@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} } @misc{GradHahnNosteretal., author = {Grad, Marius and Hahn, Konstantin and Noster, Ulf and Spieß, Lothar}, title = {Increasing the lifetime of titanium implants through a diffusion-controlled surface treatment}, series = {Th{\"u}ringer Werkstofftag 2023, 14. M{\"a}rz 2023, ILmenau}, journal = {Th{\"u}ringer Werkstofftag 2023, 14. M{\"a}rz 2023, ILmenau}, doi = {10.13140/RG.2.2.35933.59360}, 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} } @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} } @phdthesis{Grad, author = {Grad, Marius}, title = {Oberfl{\"a}chenmodifikation von Titanbasiswerkstoffen durch das Eindiffundieren von Kohlenstoff}, publisher = {Technische Universit{\"a}t Ilmenau}, address = {Ilmenau}, doi = {10.22032/dbt.66089}, abstract = {Titan und seine Legierungen finden aufgrund ihrer geringen Oberfl{\"a}chenh{\"a}rte vorwiegend in wenig verschleißbeanspruchten Bereichen Anwendung. Zur Erh{\"o}hung der H{\"a}rte werden oft Verschleißschutzschichten durch chemische oder physikalische Gasphasenabscheidung eingesetzt. Diese Schichten weisen jedoch mitunter eine schlechte Haftung auf, was zu vorzeitigem Versagen f{\"u}hren kann. Eine Alternative bietet das Diffusionsschweißen, bei dem durch den Konzentrationsgradienten verschiedener Elemente eine Diffusionsschicht zwischen Titan und einem F{\"u}gepartner entsteht. Bei hochkohlenstoffhaltigen St{\"a}hlen bildet sich an der Grenzfl{\"a}che eine TiC-Schicht. Durch chemisches Aufl{\"o}sen des Stahls kann diese Schicht freigelegt und genutzt werden. Jedoch ist dieses Verfahren noch nicht g{\"a}nzlich untersucht. Verschiedene Ver{\"o}ffentlichungen treffen widerspr{\"u}chliche Aussagen, ob neben TiC auch Eisen-Titan-Verbindungen (FeTi oder Fe2Ti) entstehen. Neben der Zusammensetzung ist auch die Mikrostruktur der entstehenden Schicht nicht abschließend untersucht. Ziel dieser Arbeit ist es, das Schichtwachstum anhand thermodynamischer Gesetzm{\"a}ßigkeiten zu untersuchen. Dabei werden der Einfluss von Temperatur, Zeit und Kohlenstoffkonzentration auf das Diffusionsverhalten und die Schichtbildungsgeschwindigkeit analysiert. Besonders relevant ist, dass der Kohlenstoff in interstitieller Form vorliegt. Die Schichtbildungskinetik wird bildgebend untersucht. Die chemische Zusammensetzung wird mittels Glimmentladungsspektroskopie (GDOES) und energiedispersiver R{\"o}ntgenspektroskopie (EDS) bestimmt, w{\"a}hrend die Phasenanalyse durch R{\"o}ntgendiffraktometrie (XRD) erfolgt. Zur Charakterisierung der Mikrostruktur werden EBSD-Messungen herangezogen. Nanoindentation dient der Ermittlung mechanischer Kennwerte wie E-Modul und H{\"a}rte. Die Ergebnisse zeigen, dass der Kohlenstoffgehalt des Stahls die Schichtbildung wesentlich beeinflusst. Ein hoher Kohlenstoffanteil kann die Bildung intermetallischer Fe-Ti-Verbindungen unterdr{\"u}cken. Die mikrostrukturellen Eigenschaften k{\"o}nnen hingegen nur durch die Prozessparameter (Temperatur und Zeit) beeinflusst werden. Die mechanischen Kennwerte sind nur durch die Phasenzusammensetzung der Schicht, welche in großen Teilen konstant ist, bestimmt. Durch das chemische Entfernen des Stahlsubstrats aus dem Verbund und dem damit einhergehenden Freilegen der Schicht, stellt das Verfahren des Diffusionsschweißens eine alternative M{\"o}glichkeit der Beschichtung von Titanbasiswerkstoffen dar. Die vorliegenden Untersuchungen belegen, dass der Prozess bestimmten Grenzen unterliegt, dieser jedoch innerhalb des erarbeiteten Prozessfensters beherrschbar ist. Dies ist der Grund, weshalb dem Diffusionsschweißen großes Potenzial im Bereich der Beschichtungstechnik zuzuordnen ist.}, language = {de} }