Project A 06
Networking with other projects
Poster
TRR277_A06_Poster_1-DFG-Begutachtung
TRR277_A06_Poster_2-DFG-Begutachtung
Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience.
This project aims to explore and evaluate the factors influencing the manufacturing of safe and durable structural steel elements by Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M). Thereby, the PBF-LB/M process, the post-treatment, and the geometrical aspects in terms of microstructure and mechanical properties will be investigated and correlations determined. In the first funding period, it is focused on analyzing small-scale specimens and complex facade elements with multiaxial stress states. Based on the results, a first methodology for a qualified Additive Manufacturing (AM) design of safe and durable structural steel elements will be derived.
Objective
Until now, a precise prediction of defined mechanical properties of PBF-LB/M-manufactured steel elements is not possible. To establish the application of PBF-LB/M in the construction industry, civil engineering, and architecture, it is necessary to develop a methodology for the reliable production of durable structural steel elements by using PBF-LB/M.
Approach
Initially, the influence of the process parameters on the cooling rates during PBF-LB/M is analyzed using in-process thermography. Besides, the effects of geometric aspects and post-treatments on the mechanical and metallurgical properties of the components will be examined. In the further course of the project, shape-optimized structural steel elements and large-scale components will be designed using the determined interrelations. Subsequently, the elements will be manufactured and tested under real operating conditions. Finally, a methodology for the economic and process-safe use of PBF-LB/M in the construction industry will be derived.
Networking with other projects
- B01: Exchange of experimental data for the validation of a mesoscale process simulation
- A07: Basic investigation of a welded connection of metal parts manufactured with different AM processes
- C01: Exchange of mechanical testing data for a numerical simulation
- C02: Intensive exchange to integrate the design restrictions of PBF-LB/M into the shape optimization process for structural steel elements and their support structure
- C04: Exchange of process characteristics to enhance the building information model
- C07: Intensive exchange about the process chain of PBF-LB/M
Project leaders
Radlbeck, Christina Dr.-Ing.
leads scientific teams for AM, fatigue and fracture and aluminium at MB and is responsible for the MB Laboratory. She supervises experiments and provides assistance in analysis and interpre- tation of results
Project(s)
Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience.
Zäh, Michael F. Prof. Dr.-Ing.
guides the scientific staff in the execution of the LPBF experiments.He provides guidance in methods for analysing the main mechanisms of action and the correlation of the results for the whole process chain. Head of iwb and supports the academic staff regarding additive manufacturing, alignment and execution of numerical heat transport simulations, questions during validation and process development.
Project(s)
Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement
Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience.
Contributors
Bähr, Siegfried M. Sc.
Siegfried Baehr is head of the department Additive Manufacturing at the iwb and assists Prof. Zaeh in leading the projects A02 and A06. He is instructing and supporting the academic staff regarding LPBF and WAAM.
Project(s)
Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement
Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience.
Blankenhagen, Jakob M. Sc.
is a doctoral researcher: Conducts scientific studies for the duration of the research project. Performs mechanical testing, fatigue testing, fracture mechanics testing, metallurgical analysis, and investigates the influence of geometry on structural performance. Analyzes all data and prepares reports, presentations, and publications.
Project(s)
Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience.
Siebert, Dorina M. Sc.
Doctoral researcher: carrying out scientific studies. She will play a decisive role in planning and conducting fatigue and fracture testing. The evaluation and interpretation of test results is also one of her tasks. Finally she undertakes statistical considerations, which are intended to serve as a basis for the development of design guidelines.”
Project(s)
Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience.
Wenzler, David L. M. Sc.
Doctoral researcher: for the duration of the research project carrying out the scientific studies. He will execute the LPBF experiments, the thermographic imaging of the LPBF process, data analysis, methods for correlations and listing of guidelines for AM elements.
Project(s)
Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience.
