@article{GradNadammalSchultheissetal., author = {Grad, Marius and Nadammal, Naresh and Schultheiss, Ulrich and Lulla, Philipp and Noster, Ulf}, title = {An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents}, series = {Applied Sciences}, volume = {11}, journal = {Applied Sciences}, number = {19}, publisher = {MPDL}, doi = {10.3390/app11199176}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:898-opus4-25612}, pages = {1 -- 22}, abstract = {One of the fundamental challenges in L-PBF of filigree geometries, such as aortic stents used in biomedical applications, is the requirement for a robust yet easily removable support structure that allows each component to be successfully fabricated without distortion. To solve this challenge, an integrative experimental approach was attempted in the present study by identifying an optimal support structure design and an optimized support removal strategy for this design. The specimens were manufactured using four different support structure designs based on the geometry exposed to the laser beam during the L-PBF. Support removal procedures included sand blasting (SB), glass bead blasting (GB), and electrochemical polishing (ECP). The two best-performing designs (line and cross) were chosen due to shorter lead times and lower material consumption. As an additional factor that indicates a stable design, the breaking load requirement to remove the support structures was determined. A modified line support with a 145° included angle was shown to be the best support structure design in terms of breaking load, material consumption, and manufacturing time. All three procedures were used to ensure residue-free support removal for this modified line support design, with ECP proving to be the most effective.}, language = {en} } @article{GradNadammalTytkoetal., author = {Grad, Marius and Nadammal, Naresh and Tytko, Darius and Noster, Ulf}, title = {On the nanoindentation behavior of a TiC layer formed through thermo-reactive diffusion during hot pressing of Ti and cast iron}, series = {Materials Letters: X}, volume = {15}, journal = {Materials Letters: X}, number = {September}, publisher = {Elsevier}, address = {Amsterdam, Niederlande}, issn = {2590-1508}, doi = {10.1016/j.mlblux.2022.100161}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:898-opus4-50066}, pages = {1 -- 4}, abstract = {Hot pressing of pure Ti and cast iron under vacuum formed a ~15 μm wide TiC-layer through the thermoreactive diffusion process. Nanoindentation testing of the TiC-layer revealed average hardness and elastic modulus values of ~35 GPa and ~400 GPa, respectively. High-resolution indentation mapping indicated hardness change across the boundary with peak values observed within the TiC-layer. Solid state high temperature diffusion holds significant potential for developing uniform hard coatings on pure Ti/Ti-alloys.}, language = {en} } @article{WiesentSchultheissLullaetal., author = {Wiesent, Lisa and Schultheiß, Ulrich and Lulla, Philipp and Nonn, Aida and Noster, Ulf}, title = {Mechanical properties of small structures built by selective laser melting 316 L stainless steel - a phenomenological approach to improve component design}, series = {Materials Science \& Engineering Technology}, volume = {51}, journal = {Materials Science \& Engineering Technology}, number = {12}, publisher = {Wiley}, doi = {10.1002/mawe.202000038}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:898-opus4-14718}, pages = {1615 -- 1629}, abstract = {Experimental investigations are conducted to quantify the influence of specimen thickness and orientation on the mechanical properties of selective laser melted stainless steel 316 L. The results indicate that the mechanical strength and ductility increase with increasing specimen thickness until a saturation value is reached from a specimen thickness of about 2 mm. Specimen orientation dependency is pronounced for thin specimens (<1.5 mm), whereas only small deviations in strength are observed for thicker specimens with orientations of 30°, 45° and 90° to build direction. The mechanical properties of the specimen orientation of 0° to build direction shows great deviation to the other orientations and the smallest overall strength. A reliable design of selective laser melted components should account for specimen thickness and orientation, e. g. by a correction factor. Furthermore, it is recommended to avoid loads vertical (90°) and parallel (0°) to build direction to guarantee higher ductility and strength.}, language = {en} } @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{WiesentSchultheissLullaetal., author = {Wiesent, Lisa and Schultheiß, Ulrich and Lulla, Philipp and Noster, Ulf and Schratzenstaller, Thomas and Schmid, Christof and Nonn, Aida and Spear, Ashley}, title = {Computational analysis of the effects of geometric irregularities and post-processing steps on the mechanical behavior of additively manufactured 316L stainless steel stents}, series = {PLoS ONE}, volume = {15}, journal = {PLoS ONE}, number = {12}, publisher = {PLOS}, doi = {10.1371/journal.pone.0244463}, pages = {1 -- 30}, abstract = {Advances in additive manufacturing enable the production of tailored lattice structures and thus, in principle, coronary stents. This study investigates the effects of process-related irregularities, heat and surface treatment on the morphology, mechanical response, and expansion behavior of 316L stainless steel stents produced by laser powder bed fusion and provides a methodological approach for their numerical evaluation. A combined experimental and computational framework is used, based on both actual and computationally reconstructed laser powder bed fused stents. Process-related morphological deviations between the as-designed and actual laser powder bed fused stents were observed, resulting in a diameter increase by a factor of 2-2.6 for the stents without surface treatment and 1.3-2 for the electropolished stent compared to the as-designed stent. Thus, due to the increased geometrically induced stiffness, the laser powder bed fused stents in the as-built (7.11 ± 0.63 N) or the heat treated condition (5.87 ± 0.49 N) showed increased radial forces when compressed between two plates. After electropolishing, the heat treated stents exhibited radial forces (2.38 ± 0.23 N) comparable to conventional metallic stents. The laser powder bed fused stents were further affected by the size effect, resulting in a reduced yield strength by 41\% in the as-built and by 59\% in the heat treated condition compared to the bulk material obtained from tensile tests. The presented numerical approach was successful in predicting the macroscopic mechanical response of the stents under compression. During deformation, increased stiffness and local stress concentration were observed within the laser powder bed fused stents. Subsequent numerical expansion analysis of the derived stent models within a previously verified numerical model of stent expansion showed that electropolished and heat treated laser powder bed fused stents can exhibit comparable expansion behavior to conventional stents. The findings from this work motivate future experimental/numerical studies to quantify threshold values of critical geometric irregularities, which could be used to establish design guidelines for laser powder bed fused stents/lattice structures.}, subject = {Koronarendoprothese}, language = {en} } @article{VoyerPeterlechnerNoster, author = {Voyer, Joel and Peterlechner, Christian and Noster, Ulf}, title = {Flame sprayed Al-12Si coatings for the improvement of the adhesion of composite casting profiles}, series = {Journal of Thermal Spray Technology}, volume = {17}, journal = {Journal of Thermal Spray Technology}, number = {5-6}, publisher = {Springer}, address = {Boston, Mass.}, issn = {1544-1016}, doi = {https://doi.org/10.1007/s11666-008-9235-8}, pages = {824 -- 830}, abstract = {In this study, flame sprayed Al-12Si coatings were produced on the surface of inlays (aluminum profiles) of composite castings parts. The aim was to enhance the strength between the joining partners inlay and cast. Due to the high surface roughness and the presence of pores in the coatings, combined with the formation of an intermetallic phase at the interface, the adhesion of flame sprayed inlays could be enhanced by a factor of 2 compared to blank inlays and by a factor of 1.3 when compared to sand-blasted inlays. However, results also show that gaps are present, mostly at the interface between the inlays and the flame sprayed coatings, and these gaps have a negative effect on the joining strength of the composite casting parts. Therefore, optimizing the adhesion of the coating on the Al profiles via an improvement in both the sand-blasting and the flame spraying parameters would be beneficial for further enhancement of the adhesion of composite casting parts.}, language = {de} } @article{AntenLebsanftKraussetal., author = {Anten, Kerstin and Lebsanft, Markus and Krauß, M. and Noster, Ulf and Scholtes, Berthold}, title = {Einfluss von Randschichtzustand und Haltezeit auf die thermische Erm{\"u}dung der Magnesiumbasislegierung AZ31}, series = {Materialwissenschaft und Werkstofftechnik}, volume = {43}, journal = {Materialwissenschaft und Werkstofftechnik}, number = {12}, publisher = {Wiley}, pages = {993 -- 1000}, abstract = {Die vorliegende Arbeit befasst sich mit Untersuchungen zur thermischen Erm{\"u}dung der Magnesiumbasislegierung AZ31 im Temperaturbereich zwischen +50°C und +290°C. Die Experimente erfolgten unter konstanter Totaldeformation (out-of-phase-Beanspruchung) und es wurde der Verlauf der Spannungsamplitude sowie der plastischen Dehnungsamplitude {\"u}ber die Zahl der Temperaturzyklen ermittelt. Insbesondere wurde der Einfluss einer mechanischen Oberfl{\"a}chenbehandlung (Festwalzen) sowie von Haltezeiten auf den Verlauf der Sch{\"a}digung untersucht. In beiden F{\"a}llen konnte kein signifikanter Unterschied zu unbehandelten Proben bzw. Beanspruchungen ohne Haltezeit festgestellt werden, welches auf die Wechselwirkungen zwischen Verformungs- und Rekristallisationsprozessen bei der thermischen Erm{\"u}dung zur{\"u}ckzuf{\"u}hren ist.}, language = {en} } @article{KettnerNosterKilianetal., author = {Kettner, Michael and Noster, Ulf and Kilian, Helmut and Gradinger, Rudolf and Kuehlein, Wolfgang and Drevenstedt, Armin and Stadler, Franz and Ladstaetter, Elisabeth and Lutz, Andreas}, title = {The InnMag project - Processing Mg for civil aircraft application}, series = {Advanced Engineering Materials}, volume = {9}, journal = {Advanced Engineering Materials}, number = {9}, publisher = {Wiley}, doi = {10.1002/adem.200700143}, pages = {813 -- 819}, abstract = {In the context of the "InnMag" project, partners from industry and science are co-operating to investigate the issues involved in adapting established production processes to the material Mg. The project's aim is to further the deployment of Mg interior parts in civil aircraft. The project covers every production step, from alloy selection, Mg ingot melting, alloying, direct chill casting, extruding, machining, surface treatment and component assembly. This paper discusses the project's targets and the results arrived at so far, particularly in the areas of direct chill casting and extrusion.}, language = {en} } @article{MundlNoster, author = {Mundl, A. and Noster, Ulf}, title = {Topology optimization using a structural component as example}, series = {Konstruktion}, journal = {Konstruktion}, number = {1-2}, publisher = {VDI Fachmedien ; Springer}, address = {D{\"u}sseldorf}, pages = {65 -- 68}, language = {en} } @article{NosterScholtes, author = {Noster, Ulf and Scholtes, Berthold}, title = {Isothermal strain-controlled quasi-static and cyclic deformation behavior of magnesium wrought alloy AZ31}, series = {International Journal of Materials Research / Zeitschrift f{\"u}r Metallkunde}, volume = {94}, journal = {International Journal of Materials Research / Zeitschrift f{\"u}r Metallkunde}, number = {5}, doi = {10.1515/ijmr-2003-0098}, pages = {559 -- 563}, abstract = {The low-cycle and high-cycle fatigue behavior of the Mg-base wrought alloy AZ31 is investigated in the temperature range 20- 300 °C using total-strain-controlled push - pull tests. It is shown that the mechanical properties of the material are substantially influenced by the direction dependent formation of deformation twins and resulting deformation asymmetry. As a consequence tensile mean stresses develop during total-strain-controlled fatigue tests without mean strain.}, language = {en} } @article{BitscheNosterPeterlechner, author = {Bitsche, Robert and Noster, Ulf and Peterlechner, Christian}, title = {F{\"u}gepartner schl{\"u}ssig zu Leichtbaukomponenten verbinden?}, series = {Lightweight Design}, volume = {1}, journal = {Lightweight Design}, number = {2}, publisher = {Springer}, doi = {10.1007/BF03223528}, pages = {30 -- 34}, abstract = {Kombinationen aus kraft- und formschl{\"u}ssigen Verbindungen erh{\"o}hen die Leistung bei im Hybridguss verbundenen Gussteilen mit Anbau- oder Einlegeteilen und machen separate F{\"u}geprozesse {\"u}berfl{\"u}ssig. Simulations-Methoden unterst{\"u}tzen das Design kraft- und formschl{\"u}ssiger Verbindungen. Ergebnisse eines Ausdr{\"u}ckversuchs zeigen eine relativ gute {\"U}bereinstimmung zwischen gemessenen und mittels Simulation ermittelten Kraft-Weg-Kurven.}, language = {de} } @article{NallaAltenbergerNosteretal., author = {Nalla, Ravi K. and Altenberger, Igor and Noster, Ulf and Liu, G.Y. and Scholtes, Berthold and Ritchie, Robert O.}, title = {On the influence of mechanical surface treatments—deep rolling and laser shock peening—on the fatigue behavior of Ti-6Al-4V at ambient and elevated temperatures}, series = {Materials Science and Engineering: A}, volume = {355}, journal = {Materials Science and Engineering: A}, number = {1-2}, publisher = {Elsevier}, issn = {1873-4936}, doi = {10.1016/S0921-5093(03)00069-8}, pages = {216 -- 230}, abstract = {It is well known that mechanical surface treatments, such as deep rolling, shot peening and laser shock peening, can significantly improve the fatigue behavior of highly-stressed metallic components. Deep rolling (DR) is particularly attractive since it is possible to generate, near the surface, deep compressive residual stresses and work hardened layers while retaining a relatively smooth surface finish. In the present investigation, the effect of DR on the low-cycle fatigue (LCF) and high-cycle fatigue (HCF) behavior of a Ti-6Al-4V alloy is examined, with particular emphasis on the thermal and mechanical stability of the residual stress states and the near-surface microstructures. Preliminary results on laser shock peened Ti-6Al-4V are also presented for comparison. Particular emphasis is devoted to the question of whether such surface treatments are effective for improving the fatigue properties at elevated temperatures up to ∼450 °C, i.e. at a homologous temperature of ∼0.4T/Tm (where Tm is the melting temperature). Based on cyclic deformation and stress/life (S/N) fatigue behavior, together with the X-ray diffraction and in situ transmission electron microscopy (TEM) observations of the microstructure, it was found that deep rolling can be quite effective in retarding the initiation and initial propagation of fatigue cracks in Ti-6Al-4V at such higher temperatures, despite the almost complete relaxation of the near-surface residual stresses. In the absence of such stresses, it is shown that the near-surface microstructures, which in Ti-6Al-4V consist of a layer of work hardened nanoscale grains, play a critical role in the enhancement of fatigue life by mechanical surface treatment.}, language = {en} } @article{NosterScholtes, author = {Noster, Ulf and Scholtes, Berthold}, title = {Bauschingerefekt und mechanische Zwillingsbildung der Magnesiumlegierung AZ31}, series = {H{\"a}rterei-technische Mitteilungen : HTM ; Zeitschrift f{\"u}r Werkstoffe, W{\"a}rmebehandlung, Fertigung}, volume = {58}, journal = {H{\"a}rterei-technische Mitteilungen : HTM ; Zeitschrift f{\"u}r Werkstoffe, W{\"a}rmebehandlung, Fertigung}, publisher = {Hanser}, pages = {322 -- 327}, language = {de} } @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} } @article{GradSchultheissDiemaretal., author = {Grad, Marius and Schultheiß, Ulrich and Diemar, Andreas and Spieß, Lothar and Noster, Ulf}, title = {Preparation methodology for the microstructural characterization of diffusion layers in a titanium/steel composite}, series = {Practical Metallography}, volume = {61}, journal = {Practical Metallography}, number = {12}, publisher = {Walter de Gruyter GmbH}, issn = {2195-8599}, doi = {10.1515/pm-2024-0087}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:898-opus4-78346}, pages = {938 -- 946}, abstract = {Hot pressing of titanium and carbon steel leads to the formation of a diffusion layer at the interface. Depending on the carbon content of the steel used, it either exclusively contains TiC or additional other phases. In the case of steel with a medium carbon concentration (0.67 wt.\% C), a pure TiC layer forms. A preparation methodology was developed to make statements about functional and microstructural properties of the respective layers such as layer thickness, porosity, or grain size. However, apart from the diffusion layer's microstructure, it also reveals the microstructure of the two base substrates. A comparison based on electron backscatter diffraction (EBSD) examinations yields similar results in terms of microstructure. A micrograph analysis based on the new preparation methodology also allows confirming the element distribution measurement by glow discharge optical emission spectroscopy (GDOES). The methodology therefore provides a way of quickly and reliably controlling the layer formation during the hot pressing process of titanium and carbon steel.}, 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} } @article{GerschNosterSchulzetal., author = {Gersch, Sebastian and Noster, Ulf and Schulz, Carsten and Bagdahn, J{\"o}rg}, title = {Influence of the Process-Related Surface Structure of L-PBF Manufactured Components on Residual Stress Measurement Using the Incremental Hole Drilling Method}, series = {Applied Sciences}, volume = {15}, journal = {Applied Sciences}, number = {18}, publisher = {MDPI}, issn = {2076-3417}, doi = {10.3390/app15189861}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:898-opus4-84929}, pages = {17}, abstract = {Laser Powder Bed Fusion (L-PBF) parts combine geometric freedom with process-induced rough surfaces that challenge residual-stress metrology. We evaluated the accuracy of the incremental hole-drilling (IHD) method with electronic speckle pattern interferometry (ESPI) by applying defined stresses via four-point bending to stress-relieved AlSi10Mg coupons, rather than measuring unknown process stresses. Flat specimens (2 mm, thin per ASTM E837) were analyzed on up-skin, side-skin, and CNC-milled surfaces; thin-specimen calibration coefficients were used. After a preliminary inter-specimen check (three specimens per surface; spread \< 8 MPa), one representative specimen per surface was tested with three drill sites to assess intra-specimen uniformity. Measured IHD-ESPI stresses agreed best at 70 MPa: deviations were ~4.1\% (up-skin), 6.0\% (side-skin), and 6.24\% (CNC-milled). At 10 MPa the relative errors increased (23.6\%, 18.4\%, and 1.40\%), consistent with reduced ESPI signal-to-noise and fixture compliance in the low-stress regime. At 140 MPa, deviations rose again (21.1\%, 14.3\%, and 13.1\%), reflecting operation near the ~60\% Rp0.2 elastic limit of hole-drilling and potential local plasticity. Surface-dependent artifacts also mattered as follows: the side-skin required no coating and performed comparably to CNC-milled, whereas the up-skin's roughness plus matting spray introduced fringe distortions and chip/coating debris near the hole. This controlled study indicates that IHD-ESPI can provide reliable results on L-PBF AlSi10Mg in the mid-stress range when surface preparation, coating, and rig compliance are carefully managed. Limitations include excluding down-skin surfaces and testing only one specimen per condition; thus, results should be generalized cautiously.}, language = {en} }