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 and numerical simulation of additive manufacturing LMD geometries
    ( 2019)
    Biegler, Max
    ;
    Wang, Jiahan
    ;
    Graf, Benjamin
    ;
    Rethmeier, Michael
    In additive manufacturing (AM) Laser Metal Deposition (LMD), parts are built by welding layers of powder feedstock onto a substrate. Applications for steel powders include forging tools and structural components for various industries. For large parts, the choice of tool-paths influences the build-rate, the part 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 LMD processes. In this contribution, automated tool-path generation approaches are shown and their results are discussed for arbitrary geometries. The investigated path strategies are the classical approaches: ""Zig-zag-"" and ""contour-parallel-strategies"". After generation, the tool-paths are automatically formatted into g-code for experimental build-up and ASCII for a numerical simulation model. Finally, the tool paths are discussed in regards to volume-fill, microstructure and porosity for the experimental samples. This work presents a part of the IGF project 18737N ""Welding distortion simulation"" (FOSTA P1140)