Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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Additives Fertigungs-Duo erleichtert Sensorintegration

2021 , Uhlmann, Eckart , Polte, Julian , Neuwald, Tobias , Kersting, Robert , Brunner-Schwer, Christian

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Flexible manufacturing with an additive process chain. Design, production and surface finish

2015 , Uhlmann, Eckart , Rethmeier, Michael , Graf, Benjamin , Kersting, Robert , Bergmann, André

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Effects on part density for a highly productive manufacturing of WC-Co via laser powder bed fusion

2021 , Polte, Julian , Neuwald, Tobias , Gordei, Anzhelika , Kersting, Robert , Uhlmann, Eckart

The additive manufacturing of parts made from difficult-to-weld materials through the usage of preheating temperatures of up to Î0 ⤠500 °C is enabled by newest L-PBF machine tools, such as the RenAM 500Q HT from the company RENISHAW PLC, Wottun-under-Edge, UK. This work aims to delevop processing parameters for the dense and crack-free manufacturing of tungsten-carbide cobalt (WC-Co) via this off-the-shelf machine tool. Therefore the laserpower and scanning speed were varied between 80 W ⤠PL ⤠350 W and 140 mm/s ⤠vS ⤠650 mm/s respectively. Furthermore the influence of a continuous and pulsed laser mode was analysed. A focus was set on the identification of parameters that enable a highly productive manufacturing while maintaining a high part density. A parameter set for relative density rel. > 94 % and a buildup rate v = 0.59 mm3/s was developed.

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Sensor integration in hybrid additive manufactured parts for real-time monitoring in turbine operations

2021 , Uhlmann, Eckart , Polte, Julian , Kersting, Robert , Brunner-Schwer, Christian , Neuwald, Tobias

Real-time monitoring of operation conditions such as tempeatures and vibrations enables efficiency enhancement for maintenance tasks. In energy industry monitoring of critical components such as turbine blades is essential for the operation safety. But the effective recording of critical process data is a challenging task due to the extreme operating conditions. With a hybrid processing approach combining two additive manufacturing technologies new classes of self-monitoring components become possible allowing data acquisition directly inside the component. Using the example of a turbine blade, the hybrid process chain is described. The turbine blade blank is produced via Laser Powder Bed Fusion (L-PBF) with channels for the integration of high temperature sensors. After integration cavities were closed by Laser Directed Energy Deposition (L-DED) followed by classical milling operations for part finishing. The data acquisition is integrated in state-of-the-art product l ifecycle monitoring (PLM) software to create a digital twin. Evaluation shows that temperature could be successfully monitored at conditions of Π= 550°C.

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