Florian Brenne

Microstructural Characterization and Mechanical Performance of Hot Work Tool Steel Processed by Selective Laser Melting

Microstructural characterization of hot work tool steel processed by selective laser melting was carried out. The findings shed light on the interrelationship between processing parameters and the microstructural evolution. It was found that the microstructure after layer-wise processing partially consists of metastable-retained austenite which transforms to martensite in a subsequent tensile test. This improves the mechanical properties of the hot work tool steel enabling direct application.

Fatigue Strength Prediction for Titanium Alloy TiAl6V4 Manufactured by Selective Laser Melting

Selective laser melting (SLM), as a metalworking additive manufacturing technique, received considerable attention from industry and academia due to unprecedented design freedom and overall balanced material properties. However, the fatigue behavior of SLM-processed materials often suffers from local imperfections such as micron-sized pores. In order to enable robust designs of SLM components used in an industrial environment, further research regarding process-induced porosity and its impact on the fatigue behavior is required. Hence, this study aims at a transfer of fatigue prediction models, established for conventional process-routes, to the field of SLM materials. By using high-resolution computed tomography, load increase tests, and electron microscopy, it is shown that pore-based fatigue strength predictions for a titanium alloy TiAl6V4 have become feasible. However, the obtained accuracies are subjected to scatter, which is probably caused by the high defect density even present in SLM materials manufactured following optimized processing routes. Based on thorough examination of crack surfaces and crack initiation sites, respectively, implications for optimization of prediction accuracy of the models in focus are deduced.

Lattice Structures Manufactured by SLM: On the Effect of Geometrical Dimensions on Microstructure Evolution During Processing

Employing selective laser melting direct microstructure manipulation is feasible through adjustment of thermal gradients and solidification velocity. Currently, the exposure strategy and laser energy have to be adapted in order to meet a processing window suited for introducing highly anisotropic microstructures. As selective laser melting allows for production of filigree complex structures, the impact of geometry on the microstructure evolution is investigated in the current study and it is shown that miniaturization of structures as well leads to the evolution of anisotropic microstructure.

Processing of New Materials by Additive Manufacturing: Iron-Based Alloys Containing Silver for Biomedical Applications

In the biomedical sector, production of bioresorbable implants remains challenging due to improper dissolution rates or deficient strength of many candidate alloys. Promising materials for overcoming the prevalent drawbacks are iron-based alloys containing silver. However, due to immiscibility of iron and silver these alloys cannot be manufactured based on conventional processing routes. In this study, iron-manganese-silver alloys were for the first time synthesized by means of additive manufacturing. Based on combined mechanical, microscopic, and electrochemical studies, it is shown that silver particles well distributed in the matrix can be obtained, leading to cathodic sites in the composite material. Eventually, this results in an increased dissolution rate of the alloy. Stress–strain curves showed that the incorporation of silver barely affects the mechanical properties.

Design of novel materials for additive manufacturing - Isotropic microstructure and high defect tolerance

Electron Beam Melting (EBM) is a powder-bed additive manufacturing technology enabling the production of complex metallic parts with generally good mechanical properties. However, the performance of powder-bed based additively manufactured materials is governed by multiple factors that are difficult to control. Alloys that solidify in cubic crystal structures are usually affected by strong anisotropy due to the formation of columnar grains of preferred orientation. Moreover, processing induced defects and porosity detrimentally influence static and cyclic mechanical properties. The current study presents results on processing of a metastable austenitic CrMnNi steel by EBM. Due to multiple phase transformations induced by intrinsic heat-treatment in the layer-wise EBM process the material develops a fine-grained microstructure almost without a preferred crystallographic grain orientation. The deformation-induced phase transformation yields high damage tolerance and, thus, excellent mechanical properties less sensitive to process-induced inhomogeneities. Various scan strategies were applied to evaluate the width of an appropriate process window in terms of microstructure evolution, porosity and change of chemical composition.

Labelling additively manufactured parts by microstructural gradation – advanced copy-proof design

Purpose As additive manufacturing techniques, such as selective laser melting, allow for straightforward production of parts on basis of simple computer-aided design files only, unauthorized replication can be facilitated. Thus, identification and tracking of individual parts are increasingly vital in light of globalized competition. This paper aims to overcome the susceptibility of additive manufacturing techniques for product piracy by establishing a method for introducing and reading out product identification markers not visible by naked-eye inspection. Design/methodology/approach Lasers of different nominal power were used for altering the solidification mechanisms during processing in distinct areas of the samples. The resulting local microstructural characteristics and mechanical properties, respectively, were determined by scanning electron microscopy and hardness measurements. The applicability of an advanced eddy current technique for reading out local differences in electro-magnetic properties was examined. Findings The findings show that distinct microstructural features are obtained in dependence of the locally applied laser power. These features manifest themselves not only in terms of grain morphology, texture and hardness but also induce changes in the local electro-magnetic properties. The inscribed pattern can be non-destructively visualized by using an advanced eddy current technique. Originality/value Conventional copy protection basically consists in supplementary labelling or surface modification. In the present study, a new method is proposed for additively manufactured parts, overcoming the drawbacks of the former methods through process-induced microstructure manipulation. Slight alterations in the electro-magnetic material properties can be detected by advanced eddy current method allowing for identification of arbitrary and inimitable component information in additively manufactured parts.