Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Analysis and recycling of bronze grinding waste to produce maritime components using directed energy deposition
    ( 2021)
    Müller, Vinzenz
    ;
    Marko, Angelina
    ;
    Kruse, Tobias
    ;
    Biegler, Max
    ;
    Rethmeier, Michael
    Additive manufacturing promises a high potential for the maritime sector. Directed Energy Deposition (DED) in particular offers the opportunity to produce large-volume maritime components like propeller hubs or blades without the need of a costly casting process. The post processing of such components usually generates a large amount of aluminum bronze grinding waste. The aim of the presented project is to develop a sustainable circular AM process chain for maritime components by recycling aluminum bronze grinding waste to be used as raw material to manufacture ship propellers with a laser-powder DED process. In the present paper, grinding waste is investigated using a dynamic image analysis system and compared to commercial DED powder. To be able to compare the material quality and to verify DED process parameters, semi-academic sample geometries are manufactured.
  • Publication
    Automated Tool-Path Generation for Rapid Manufacturing of Additive Manufacturing Directed Energy Deposition Geometries
    ( 2020)
    Biegler, Max
    ;
    Wang, Jiahan
    ;
    Kaiser, Lukas
    ;
    Rethmeier, Michael
    In additive manufacturing (AM) directed energy deposition (DED), parts are built by welding layers of powder or wire feedstock onto a substrate with applications for steel powders in the fields of forging tools, spare parts, and structural components for various industries. For large and bulky parts, the choice of tool-paths influences the build rate, the mechanical performance, and the distortions in a highly geometry-dependent manner. With weld-path lengths in the range of hundreds of meters, a reliable, automated tool-path generation is essential for the usability of DED processes. This contribution presents automated tool-path generation approaches and discusses the results for arbitrary geometries. So-called “zig-zag” and “contour-parallel” processing strategies are investigated and the tool-paths are automatically formatted into machine-readable g-code for experimental validation to build sample geometries. The results are discussed in regard to volume-fill, microstructure, and porosity in dependence of the path planning according to photographs and metallographic cross-sections.