TY - JOUR A1 - Grad, Marius A1 - Nadammal, Naresh A1 - Schultheiss, Ulrich A1 - Lulla, Philipp A1 - Noster, Ulf T1 - An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents JF - Applied Sciences N2 - 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. Y1 - 2021 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:898-opus4-25612 N1 - Corresponding author: Marius Grad VL - 11 IS - 19 SP - 1 EP - 22 PB - MPDL ER - TY - JOUR A1 - Grad, Marius A1 - Nadammal, Naresh A1 - Tytko, Darius A1 - Noster, Ulf T1 - On the nanoindentation behavior of a TiC layer formed through thermo-reactive diffusion during hot pressing of Ti and cast iron JF - Materials Letters: X N2 - 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. KW - Titanium alloys KW - Hard coating KW - Nanoindentation KW - Electron backscatter diffraction Y1 - 2022 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:898-opus4-50066 SN - 2590-1508 N1 - Corresponding author: Marius Grad VL - 15 IS - September SP - 1 EP - 4 PB - Elsevier CY - Amsterdam, Niederlande ER - TY - GEN A1 - Grad, Marius A1 - Hahn, Konstantin A1 - Noster, Ulf A1 - Spieß, Lothar T1 - Increasing the lifetime of titanium implants through a diffusion-controlled surface treatment T2 - Thüringer Werkstofftag 2023, 14. März 2023, ILmenau Y1 - 2023 U6 - https://doi.org/10.13140/RG.2.2.35933.59360 ER - TY - JOUR A1 - Wiesent, Lisa A1 - Schultheiß, Ulrich A1 - Lulla, Philipp A1 - Nonn, Aida A1 - Noster, Ulf T1 - Mechanical properties of small structures built by selective laser melting 316 L stainless steel – a phenomenological approach to improve component design JF - Materials Science & Engineering Technology JF - Materialwissenschaft und Werkstofftechnik N2 - 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. T2 - Mechanische Eigenschaften von kleinen Strukturen aus selektiv lasergeschmolzenem 316 L Edelstahl – ein phänomenologischer Ansatz zur Verbesserung des Bauteildesigns Y1 - 2020 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:898-opus4-14718 N1 - Corresponding author: Lisa Wiesent VL - 51 IS - 12 SP - 1615 EP - 1629 PB - Wiley ER - TY - JOUR A1 - Grad, Marius A1 - Zentgraf, Jan A1 - Schultheiss, Ulrich A1 - Esper, Lukas A1 - Diemar, Andreas A1 - Noster, Ulf A1 - Spiess, Lothar T1 - Effect of Carbon Content on the Phase Composition, Microstructure and Mechanical Properties of the TiC Layer Formed in Hot-Pressed Titanium-Steel Composites JF - Metals N2 - 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. Y1 - 2024 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:898-opus4-74617 SN - 2075-4701 N1 - Cooresponding author der OTH Regensburg: Marius Grad VL - 14 IS - 9 PB - MDPI AG ER - TY - JOUR A1 - Wiesent, Lisa A1 - Schultheiß, Ulrich A1 - Lulla, Philipp A1 - Noster, Ulf A1 - Schratzenstaller, Thomas A1 - Schmid, Christof A1 - Nonn, Aida A1 - Spear, Ashley T1 - Computational analysis of the effects of geometric irregularities and post-processing steps on the mechanical behavior of additively manufactured 316L stainless steel stents JF - PLoS ONE N2 - 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. KW - Heat treatment KW - Lasers KW - Surface treatments KW - Specimen preparation and treatment KW - Material properties KW - Stiffness KW - Deformation KW - Powders KW - Koronarendoprothese KW - Rapid prototyping KW - Numerische Methode Y1 - 2020 U6 - https://doi.org/10.1371/journal.pone.0244463 N1 - Corresponding author: Lisa Wiesent VL - 15 IS - 12 SP - 1 EP - 30 PB - PLOS ER - TY - CHAP A1 - Nobre, J. P. A1 - Noster, Ulf A1 - Gibmeier, J. A1 - Altenberger, Igor A1 - Kornmeier, M. A1 - Dias, A. A1 - Scholtes, Berthold ED - Kainer, Karl U. T1 - Mechanical Behavior and Residual Stresses in AZ31 Wrought Magnesium Alloy Subjected to Four Point Bending T2 - Magnesium Alloys and Their Applications N2 - Several specimens of AZ31 magnesium alloy were taken in different directions from a rolled plate and subjected to tensile, compressive and four-point bending tests. Tensile and compressive tests allowed to characterize the mechanical properties of the material in the rolling and cross rolling directions. The bending tests were carried out in four different specimen types to take the effect of the anisotropy induced by the rolling procedure itself into account. Six strain gages per specimen allowed to observe the evolution of the strain with the bending moment during the tests. All bending specimens were bent until a total compressive deformation of 2.5 %. It was observed that the corresponding tensile strain was significant lower and slightly different for each specimen type. In addition, a characteristic non-uniform distribution of deformation twinning was observed. The induced residual stresses after bending were characterized by X-ray diffraction (XRD) and incremental hole-drilling (IHD). Due to the different mechanical behavior in tension and compression, an asymmetric residual stress distribution after bending could be observed. The neutral axis was, in all cases, shifted towards the tensile side. This observation agrees with the strain measurements during bending tests. Y1 - 2006 SN - 9783527607556 U6 - https://doi.org/10.1002/3527607552.ch53 SP - 336 EP - 341 PB - Wiley CY - Hoboken ER - TY - JOUR A1 - Voyer, Joel A1 - Peterlechner, Christian A1 - Noster, Ulf T1 - Flame sprayed Al-12Si coatings for the improvement of the adhesion of composite casting profiles JF - Journal of Thermal Spray Technology N2 - 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. KW - aluminum composites KW - fatigue and fracture KW - flame spray KW - influence of properties Y1 - 2008 U6 - https://doi.org/https://doi.org/10.1007/s11666-008-9235-8 SN - 1544-1016 SN - 1059-9630 VL - 17 IS - 5-6 SP - 824 EP - 830 PB - Springer CY - Boston, Mass. ER - TY - JOUR A1 - Anten, Kerstin A1 - Lebsanft, Markus A1 - Krauß, M. A1 - Noster, Ulf A1 - Scholtes, Berthold T1 - Einfluss von Randschichtzustand und Haltezeit auf die thermische Ermüdung der Magnesiumbasislegierung AZ31 JF - Materialwissenschaft und Werkstofftechnik N2 - Die vorliegende Arbeit befasst sich mit Untersuchungen zur thermischen Ermüdung 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 über die Zahl der Temperaturzyklen ermittelt. Insbesondere wurde der Einfluss einer mechanischen Oberflächenbehandlung (Festwalzen) sowie von Haltezeiten auf den Verlauf der Schädigung untersucht. In beiden Fällen konnte kein signifikanter Unterschied zu unbehandelten Proben bzw. Beanspruchungen ohne Haltezeit festgestellt werden, welches auf die Wechselwirkungen zwischen Verformungs- und Rekristallisationsprozessen bei der thermischen Ermüdung zurückzuführen ist. T2 - Influence of near surface materials states and of hold-times on thermal fatigue of magnesium base alloy AZ31 Y1 - 2012 VL - 43 IS - 12 SP - 993 EP - 1000 PB - Wiley ER - TY - CHAP A1 - Juijerm, Patiphan A1 - Altenberger, Igor A1 - Noster, Ulf A1 - Scholtes, Berthold T1 - Residual stress relaxation and cyclic deformation behavior of deep rolled AlMg4.5Mn (AA5083) at elevated temperatures T2 - Materials Science Forum N2 - The cyclic deformation behavior of deep rolled and polished aluminium wrought alloy AlMg4,5Mn in the temperature range 20-300°C has been investigated. Results of quasistatic tension and compression tests of untreated specimens in the temperature range 20-300°C are presented. To characterize the fatigue behavior for stress-controlled tests as a function of test temperature, s-n curves, cyclic deformations curves and mean strains as a function of number of cycles are given. The residual stress- and work hardening states near the surface of deep rolled aluminium alloy AlMg4.5Mn before and after fatigue tests were investigated by X-ray diffraction methods. The investigated AlMn4.5Mn aluminium alloy shows cyclic hardening until fracture at all stress amplitudes in stress-controlled fatigue tests at 25-150°C. With increasing temperature the deformation behavior shifts from cyclic hardening to cyclic softening. Below a certain stress amplitude at a given temperature deep rolling led to a reduction of the plastic strain amplitude as compared to the untreated state through cyclically stable near-surface work hardening as indicated by stable FWHM-values. This reduction in plastic strain amplitude is associated with enhanced fatigue lives. The effectiveness of deep rolling is governed by the cyclic and thermal stability of near-surface work hardening rather than macroscopic compressive residual stresses. Since near-surface work hardening is known to retard crack initiation, deep rolling is also effective in temperature- and stress ranges where macroscopic compressive residual stresses have relaxed almost completely, but where near-surface work hardening prevails. Above certain stress amplitudes and temperatures, deep rolling has no beneficial effect on the fatigue behavior of AlMg4.5Mn. This is a consequence of instable near-surface microstructures, especially instable near-surface work hardening. KW - deep rolling KW - residual stress relaxation KW - high temperature fatigue Y1 - 2005 U6 - https://doi.org/10.4028/www.scientific.net/MSF.490-491.436 VL - 490-491 SP - 436 EP - 441 PB - Trans Tech Publications ER - TY - JOUR A1 - Kettner, Michael A1 - Noster, Ulf A1 - Kilian, Helmut A1 - Gradinger, Rudolf A1 - Kuehlein, Wolfgang A1 - Drevenstedt, Armin A1 - Stadler, Franz A1 - Ladstaetter, Elisabeth A1 - Lutz, Andreas T1 - The InnMag project - Processing Mg for civil aircraft application JF - Advanced Engineering Materials N2 - 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. Y1 - 2007 U6 - https://doi.org/10.1002/adem.200700143 VL - 9 IS - 9 SP - 813 EP - 819 PB - Wiley ER - TY - JOUR A1 - Mundl, A. A1 - Noster, Ulf T1 - Topology optimization using a structural component as example JF - Konstruktion T2 - Topologieoptimierung am Beispiel eines Strukturbauteils Y1 - 2006 IS - 1-2 SP - 65 EP - 68 PB - VDI Fachmedien ; Springer CY - Düsseldorf ER - TY - CHAP A1 - Ucsnik, Stephan A. A1 - Gradinger, Rudolf A1 - Noster, Ulf A1 - Pahr, Dieter H. T1 - Finite element based optimization of a novel metal-composite-joint T2 - 1st EUCOMAS, European Conference on Materials and Structures in Aerospace, Conference Berlin, May 26 - 27, 2008  N2 - Aerospace and automotive industries employ three main techniques to set up joints between metal and fibre reinforced plastics parts (FRP); adhesive bonding, mechanical fastening with rives/bolts and a hybrid combination. A new joint technique has been developed to combine the two advantageous mechanisms form-closure and adhesion in a fibre-friendly way. Prior is established through metal structures (pins) which are perpendicularly welded onto metal surfaces with an arc-welding-process. They intrude into the FRP during lay-up and therefore set up a first connection. The composite-matrix is responsible for latter adhesive bonding and final form closure. Finite-element-analyses of cylindrically shaped joints are carried out to get detailed knowledge of the influence of parameters like pin-number, pin-position, pin-height, pin-form sleeve-geometry, and stiffness behaviour. Long calculation times of 3D-models lead to the introduction of a corresponding 2D-axisymmetric-model which is used to run parameter-studies within a reasonable time. For this novel technique the combination of fibre-friendly form closure and adhesive bonding of interface plays a major role. A well selected amount of vertical reinforcements, their placement and geometrical dimensions will lead to a stiffer joint. Goal is to minimize fibre-deletion and overlap length to improve load-transfer and joint-strength, to reduce weight in high-strength-applications as well as the avoidance of safety rivets. Y1 - 2008 SN - 0083-5560 SP - 371 EP - 379 PB - VDI-Verlag CY - Düsseldorf ER -