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Additive Manufacturing

SPP 2122 - Materials for Additive Manufacturing

Duration: 2019 until 2024 Consortium: 23 Research Institutes Sponsor: Deutsche Forschungsgesellschaft

Lasers in production processes, including additive manufacturing, are becoming more and more powerful, but the materials powders available are often inadequate for today’s laser processing tasks. Fundamental research focusing on the powder materials synthesis and engineering for laser-based additive manufacturing to shape the process chain right from the start is needed, i.e. powder materials development. This Priority Programme’s main objective is the synthesis of new metal and polymer powders for efficient laser-based 3D additive manufacturing by means of formulations, additivations and (chemical) modifications of both, new and commercial powders. By this, the range of powder materials accessible for laser-based additive manufacturing shall be enhanced significantly.



Qualification of new steel-alloying strategies for LAM powders by combined in-situ additivation, agglomeration and in-/post-process treatments

Duration: 2019 until 2021 Project partners: iwt_lwtLWT1

Main objective of this joint proposal within Priority Programme 2122 is the development of new starting materials and their qualification for processing martensitic-hardenable tool steels or cast irons by Laser Powder Bed Fusion (L-PBF) due to the increasing demand of LAM parts and the fact that most readily processable materials by L-PBF are mainly Al-, Ti- or Ni-based alloys. This project considers strategies on grey cast iron alloy and adjust the alloying concepts to process white cast iron and ledeburitic cold work tool steel. In order to process the complex material-oriented research within this project, all aspects will be addressed in a holistic approach with regard to powder production and powder conditioning, alloy design and SLM-processing of the designed powders as well as microstructural, micro-magnetic and mechanical characterization of the SLM-components.

For further information, please refer to:
M.Sc. Abootorab Baqerzadeh Chehreh



Microstructure and defect controlled additive manufacturing of γ-titanium aluminides for function-based control of local materials properties

Duration: 2019 until 2022 Project partner: Logo_TU_Dresden Sponsor: Deutsche Forschungsgesellschaft
Niederdruckturbine__mtu_bdli.de_mit QuelleMikrostruktur

The superior target is to understand the fundamental relationships between process parameters, solidification and cooling conditions and the microstructure formation and to systematically investigate its impact on the deformation and fracture behavior in additively manufactured γ-titanium aluminides (TiAl). A fundamental analysis of the fatigue deformation and fracture behavior and a correlation of the microstructure characteristics with the fatigue properties will be allowed due to a further development of the mechanism-based testing methodology for a resource-efficient characterization of the fatigue behavior of γ-titanium aluminides at room and high temperatures. Especially, the continuously transfer of the results in correlation matrices in order to realize a model-based description of the fundamental relationships between microstructure and properties will enable a transformation of the research results to additively manufactured γ-titanium aluminides in industry.

For further information, please refer to:
M.Sc. Mirko Teschke



Mechanism-based investigation of additively-manufactured aluminium matrix composites (AMC) for enhanced mechanical strength

Duration: 2019 until 2022 Project partners: MeSH_projektpartner   IAPT-Logo Sponsor: Deutsche Forschungsgesellschaft

The processing of aluminium matrix composite (AMC) powders by means of additive manufacturing will offer the possibility to manufacture tailor-made AMC components. Hereby, the main focus is on SiC particles reinforced AlSi10Mg powder. Fatigue behaviour plays an important role in structural applications. The specific microstructure and remnant porosity induced by the SLM process reflects complicated fatigue damage phenomena. This challenge dictates that understanding of multi-scale strength attributes of macro- and micro-level structures is necessary. The basic understanding of deformation mechanisms in the SLM-AMC process chain will open the door for further effective exploitation in industrial and structural applications and will highlight future fundamental research aspects.

For further information, please refer to:
M.Sc. Jochen Tenkamp



Damage tolerance evaluation of electron beam melted cellular structures by advanced characterization techniques

Duration: 2018 until 2020 Project partner: Universität Kassel Sponsor: Deutsche Forschungssgesellschaft (DFG)

Due to increasing resource scarcity, the efficient use of materials and the reduction of energy input become increasingly important. For the development of new light-weight and resource-efficient components, metallic cellular structures are the essential elements. In the course of this project, cellular structures are investigated regarding their microstructure and defect distribution as well as their quasistatic and cyclic deformation and damage behavior. Concerning the fabrication of cellular structures by additive manufacturing, electron beam melting (EBM) provides more design freedom and opportunities as compared to conventional manufacturing processes.

For further information, please refer to:
M.Sc. Daniel Kotzem



Mechanism-based assessment of the influence of powder production and process parameters on the microstructure and the deformation behavior of SLM-compacted C+N steels in air and in corrosive environments

Duration: 2017 until 2019 Project partner: LWT2LWT1 Sponsor: Deutsche Forschungsgesellschaft (DFG)

Selective laser melting (SLM) combines a rapid production method with a high level of individualization for complex metallic structures. This can be achieved with efficient use of raw material and manufacturing resources. Due to the fact that only a few materials, mainly Al- and Ti-alloys, are readily processable, the proposed research topic is planned to expand the knowledge about SLM processability of stainless martensitic and austenitic C+N steels. The whole process chain from powder production to deposition by means of SLM process is the main subject of investigation during this project. Characterization of the microstructure and defect development as well as its influence on the quasistatic and cyclic damage behavior is applied to understand the process-property relationship.

For further information, please refer to:
M.Sc. Felix Stern



Mechanism-based understanding of functional grading focused on fatigue behaviour of additively processed Ti-6Al-4V and Al-12Si alloys

Duration: 2017 until 2019 Project partner: IAPT Sponsor: Deutsche Forschungsgemeinschaft
FAM-Fatigue1 FAM-Fatigue_2

Major objective of the project is to harness the potential of the SLM process to obtain localised part properties (within a range of few hundred microns) which are favourable for fatigue behaviour of a component. Overcoming the issues causing reduction of fatigue strength can be very expensive if the manufacturing of the whole component is oriented for fatigue performance. The expected success in manufacturing functionally graded structures will be helpful for industry for manufacturing reliable components. An understanding of graded microstructures and the interaction between different microstructural features regarding damage mechanisms will be determined for the first phase of this project.

For further information, please refer to:
M.Sc. Mustafa Mamduh Mustafa Awd