Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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Qualitätssicherung beim Laser-Pulver-Auftragschweißen

2024-02-01 , Lemke, Josefine

In der modernen Fertigungstechnik spielt der Einsatz von korrosionsbeständigem Stahl eine große Rolle. Die kohlenstoffarme Edelstahllegierung 1.4404 (AISI 316L) ist ein häufig eingesetzter Werkstoff in der additiven Fertigung. Hier kann das Laser-Pulver-Auftragschweißen (LPA), engl. Directed Energy Deposition DED-LB, das weit verbreitete Laser Powder Bed Fusion (L-PBF) aufgrund höherer Auftragsraten und seiner Flexibilität in einigen Bereichen ergänzen und sogar ersetzen. Mit interessanten Perspektiven in der Bremsscheibenfertigung für Automobile.

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Resource efficient production of car body parts - implementation of digital twins across process chains

2022-09-21 , Weber, Joshua , Lemke, Josefine , Sunderkoetter, Christina , Haase, Patrick , Hoefemann, Matthias , Joos, Paul , Merklein, Marion

Sustainable production and environmentally friendly life cycle of every car is a main goal in the automotive industry. But there is a conflict between the rising demands of crash safety, the addition of components due to electric mobility and the reduction of weight. Car body parts can increase the crash safety and have a high lightweight construction potential. Especially tailor welded blanks made of multi-phase steel with a tensile strength of 1000 MPa, which are not established in car body parts, have the potential to improve the crash safety, save resources and lower the weight. The main challenge in the manufacturing of tailor welded blanks made of highest strength steel is the complex and expensive development. Due to the heat input and geometrical changes, the welding process affects the forming properties of the metal sheets. To evaluate the influence from different welding parameters to the forming process, a high number of expensive experiments must be repeated. This includes welding and forming parameter changes as well as adjustments to the forming tool. In order to make the development and manufacturing of tailor welded blanks made of highest strength steels more resource efficient, this work discusses the development and implementation of a digital and bidirectional twin in an industry-oriented environment. The objective is to demonstrate the data management based on the sheet metal properties, the change of properties due to laser welding simulated in Simufact Welding and the final forming process in AutoForm Forming. Additionally, the concept of a life cycle assessment of a tailor welded blank during these steps is developed. As summary the challenges, limitations, and improvements of the digital and bidirectional twin as replacement or, in addition to a consisting development process are discussed.

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More sustainable in the automobile with tailor welded blank (TWB)

2022-07-01 , Lemke, Josefine , Weber, Joshua , Kompenhans, Moritz , Höfemann, Matthias , Joos, Paul

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Tailor Welded Blanking Digital

2023-11-30 , Weber, Joshua , Daniel, González , Höfemann, Matthias , Joos, Paul , Rys, Anastasia , Lemke, Josefine

Der immer effizientere Einsatz von Energie und Ressourcen bleibt eine große Herausforderung, die nur mit innovativen Lösungen zu bewältigen ist. Ein schneller, günstiger und ressourcenschonender Ansatz ist die Anwendung von digitalen Methoden. Vor allem bei anspruchsvolleren Fertigungsketten, wie die Herstellung von Karosseriebauteilen aus Tailor Welded Blanks, ist es sinnvoll, die Produktauslegung bzw. die Prozessauslegung vor der eigentlichen Produktion digital und ganzheitlich zu simulieren, um Werkzeuganpassungen und unnötige Versuche zu verhindern. Dies funktioniert mit der Benutzung eines sogenannten digitalen Zwillings für die Fertigungskette durch die Verknüpfung von numerischen Simulationen, die die einzelnen Prozessschritte abbilden.

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Result quality evaluation of Directed Energy Deposition Additive Manufacturing simulations with progressive simplification of transient heat-source motion

2022-09-05 , Biegler, Max , Elsner, Beatrix A.M. , Neubauer, Ingo , Lemke, Josefine , Rethmeier, Michael

Directed Energy Deposition (DED) additive manufacturing has recently been adopted in the industry for the build-up of structural components with weld lengths up to kilometers. As with all welding processes, DED suffers from thermal distortion, causing loss of dimensional accuracy and risk of cracking. Currently, process optimization with objective to minimize distortion requires expensive experimental trial-and-error. With numerical simulation of the DED process, this distortion compensation can be performed virtually, significantly reducing experimental trials. Although such approaches are generally available, their widespread adoption is currently being hampered by long computational times for large builds. This work presents a novel approach to reduce the calculation time by a simplification of the transient heat-source motion. This approach is assessed in terms of result accuracy for an industrial-scale component by progressively reducing the resolution of the heat-source motion. Calculation times as well as distortions in comparison to experimental trials are investigated.

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A life cycle assessment of joining processes in the automotive industry, illustrated by the example of an EV battery case

2023 , Brunner-Schwer, Christian , Lemke, Josefine , Biegler, Max , Schmolke, Tobias , Spohr, Sebastian , Meschut, Gerson , Eckstein, Lutz , Rethmeier, Michael

Current ecological, economic and social changes are leading to a change in development, design and production of future vehicles. In this context, it is the stated goal of many manufacturers to advance the development of an environmentally friendly vehicle and climate-neutral production throughout the entire supply chain. This study presents a comparative life cycle assessment of the joining processes laser beam welding, laser brazing and resistance spot welding. For this purpose, an approach tailored to welding processes is presented and applied to the example of a battery case for electric vehicles. For the welding process under consideration, the main influences on the resulting environmental impact categories are evaluated and compared. The requirements for ecologically efficient welding processes are discussed and outlined. The results show that particularly the materials involved, such as the consumption of the filler material, have the greatest environmental impact and thus offer the greatest potential for savings.

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Nachhaltiger im Automobil mit TWB

2022-07-30 , Lemke, Josefine , Weber, Joshua , Kompenhans, Moritz Niklas , Höfemann, Matthias , Joos, Paul

CO2-Footprint von Fahrzeugen wird maßgeblich durch ihr Gewicht bestimmt. Spezielle Blechplatinen - bislang noch nicht in Serie eingesetzte Tailor Welded Blanks aus höchstfesten Stählen mit Festigkeiten von 1000 MPa - können diesen verringern. Die Verarbeitung geschweißter höchstfester Platinen kann jedoch noch zu Diskontinuität im Bauteil führen. Den Prozess rein experimentell auszulegen ist teuer und verschwendet Material und Ressourcen. Dem begegnet das BMWK-Projekt TWBlock mit numerischen Simulationen und deren Absicherung durch die Blockchain-Technologie über die gesamte Prozess- und Wertschöpfungskette.

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