Now showing 1 - 3 of 3
  • Publication
    Geometric distortion-compensation via transient numerical simulation for directed energy deposition additive manufacturing
    ( 2020) ;
    Elsner, B.A.M.
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    Graf, B.
    ;
    Components distort during directed energy deposition (DED) additive manufacturing (AM) due to the repeated localised heating. Changing the geometry in such a way that distortion causes it to assume the desired shape - a technique called distortion-compensation - is a promising method to reach geometrically accurate parts. Transient numerical simulation can be used to generate the compensated geometries and severely reduce the amount of necessary experimental trials. This publication demonstrates the simulation-based generation of a distortion-compensated DED build for an industrial-scale component. A transient thermo-mechanical approach is extended for large parts and the accuracy is demonstrated against 3d-scans. The calculated distortions are inverted to derive the compensated geometry and the distortions after a single compensation iteration are reduced by over 65%.
  • Publication
    Prevention of liquid metal embrittlement cracks in resistance spot welds by adaption of electrode geometry
    ( 2020)
    Böhne, Christoph
    ;
    Meschut, Gerson
    ;
    ;
    Frei, Julian
    ;
    Advanced high strength steels are usually coated by a zinc layer for an increased resistance against corrosion. During the resistance spot welding of zinc coated steel grades, liquid metal embrittlement (LME) may occur. As a result, cracking inside and around the spot weld indentation is observable. The extent of LME cracks is influenced by a variety of different factors. In this study, the impact of the used electrode geometry is investigated over a stepwise varied weld time. A spot welding finite element simulation is used to analyse and explain the observed effects. Results show significant differences especially for highly increased weld times. Based on identical overall dimensions, electrode geometries with a larger working plane allow for longer weld times, while still preventing LME within the investigated material and maintaining accessibility.
  • Publication
    Investigation of liquid metal embrittlement of dual phase steel joints by electro-thermomechanical spot-welding simulation
    ( 2019)
    Frei, Julian
    ;
    ; ;
    Böhne, Christoph
    ;
    Meschut, Gerson
    A 3D electro-thermomechanical model is established in order to investigate liquid metal embrittlement. After calibration to a dual phase steel of the 1000 MPa tensile strength class, it is used to analyse the thermo-mechanical system of an experimental procedure to enforce liquid metal embrittlement during resistance spot welding. In this procedure, a tensile stress level is applied to zinc coated advanced high strength steel samples during welding. Thereby, liquid metal embrittlement formation is enforced, depending on the applied stress level and the selected material. The model is suitable to determine and visualise the corresponding underlying stresses and strains responsible for the occurrence of liquid metal embrittlement. Simulated local stresses and strains show good conformity with experimentally observed surface crack locations.