like vascular support structures (stents), surface quality is critical to ensure successful implantation without harming the surrounding tissue and ensure the patients' health. Therefore, enhancing the surface quality is crucial. Electropolishing is a method for removing surface roughness by smoothing out micro-peaks and valleys. However, L-PBF structures have a high surface roughness due to metal particles adhering on the surface. To achieve a smooth surface for additively manufactured implants like stents using electropolishing, the removal of these particles needs to be studied in more detail. The objective of this study is to examine the electropolishing mechanism of 316L stainless steel samples additively manufactured through Laser Powder Bed Fusion (L-PBF). The main objective is to investigate the removal properties and surface characteristics during electropolishing. To achieve this, various surfaces were characterized for morphology and roughness during Hull cell experiments. Markings are utilized on the Hull cell sample surfaces to identify points of interest during quasi-in-situ measurements. The surfaces are then analyzed after multiple time steps, applying different currents to investigate particle dissolution. The surface characteristics are analyzed through scanning electron microscopy, and surface roughness is analyzed using laser scanning microscopy. The results show that the electropolishing process preferentially removes the adhering particles present on the surface of the samples. Increasing the current density results in faster particle dissolution and a smoother surface (see Figure 1a and b). The mechanism of material removal of various surface features, as shown in Figure 1 (red circle, yellow arrow and red square), was assessed based on the experimental results of the surface structures seen on the SEM images. It was found that different surface features were removed during the experiment at different polishing times and current densities. The amount of charge flowed was found to correlate with surface morphology. Based on the obtained results, various surface features (such as large adherent particles, agglomerates of smaller particles, and valleys) and their changes with increasing test duration and current density were observed by quasi-in situ analyses. A reduction in the diameter of round particles adhering to the surface was observed at both low and higher current densities (see Figure 1a red circle a). Increasing the polishing time resulted in leveling of both large particles and valleys (see Figure 1b red square). Also, dissolution of agglomerates of smaller particles occurred at different polishing times as a function of current density and polishing time (see Figure 1a yellow arrow) are observed. Smoothed surface structures can be observed in regions with equivalent surface charge density (see Figure 2). As a result, comparable surface morphologies may appear at the same area charge density, irrespective of a specific current density. So, it may be adequate to only consider the amount of charge flowed to describe the electropolishing of additive materials. In conclusion, comprehending the dissolution characteristics of particles on L-PBF surfaces is essential for attaining satisfactory surface finish in electropolishing. The results of this study offer valuable perspectives into the electropolishing mechanism of additively manufactured 316L stainless steel and can guide future investigations on surface finishing and polishing of additive manufactured implants like stents. Figure 1}, language = {en} } @article{EsperSchultheissGradetal., author = {Esper, Lukas and Schultheiss, Ulrich and Grad, Marius and Noster, Ulf and Bund, Andreas}, title = {Application of the Hull Cell for Identifying Electropolishing Parameters to Adjust Surface Morphology in Additive Manufacturing}, series = {ECS Advances}, volume = {4}, journal = {ECS Advances}, number = {4}, publisher = {The Electrochemical Society}, issn = {2754-2734}, doi = {10.1149/2754-2734/ae184f}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:898-opus4-86295}, pages = {9}, abstract = {Additively processed materials are increasingly used to manufacture customized parts, e.g. medical implants. Implant surfaces often require a smooth finish, which can be achieved by post-processing and well-defined process parameters. In this study, the effects of electropolishing of metal parts produced by laser powder bed fusion are investigated using Hull cell experiments and a three-electrode setup. Current density voltage curves were measured with the three-electrode setup to identify the regimes for electropolishing. Subsequently different constant-currents were applied and Hull cell experiments were conducted. The surface roughness (Sz, Sa) and the mass removal were analysed. Surface morphologies were assessed using laser scanning and scanning electron microscopy. A reduction of the initial surface roughness of more than 90\% to Sa \< 0.3 μm has been achieved. Considering the passed electrical charge during electropolishing, results from Hull cell experiments are systematically correlated with current-controlled electropolishing. This approach enables the precise tailoring of polishing parameters to achieve surfaces with defined roughness. Furthermore, the study demonstrates the suitability of Hull cells in determining electropolishing parameters for additive materials and highlights their contribution to post-processing in additive manufacturing.}, language = {en} }