@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{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{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} }