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17.05.2019 12:00

Additive machines discover superalloys

Markus Forytta Unternehmenskommunikation
Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS

    Fraunhofer lighthouse project "futureAM" expected to speed up
    "additive manufacturing" by a factor ten

    Scientists at the Fraunhofer Institute for Material and
    Beam Technology IWS in Dresden have developed innovative methods enabling
    more materials to be processed in additive manufacturing than ever before. For
    example, additive manufacturing systems could facilitate better future aircraft
    engines with lower fuel consumption.

    However, engineers must first improve the current industrial 3D printers in such a way that these machines can also process very strong and extremely heat-resistant alloys. Here, the Dresden researchers rely on their profound experience with laser powder buildup
    welding technologies and employ artificial intelligence (AI). They contribute
    their profound materials expertise to the Fraunhofer joint project "futureAM".
    The aim of the partners is to speed up additive manufacturing systems for
    metal components by a factor ten and also to manage superalloys.

    Fraunhofer IWS engineers have refined laser powder buildup welding over decades in
    order to allow more materials to be applied in additive manufacturing. In this
    procedure, a system feeds various filler powders into a process zone. There, a laser
    melts the powder and deposits it on a workpiece surface. As a result, the desired part is
    generated in a layer by layer process. "One of the advantages of this additive
    procedure is that we can adapt the process very flexibly to the requirements of highperformance materials," explains Fraunhofer IWS project administrator Michael Müller.
    In this way it is also possible, for example, to print nickel-based alloys that are difficult
    to weld and process using traditional methods. However, this only works if the
    temperature, powders, feed rate and other parameters are correct. "We have to adjust
    all the set screws precisely," explains Michael Müller. "This is the only way we can find
    the right recipe." Within the framework of the Fraunhofer lighthouse project
    "futureAM - Next Generation Additive Manufacturing", IWS engineers are recording
    numerous sensor data with very high sampling rates for this purpose. However, this
    generates large amounts of data ("big data") that are difficult for people to
    understand.

    AI learns to decide

    Nevertheless, Fraunhofer experts use advanced methods of "artificial intelligence" (AI)
    and "machine learning", which are also researched under the catchword "Big Data" in
    a working group led by Prof. Karol Kozak, Head of Image Processing and Data
    Management at Fraunhofer IWS, to find hidden connections in these signal floods. For
    example, special analysis algorithms link the measured sensor values with the institute's
    powder database and evaluate further process parameters. Gradually, the machines
    learn to make their own decisions. For example, they can determine for themselves
    whether a slight rise in temperature in the welding process can be tolerated or whether
    they have to take immediate countermeasures before the entire component ends up as
    waste. "Industry is looking for ever more and ever different materials which are,
    however, often difficult to process," emphasizes Prof. Frank Brückner, Business Unit
    Manager Generation and Printing at Fraunhofer IWS.

    Better aircraft engines in sight

    The aircraft engines mentioned above are examples illustrating precisely this prospect:
    they could work more efficiently and at higher temperatures if most materials were not
    already failing at temperatures of around 1200 degrees. Admittedly, there are materials
    that can withstand such high temperatures, but they are very cost-intensive and
    difficult to process using traditional methods. Additive manufacturing is intended to
    solve this dilemma. Moreover, it could help to achieve a more cost-effective design:
    "Using laser powder buildup welding, we can feed different powders into the process
    zone simultaneously or successively with precisely adjustable feed rates," explains
    Michael Müller. Designing an entire component out of a singular material is not very
    effective since the component is not exposed to the same heat at all points."
    Preferably, the expensive, highly resistant material should only be used where it gets
    really hot," says Michael Müller. "In other areas, a less expensive material will be
    sufficient." This is precisely what can be achieved with additive manufacturing systems
    – once they have learned to process the required superalloy. "The next step is to
    combine various high-performance materials within a single component," announces
    project administrator Müller. In the "futureAM" joint project, the IWS and five other
    Fraunhofer Institutes are pooling this technology and further expertise to push additive
    manufacturing to a new level. By summer 2020, they want to integrate all their
    expertise into the additive manufacturing process chain and demonstrate it on realistic
    components.

    Background information: This is "Additive manufacturing"

    Additive manufacturing (AM) is regarded as a key technology for "Industrie 4.0". It is
    designed to combine the advantages of mass production and manufacturing and even
    to generate individual parts ("batch size 1") economically on an industrial scale. AM
    machines can also freely create highly complex components that cannot be produced
    using conventional milling and turning machines. These machines use principles similar
    to those used by 3D printers in the creative and DIY scene: The desired component is
    designed on the computer; subsequently this model is fed into the system, whereupon
    a heating module or laser heats a plastic. From this material melt, the system generates
    the designed part layer by layer. Compared to 3D printers for private use, AM systems
    are far more efficient. They can, for example, process metals and ceramics as well as
    plastics, usually use laser technology and work with extreme precision and more
    complex CAD models.

    "futureAM" takes additive manufacturing to a new Level

    In November 2017, the Fraunhofer lighthouse project futureAM was launched with the
    aim of accelerating additive manufacturing of metal components by at least a factor of
    ten. The focus is on a holistic view of digital and physical added value from incoming
    order to the finished metal 3D printing component. The central goal is a leap into a
    new technology generation of additive manufacturing. Five other Fraunhofer institutes
    are participating in this project under the leadership of the Fraunhofer ILT: IWS, IWU,
    IAPT, IGD and IFAM.

    Visit us at the exhibitions "LASER World of PHOTONICS" in hall A2, booth 431,
    and "RAPID.TECH + FABCON 3.D" at AGENT-3D booth 2-435.


    Wissenschaftliche Ansprechpartner:

    Business Unit Manager Additive Manufacturing and Printing
    Prof. Dr. Frank Brückner
    Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS
    frank.brueckner@iws.fraunhofer.de
    Phone +49 351 83391-3452
    Winterbergstraße 28, 01277 Dresden
    www.iws.fraunhofer.de


    Weitere Informationen:

    https://www.iws.fraunhofer.de/en/pressandmedia/press_releases/2019/presseinforma...


    Bilder

    By means of laser powder build-up welding, components made of different materials can be integrally manufactured.
    By means of laser powder build-up welding, components made of different materials can be integrally ...
    © Fraunhofer IWS Dresden
    None

    Fraunhofer IWS Dresden has developed a process and material database which stores all details of the manufactured components.
    Fraunhofer IWS Dresden has developed a process and material database which stores all details of the ...
    © Fraunhofer IWS Dresden
    None


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    Maschinenbau, Umwelt / Ökologie, Verkehr / Transport, Werkstoffwissenschaften
    überregional
    Forschungs- / Wissenstransfer, Forschungsergebnisse
    Englisch


     

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