TY - GEN A1 - Käsbauer, Johannes A1 - Schmailzl, Anton A1 - Loose, Tobias A1 - Hierl, Stefan T1 - Thermo-Mechanical Modeling of Quasi-Simultaneous Laser Transmission Welding using LS-DYNA with Focus on Accuracy of Heat Input Calculation T2 - Technology Day 2020 - Plastics on the test rig, Traboch, 04.03.2020 Y1 - 2020 ER - TY - GEN A1 - Käsbauer, Johannes A1 - Schmailzl, Anton A1 - Loose, Tobias A1 - Hierl, Stefan T1 - Potentials of the EFG-Method for Modeling Quasi-Simultaneous Laser Transmission Welding Considering the Melt Flow T2 - Simulationsforum 2019 - Schweißen und Wärmebehandlung, Weimar Y1 - 2019 ER - TY - CHAP A1 - Meisner, Dennis A1 - Forstner, Lukas A1 - Kaftiranis, Nikitas A1 - Hierl, Stefan T1 - Investigation of process improvements through laser preheating in extrusion-based additive manufacturing process T2 - Lasers in Manufacturing Conference (LIM 2023), 26. Juni bis 29. Juni 2023, München N2 - Fused layer modeling (FLM) is widely used and is gaining more acceptance in the industry mainly due to its material variety and low costs. However, the usage is limited by a process-related anisotropy of the produced parts. The strength and ductility of the printed parts are significantly lower in the build-up direction than perpendicular to it. This is caused by insufficient interlayer bonding resulting from a reduced surface temperature in the process zone. To overcome this problem, a diode laser is integrated into the conventional FLM process to increase the surface temperature between the already printed surface and the newly applied substrate directly at the deposition zone. The investigations carried out show a significant improvement in the mesostructure, as well as a clear reduction in the anisotropy of the printed test specimens. KW - fused layer modeling KW - laser preheating KW - anisotropy KW - interlayer bonding KW - mesostructure Y1 - 2023 UR - https://www.wlt.de/sites/default/files/2023-09/Contribution_140.pdf PB - Wissenschaftliche Gesellschaft Lasertechnik und Photonik e.V. (WLT) ER - TY - JOUR A1 - Maiwald, Frederik A1 - Roider, Clemens A1 - Schmidt, Michael A1 - Hierl, Stefan T1 - Optical Coherence Tomography for 3D Weld Seam Localization in Absorber-Free Laser Transmission Welding JF - Applied Sciences N2 - Quality and reliability are of the utmost importance for manufacturing in the optical and medical industries. Absorber-free laser transmission welding enables the precise joining of identical polymers without additives or adhesives and is well-suited to meet the demands of the aforementioned industries. To attain sufficient absorption of laser energy without absorbent additives, thulium fiber lasers, which emit in the polymers’ intrinsic absorption spectrum, are used. Focusing the laser beam with a high numerical aperture provides significant intensity gradients inside the workpiece and enables selective fusing of the internal joining zone without affecting the surface of the device. Because seam size and position are crucial, the high-quality requirements demand internal weld seam monitoring. In this work, we propose a novel method to determine weld seam location and size using optical coherence tomography. Changes in optical material properties because of melting and re-solidification during welding allow for weld seam differentiation from the injection-molded base material. Automatic processing of the optical coherence tomography data enables the identification and measurement of the weld seam geometry. The results from our technique are consistent with microscopic images of microtome sections and demonstrate that weld seam localization in polyamide 6 is possible with an accuracy better than a tenth of a millimeter. KW - image processing KW - laser transmission welding KW - optical coherence tomography KW - process monitoring KW - transparent polymers Y1 - 2022 U6 - https://doi.org/10.3390/app12052718 N1 - Corresponding author: Frederik Maiwald VL - 12 IS - 5 SP - 1 EP - 11 PB - MPDI CY - Basel ER - TY - JOUR A1 - Maiwald, Frederik A1 - Kroth, Lea A1 - Geiger, René A1 - Schmitt, Bernhard A1 - Hierl, Stefan A1 - Schmidt, Michael T1 - Laser welding of polymer foils with spatially adapted intensity distributions JF - Joining Plastics N2 - Absorber-free laser transmission welding is characterized by its contactless energy input and geometricflexibility and enables the precise and clean joining of polymer films without absorbing additives or adhesives. It is therefore well suited for applications with high demands regarding process reliability and cleanliness such as packaging, fluid containersor as sealing film in medicaland food industry. A homogeneous weld seam temperature is necessary for a large processwindow. In this work, the naturally Gaussian-shaped intensity distributionof the laser beam is there foreconverted into a donut-shaped and a flat-top-shaped distribution. When using the donut-shape, the processwindow for welding polypropylene or polyethylene films is increased by up to a factor of 3. At the same time, the weld seam strength almost corresponds to the strength of the base material. KW - Laserschweissen KW - Kunststofffolie Y1 - 2025 U6 - https://doi.org/10.53192/JP20250146 SN - 1864-3450 IS - 1 SP - 46 EP - 52 PB - DVS Media CY - Düsseldorf ER - TY - JOUR A1 - Maiwald, Frederik A1 - Hierl, Stefan T1 - Absorber-free laser transmission welding of transparent polymers JF - Laser Systems Europe KW - Medical KW - Fibre lasers KW - Welding KW - Plastics Y1 - 2021 UR - https://www.lasersystemseurope.com/analysis-opinion/absorber-free-laser-transmission-welding-transparent-polymers VL - 50 IS - Spring 2021 PB - Europa Science CY - Cambridge ER - TY - GEN A1 - Maiwald, Frederik A1 - Schulze, Julian A1 - Schmidt, Michael A1 - Hierl, Stefan T1 - In-situ optical coherence tomography for spatio-temporal analysis of melt pool crystallization in absorber-free laser transmission welding of polymers T2 - The 9th International Congress on Laser Advanced Materials Processing (LAMP2025), Ise-city, Mie-prefecture, Japan, June 10 to June 13, 2025 Y1 - 2025 PB - Japan Laser Processing Society ER - TY - JOUR A1 - Reindl, Thomas A1 - Meisner, Dennis A1 - Hierl, Stefan T1 - Benchmarking of plastic-based Additive Manufacturing Processes JF - RTejournal - Forum für Rapid Technologie N2 - Additive Manufacturing (AM) is a future-oriented manufacturing technology that is experiencing an enormous boom in the times of Industry 4.0. As a result, various AM technologies and printer models from different manufacturers are entering the market over a short time span. With the advancing establishment of this manufacturing technology for series applications, the expectations and requirements of the fabricated components are also increasing. However, a major challenge is the application-specific selection of the most suitable AM process due to a lack of comparable data. Furthermore, there needs to be more know-how regarding the geometrical and mechanical characteristics of AM parts. This paper addresses this problem by comparing the three most common plasticbased AM processes in the areas of surface quality, dimensional accuracy, and mechanical properties. Roughness measurements, evaluation of a benchmark artifact, tensile tests, and load increase tests are carried out. Based on the results, the individual possibilities and limitations of the compared AM processes can be detected. KW - Additive Manufacturing KW - benchmark artifact KW - dimensional accuracy KW - Fused Layer Modeling KW - mechanical properties KW - Multi Jet Fusion KW - process benchmark KW - Selective Laser Sintering KW - surface quality Y1 - 2023 U6 - https://doi.org/https://doi.org/10.58134/fh-aachen-rte_2023_002 PB - Fachhochschule Aachen ER - TY - CHAP A1 - Maiwald, Frederik A1 - Kroth, Lea A1 - Laskin, Alexander A1 - Hierl, Stefan A1 - Schmidt, Michael T1 - Enlarging the process window in absorber-free laser transmission welding of polymer foils using tailored laser intensity distribution T2 - Procedia CIRP N2 - Absorber-free laser transmission welding enables precise and clean joining of polymer foils without absorbent additives or adhesives. It is well suited for applications in medical technology and food industry, which impose high demands on process reliability. To achieve a large process window and thus a reliable process, a homogeneous weld seam temperature is desirable. For this purpose, the intensity distribution of the laser beam is adapted locally by refractive beam shaping optics. Using a donut-shaped intensity distribution, the weld seam temperature is homogenized. Thus, the process window for welding polypropylene or polyethylene foils is enlarged up to a factor of 4 compared to a conventional, Gaussian-shaped distribution. This enables the reliable welding of even 85 µm thin foils, which could only be welded to a limited extent with a conventional laser intensity distribution. Y1 - 2024 U6 - https://doi.org/10.1016/j.procir.2024.08.159 N1 - accepted by publisher VL - 124 SP - 489 EP - 493 PB - Elsevier ER - TY - JOUR A1 - Kuettner, Andreas A1 - Raths, Max A1 - Fischer, Samuel A1 - Laumer, Tobias T1 - Heat staking of polymer parts generated by fused layer modeling JF - The International Journal of Advanced Manufacturing Technology N2 - Heat staking is a joining technology by which thermoplastic pins are formed by force and temperature to create a form- and force-fitting connection between components. This paper examines the characteristics of 3D printed pins in comparison to conventionally turned pins for heat staking applications. The 3D printed pins are created using fused layer modeling, with variations in horizontal and vertical building directions, as well as different layer thicknesses. The study investigates the impact of significant factors on the heat staking process, including the forming force and temperature. Tensile tests, micrographs, and micro-CT measurements were conducted to determine the properties of the heat-staked joints. Additionally, a stage plan was developed to enhance the understanding of the forming process of both printed and conventionally turned materials. The findings suggest that, under specific process parameters, 3D printed pins exhibit comparable strength to conventionally manufactured pins. The research also demonstrates that the anisotropy resulting from the layer-by-layer construction of the pins significantly influences the strength of the connection. Furthermore, the study reveals that 3D printed pins exhibit good forming accuracy during the heat staking process, and the cavities formed during printing can be substantially reduced. KW - Heat staking KW - Additive manufacturing KW - 3D printing KW - Material qualification KW - Polycarbonate (PC) KW - Fused layer modeling (FLM) Y1 - 2023 U6 - https://doi.org/10.1007/s00170-023-11850-y VL - 128 SP - 547 EP - 562 PB - Springer Nature ER - TY - PAT A1 - Maiwald, Frederik A1 - Hierl, Stefan T1 - Laser welding device for clamping and welding components and method for clamping and welding components Y1 - 2023 UR - https://data.epo.org/publication-server/rest/v1.0/publication-dates/20230830/patents/EP4234213NWA1/document.pdf ER - TY - JOUR A1 - Raths, Max A1 - Bauer, Lukas A1 - Kuettner, Andreas A1 - Fischer, Samuel A1 - Laumer, Tobias T1 - Gradual error detection technique for non-destructive assessment of density and tensile strength in fused filament fabrication processes JF - The International Journal of Advanced Manufacturing Technology N2 - Fused filament fabrication (FFF) is a widely used additive manufacturing process for producing functional components and prototypes. The FFF process involves depositing melted material layer-by-layer to build up 3D physical parts. The quality of the final product depends on several factors, including the component density and tensile strength, which are typically determined through destructive testing methods. X-ray microtomography (XCT) can be used to investigate the pore sizes and distribution. These approaches are time-consuming, costly, and wasteful, making it unsuitable for high-volume manufacturing. In this paper, a new method for non-destructive determination of component density and estimation of the tensile strength in FFF processes is proposed. This method involves the use of gradual error detection by sensors and convolutional neural networks. To validate this approach, a series of experiments has been conducted. Component density and tensile strength of the printed specimens with varying extrusion factor were measured using traditional destructive testing methods and XCT. The cumulative error detection method was used to predict the same properties without destroying the specimens. The predicted values were then compared with the measured values, and it was observed that the method accurately predicted the component density and tensile strength of the tested parts. This approach has several advantages over traditional destructive testing methods. The method is faster, cheaper, and more environmentally friendly since it does not require the destruction of the product. Moreover, it facilitates the testing of each individual part instead of assuming the same properties for components from one series. Additionally, it can provide real-time feedback on the quality of the product during the manufacturing process, allowing for adjustments to be made as needed. The advancement of this approach points toward a future trend in non-destructive testing methodologies, potentially revolutionizing quality assurance processes not only for consumer goods but various industries such as electronics or automotive industry. Moreover, its broader applications extend beyond FFF to encompass other additive manufacturing techniques such as selective laser sintering (SLS), or electron beam melting (EBM). A comparison between the old destructive testing methods and this innovative non-destructive approach underscores the possible fundamental change toward more efficient and sustainable manufacturing practices. This approach has the potential to significantly reduce the time and cost associated with traditional destructive testing methods while ensuring the quality of FFF-manufactured products. KW - Error detection KW - Additive manufacturing KW - Fused filament fabrication KW - Artificial neural network KW - Image processing KW - Porosity Y1 - 2024 U6 - https://doi.org/10.1007/s00170-024-13280-w SN - 1433-3015 SN - 0268-3768 N1 - Open Access funding enabled and organized by Projekt DEAL. IS - 131 SP - 4149 EP - 4163 PB - Springer CY - London ER - TY - JOUR A1 - Bartsch, Alexander A1 - Burger, Moritz A1 - Grad, Marius A1 - Esper, Lukas A1 - Schultheiß, Ulrich A1 - Noster, Ulf A1 - Schratzenstaller, Thomas T1 - 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 JF - Discover Mechanical Engineering N2 - 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. KW - Laser cutting KW - Titanium sheet KW - Kerf Y1 - 2023 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:898-opus4-65647 N1 - Corresponding author: Alexander Bartsch IS - 10 PB - Springer ER - TY - INPR A1 - Grad, Marius A1 - Haag, Lydia A1 - Hahn, Konstantin A1 - Schultheiß, Ulrich A1 - Esper, Lukas A1 - Noster, Ulf T1 - Influence of carbon content on the formation of TiC at diffusion bonded titanium-steel interface N2 - 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. Y1 - 2023 U6 - https://doi.org/10.2139/ssrn.4261928 PB - Elsevier ER - TY - INPR A1 - Burger, Moritz A1 - Bartsch, Alexander A1 - Grad, Marius A1 - Esper, Lukas A1 - Schultheiß, Ulrich A1 - Noster, Ulf A1 - Schratzenstaller, Thomas T1 - 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 N2 - 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. Y1 - 2023 U6 - https://doi.org/10.21203/rs.3.rs-2520041/v1 N1 - Erschienen in der Zeitschrift: Discover Mechanical Engineering, https://opus4.kobv.de/opus4-oth-regensburg/frontdoor/index/index/docId/6564 ER - TY - GEN A1 - Esper, Lukas A1 - Noster, Ulf A1 - Schultheiss, Ulrich A1 - Bund, Andreas T1 - Quasi-in-Situ Analysis of Electropolished Additively Manufactured Stainless Steel Surfaces T2 - ECS Meeting Abstracts, F01: Advances in Industrial Electrochemistry and Electrochemical Engineering N2 - 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 KW - General Earth and Planetary Sciences KW - General Environmental Science Y1 - 2023 U6 - https://doi.org/10.1149/MA2023-02241342mtgabs SN - 2151-2043 VL - MA2023-02 SP - 1342 EP - 1342 PB - The Electrochemical Society ER - TY - JOUR A1 - Esper, Lukas A1 - Schultheiss, Ulrich A1 - Grad, Marius A1 - Noster, Ulf A1 - Bund, Andreas T1 - Application of the Hull Cell for Identifying Electropolishing Parameters to Adjust Surface Morphology in Additive Manufacturing JF - ECS Advances N2 - 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. Y1 - 2025 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:898-opus4-86295 SN - 2754-2734 N1 - Corresponding author der OTH Regensburg: Lukas Esper VL - 4 IS - 4 PB - The Electrochemical Society ER - TY - JOUR A1 - Gersch, Sebastian A1 - Noster, Ulf A1 - Schulz, Carsten A1 - Bagdahn, Jörg T1 - Influence of the Process-Related Surface Structure of L-PBF Manufactured Components on Residual Stress Measurement Using the Incremental Hole Drilling Method JF - Applied Sciences N2 - 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. KW - L-PBF KW - residual stress KW - hole drilling method KW - surface roughness KW - surface condition KW - AlSi10Mg Y1 - 2025 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:898-opus4-84929 SN - 2076-3417 VL - 15 IS - 18 PB - MDPI ER -