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Session Chair: Dr. Peer Woizeschke, BIAS – Bremer Institut für angewandte Strahltechnik GmbH, Germany
Location:Room 2 ICM
11:15am - 11:45am
Invited Talk: Insight into fatigue behaviour of additively manufactured alloys: results of the DREAM project
Department of Engineering „Enzo Ferrari“, Univ. Modena e Reggio Emilia, Italy
11:45am - 12:00pm
3D printing of Al-Li with increased Li content using laser assisted powder bed fusion
Burak Yürekli1, Dongmei Liu2, Tobias Ullsperger1, Hagen Kohl1, Lisa Schade1, Gabor Matthäus1, Markus Rettenmayr2, Stefan Nolte1,3
1Institute of Applied Physics, Friedrich Schiller University Jena, Germany; 2Otto Schott Institute of Materials Research, Friedrich Schiller University Jena, Germany; 3Fraunhofer Institute for Applied Optics and Precision Engineering, IOF Jena, Germany
Based on the extremely low atomic mass of Li, the binary alloy Al-Li holds high potential for future light-weight alloys. In particular, the elastic modulus significantly increases with rising Li content, offering the potential of extremely high stiffness as compared to conventional Al alloys. However, due to the limited solubility of Li accompanied by the formation of brittle δ-AlLi phase during solidification, the maximum Li content is generally limited to about 2 wt. %. Here we present laser assisted 3D printing using Al-Li with an increased Li content of 4 wt. %. The process is based on custom-made Al-Li powder, which is characterized in terms of powder particle size, density, absorption, and thermal conductivity. In contrast to common approaches, here, ultrashort laser pulses are used for the melting process, delivering 3D printed parts with a drastically reduced fraction δ-AlLi phase due to the increased solidification rates of the melt pool.
12:00pm - 12:15pm
Adjusting the surface roughness of WE43 components manufactured by laser-based powder bed fusion
Tjorben Griemsmann, Niclas Söhnholz, Christian Hoff, Jörg Hermsdorf, Stefan Kaierle
Laser Zentrum Hannover e.V., Germany
The outstanding characteristics of magnesium alloys make them promising materials for biomedical or lightweight construction applications, especially in combination with the advantages of laser-based powder bed fusion. While most research in this field focusses porosity and microstructural properties, the surface quality is left out. Because the surface is an important factor for corrosion and notch effects, this work addresses the adjustment of the surface roughness from parts made out of a WE43 alloy. Using design of experiments contour scan trials are carried out for vertical and down skin surfaces. As a result, the roughness of vertical surfaces is reduced from approximately 27.1 µm (Ra) and 172.2 µm (Rz) without contour scans to 10.9 µm and 87.4 µm with contour scans. The applicability of the contour parameters is approved by cross sections to investigate the porosity of the contour volume interface and a topology optimized gear housing is manufactured for validation.
12:15pm - 12:30pm
Influence of process-relevant parameters and heat treatments on the microstructure and resulting mechanical behavior of additively manufactured AlSi10Mg via laser powder bed fusion
Andreas Kempf1, Leonardo Agudo Jácome2, Kai Hilgenberg3
1Volkswagen AG, Werkstofftechnik, 38436 Wolfsburg, Deutschland; 2Bundesanstalt für Materialforschung und -prüfung (BAM), Division 5.1 – Materialographie, Fraktographie und Alterung technischer Werkstoffe, 12205 Berlin, Deutschland; 3Bundesanstalt für Materialforschung und -prüfung (BAM), Division 9.6 – Additive manufacturing of metallic components, 12205 Berlin, Deutschland
Within the group of additive manufacturing (AM) technologies for metals, laser powder bed fusion (L-PBF) has a leading position. Nevertheless, reproducibility of part properties has not reached sufficient maturity hindering the use for industrial applications especially for safety-relevant components. This article presents the results of various experimental tests performed with the aluminium alloy AlSi10Mg identifying reasons for the high deviations in mechanical properties. Herein, it is discussed how microstructure is influenced by different process parameters (laser power, scanning speed, energy density, building time) and how it can be adjusted by suitable post process heat treatments. The impact of resulting changes in microstructure on the mechanical behavior is shown by quasistatic and cyclic tests considering samples manufactured with different L-PBF machines.