Achtung:

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Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13. Show image information
Industry partners of the DMRC. Show image information
Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC. Show image information
Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part. Show image information
Additive manufactured reaction wheel bracket for telecomunication satellites. Show image information
Employees of the DMRC working with the "freeformer" from Arburg. Show image information
Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM). Show image information

Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13.

Industry partners of the DMRC.

Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC.

Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part.

Additive manufactured reaction wheel bracket for telecomunication satellites.

Employees of the DMRC working with the "freeformer" from Arburg.

Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM).

Fatigue Behavior of FDM and LS Parts

In practice, the knowledge of the fatigue properties, in addition to the static material properties, is crucial for a reliable component design.  Many components are not only statically loaded, but also dynamically loaded in the area of application, such as a fastener on an airplane. In addition to the actual load carried during turbulence or takeoffs and landings, this component is subjected to a certain oscillation, which leads to peak loads. By determining SN - curves, reliable statements about the relationship between the number of load cycles and the discontinued load can be determined, so that the risk of an unexpected failure of the components is drastically minimized. If plastic components are permanently loaded, e.g., such as it may be in the case of a fastener, a creep of the material also occurs. Creep designates the plastic deformation under a sustained load. This can eventually lead to the failure of the component.

In this project, dynamic strength values in the form of SN - curves are initially determined for Laser Sintering (LS), components made out of the material Polyamid 12 (Type PA 2200), as well as Fused Deposition Modeling (FDM), components made from the materials Ultem 1010 and Ultem 9085. The dynamic testing of plastics is connected to some specific features, due to the plastic-specific material behavior. For metallic materials, higher test speeds of 100 Hz, for example, are used to achieve a high number of load cycles in a short time on the test bench. Due to internal friction of the molecules, plastics have the ability to reach the softening temperature because of the simultaneous poor thermal conduction properties and low temperature resistance at high test at high test frequencies. This leads to an early failure of the test specimens. Thus, dynamic testing of plastic components with significantly reduced testing frequency, in comparison to metallic materials, should be carried out, resulting in a significant increase of the test duration.

In addition to the dynamic characteristics, the FDM materials are also analyzed on the basis of long-term creep tests, in which the failure time is determined for different load levels.

The use of components as the final product generally places a great demand on the appearance. For this purpose, previous projects at the DMRC have analyzed chemical possibilities for surface treatments for the materials listed above. Chemical methods have the advantage of an effective leveling of the most rough and wavy surfaces from additively manufactured products. Another focus of this project is to analyze the influence of the chemicals on the dynamic strength values and creep properties.

Further project information
Project statusIn progress
Project duration21 month
Funding50 % Land of North Rhine-Westphalia
50 % DMRC industry partner
Project managerProf. Dr.-Ing. Volker Schöppner
Project coordinatorTimothy Schniepp (Stratasys Inc.)
Scientific staffMatthias Fischer
Frederick Knoop
Involved chairsKunststofftechnik Paderborn (KTP)
Contact

Prof. Dr.-Ing. Volker Schöppner

Kunststoffverarbeitung

Volker Schöppner
Phone:
+49 5251 60-3057
Fax:
+49 5251 60-3821
Office:
P1.5.11.3
Web:

M.Sc. Matthias Fischer

DMRC

Fused Deposition Modeling

Matthias Fischer
Phone:
+49 5251 60-5542
Fax:
+49 5251 60-5409
Office:
W2.207

M.Sc. Frederick Knoop

DMRC

Fused Deposition Modeling

Frederick Knoop
Phone:
+49 5251 60-5518
Fax:
+49 5251 60-5409
Office:
W2.102

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