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Mechanical properties of sheet metal components with local reinforcement produced by additive manufacturing

: Ünsal, I.; Hama-Saleh, R.; Sviridov, A.; Bambach, M.; Weisheit, A.; Schleifenbaum, J.H.


Fratini, Livan (Ed.) ; European Scientific Association for Material Forming:
21st International ESAFORM Conference on Material Forming, ESAFORM 2018. Proceedings : 23-25 April 2018, Palermo, Italy
Melville/NY: AIP Publishing, 2018 (AIP Conference Proceedings 1960)
ISBN: 978-0-7354-1663-5
Art. 160028
International Conference on Material Forming (ESAFORM) <21, 2018, Palermo>
Fraunhofer ILT ()

New technological challenges like electro-mobility pose an increasing demand for cost-efficient processes for the production of product variants. This demand opens the possibility to combine established die-based manufacturing methods and innovative, dieless technologies like additive manufacturing [1, 2]. In this context, additive manufacturing technologies allow for the weight-efficient local reinforcement of parts before and after forming, enabling manufacturers to produce product variants from series parts [3].
Previous work by the authors shows that the optimal shape of the reinforcing structure can be determined using sizing optimization. Sheet metal parts can then be reinforced using laser metal deposition. The material used is a pearlite-reduced, micro-alloyed steel (ZE 630). The aim of this paper is to determine the effect of the additive manufacturing process on the material behavior and the mechanical properties of the base material and the resulting composite material. The parameters of the AM process are optimized to reach similar material properties in the base material and the build-up volume. A metallographic analysis of the parts is presented, where the additive layers, the base material and also the bonding between the additive layers and the base material are analyzed. The paper shows the feasibility of the approach and details the resulting mechanical properties and performance.