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

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

Industry partners of the DMRC

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)

Powder particles are used as raw material for laser-based additive manufacturing

Additive manufactured lightweight structures for civil aircraft components (KOBFS)

The Selective Laser Melting (SLM) process provides huge advantages for aircraft components like valve blocks and structural parts. In this project funded by the BMWi – “Federal Ministry for Economic Affairs and Energy”, the benefits of substituting conventionally manufactured parts by additively manufactured parts will be examined and quantified. The scopes are reducing costs, weight and time in comparison to the traditional design and the conventional manufacturing method.

Objectives
The aim is to develop a decision support scheme for future applications during the product engineering process and to elaborate the fundamentals for an Additive Manufacturing material database based on lightweight and composite structures, besides solid material properties. Moreover, investigations working on improving the process through topology optimization, which includes increasing the building speed of the SLM process and to develop fast and stable process routes that can be used for serial production, will be acquired. The intention is to reduce the processing time in every stage of the process chain, particularly in the Additive Manufacturing process.

Procedure
The project is divided into two work packages, the first work package works on identifying promising aircraft components and to adapt a trade-off methodology to rank these parts. According to this trade-off methodology, a decision scheme for future decisions will be developed with a complete description of process chain mapping possibilities and influencing factors for the process.

Figure 1: Topology optimized component with finished interface surfaces

The second work package works on the development of lightweight structures and composite structures and their mechanical properties for several target functions. Moreover, the mechanical properties of solid material built with various adjusted parameter sets will be determined. The gained knowledge of the previous working steps will be merged in topology-optimized components to demonstrate the possibilities of Additive Manufacturing as a key technology of the future.

Latest results
Since the project started in January 2016, the fundamentals for the different working steps are finalized. The material database is discussed and the programming of a trade-off methodology tool has started. Furthermore, the initial steps for the determination of mechanical properties of the structures to be examined were done.

A knowledge base of the behavior of lattice, composite, support structures, and the influence of the part position on the building plate has been established. In addition to that, powder ageing effects in different build jobs with the same powder were analyzed. Investigations on adapting the default process route and for increasing the building speed through parameter optimization has been done. The results are shown in figure 2.

Figure 2: Optical density analysis of cross section images (x-z-plane) before and after HIP-process

Outlook
The next working steps are further investigations on the topics mentioned above. The whole project is an iterative process and the gained knowledge during the project will be used for topology optimized parts. Moreover, addi-tional and extensive investigations on increasing the building speed while at least holding the properties and on combining different materials in composite structures will be examined finally.

Further project information
Duration 01/2016 – 03/2019
Partner Liebherr, Boeing
Supported by BMWi – Federal Ministry of Economic Affairs and Energy  
Research leader Prof. Dr.-Ing. Thomas Tröster (LiA)
Research assistants Dominik Ahlers, M.Sc.
Peter Koppa, M.Sc.

Funded by

Federal Ministry of Economic Affairs and Energy

Contact

Dominik Ahlers

DMRC

Metal Laser Melting

Dominik Ahlers
Telefon:
+49 5251 60-5422
Büro:
W 2.101

Die Universität der Informationsgesellschaft