Filtern
Dokumenttyp
Sprache
- Englisch (2) (entfernen)
Volltext vorhanden
- ja (2)
Gehört zur Bibliographie
- nein (2)
Schlagworte
- Selektives Laserschmelzen (2) (entfernen)
Institut
Additive manufacturing is an essential tool in innovative production processes. The extended degrees of freedom offer much potential in usage, construction, and product design. Rising raw material and energy costs, constantly increasing environmental requirements, and the increasing demand for resource-saving products represent a paradigm shift in classic production processes.
In addition to the purely energetic evaluation, developing energy models is a method to determine energy consumption and reduce it in the long term. The specific energy consumption model, also known as the SEC model, allows a quick estimation of energy consumption by multiplying the SEC with a unit like the mass of the workpiece, the manufacturing time, or the exposed area. Here, high dependence on the used machine, the considered peripheral devices, and the geometry are noticeable.
Previous studies, such as those by Kellens et al. and Baumers et al., have laid the basis for understanding the energy demands of PBF-LB/M processes. Various energy models have subsequently been proposed, including those by Paul and Anand, Yi et al., Lv et al., and Hui et al. These models are often limited by their specificity to sub-processes or subsystems. This results in limitations in their applicability to other manufacturing machines or inaccuracies in energy consumption predictions. The simulation accuracy ACC is mostly in the range of 90% with the limitation of small sample sizes. Moreover, nearly, all these models rely heavily on process time information, making the accuracy of their simulations largely dependent on the quality of the underlying time model.
In the following study, two manufacturing machines of the PBF-LB/M process are analyzed and compared with other studies. The aim is to analyze the power and resource consumption to use these data to build an improved energy model with a high accuracy, which can be used as an additional parameter in the adapted design methodology. Furthermore, potential savings are derived from the load curves.
The number of additive manufacturing methods and materials is growing rapidly, leaving gaps in the knowledge of specific material properties. A relatively recent addition is the metal-filled filament to be printed similarly to the fused filament fabrication (FFF) technology used for plastic materials, but with additional debinding and sintering steps. While tensile, bending, and shear properties of metals manufactured this way have been studied thoroughly, their fatigue properties remain unexplored. Thus, the paper aims to determine the tensile, fatigue, and impact strengths of Markforged 17-4 PH and BASF Ultrafuse 316L stainless steel to answer whether the metal FFF can be used for structural parts safely with the current state of technology. They are compared to two 316L variants manufactured via selective laser melting (SLM) and literature results. For extrusion-based additive manufacturing methods, a significant decrease in tensile and fatigue strength is observed compared to specimens manufactured via SLM. Defects created during the extrusion and by the pathing scheme, causing a rough surface and internal voids to act as local stress risers, handle the strength decrease. The findings cast doubt on whether the metal FFF technique can be safely used for structural components; therefore, further developments are needed to reduce internal material defects.