Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Resource efficient production of car body parts - implementation of digital twins across process chains
    ( 2022-09-21)
    Weber, Joshua
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    Lemke, Josefine orcid-logo
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    Sunderkoetter, Christina
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    Haase, Patrick
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    Hoefemann, Matthias
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    Joos, Paul
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    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.
  • Publication
    Revealing dynamic processes in laser powder bed fusion with in situ X-ray diffraction at PETRA III
    ( 2022)
    Krohmer, E.
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    Schmeiser, F.
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    Wahlmann, B.
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    Rosigkeit, J.
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    Graf, G.
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    Spoerk-Erdely, P.
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    Clemens, H.
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    Staron, P.
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    Körner, C.
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    Reimers, W.
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    Uhlmann, Eckart
    The high flux combined with the high energy of the monochromatic synchrotron radiation available at modern synchrotron facilities offers vast possibilities for fundamental research on metal processing technologies. Especially in the case of laser powder bed fusion (LPBF), an additive manufacturing technology for the manufacturing of complex-shaped metallic parts, in situ methods are necessary to understand the highly dynamic thermal, mechanical, and metallurgical processes involved in the creation of the parts. At PETRA III, Deutsches Elektronen-Synchrotron, a customized LPBF system featuring all essential functions of an industrial LPBF system, is used for in situ X-ray diffraction research. Three use cases with different experimental setups and research questions are presented to demonstrate research opportunities. First, the influence of substrate pre-heating and a complex scan pattern on the strain and internal stress progression during the manufacturing of Inconel 625 parts is investigated. Second, a study on the nickel-base superalloy CMSX-4 reveals the formation and dissolution of γ′ precipitates depending on the scan pattern in different part locations. Third, phase transitions during melting and solidification of an intermetallic γ-TiAl based alloy are examined, and the advantages of using thin platelet-shaped specimens to resolve the phase components are discussed. The presented cases give an overview of in situ X-ray diffraction experiments at PETRA III for research on the LPBF technology and provide information on specific experimental procedures.