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Additive manufacturing (AM) works by creating objects layer by layer in a manner similar to a 2D printer with the “printed” layers stacked on top of each other. The layer-wise manufacturing nature of AM enables fabrication of freeform geometries which cannot be fabricated using conventional manufacturing methods as a one part. Depending on how each layer is created and bonded to the adjacent layers, different AM methods have been developed. In this chapter, the basic terms, common materials, and different methods of AM are described, and their potential applications are discussed.
The thermal conductivity of components manufactured using Laser Powder Bed Fusion (LPBF), also called Selective Laser Melting (SLM), plays an important role in their processing. Not only does a reduced thermal conductivity cause residual stresses during the process, but it also makes subsequent processes such as the welding of LPBF components more difficult. This article uses 316L stainless steel samples to investigate whether and to what extent the thermal conductivity of specimens can be influenced by different LPBF parameters. To this end, samples are set up using different parameters, orientations, and powder conditions and measured by a heat flow meter using stationary analysis. The heat flow meter set-up used in this study achieves good reproducibility and high measurement accuracy, so that comparative measurements between the various LPBF influencing factors to be tested are possible. In summary, the series of measurements show that the residual porosity of the components has the greatest influence on conductivity. The degradation of the powder due to increased recycling also appears to be detectable. The build-up direction shows no detectable effect in the measurement series.
In the Laser Powder Bed Fusion (LPBF) process, parts are built out of metal powder material by exposure of a laser beam. During handling operations of the powder material, several influencing factors can affect the properties of the powder material and therefore directly influence the processability during manufacturing. Contamination by moisture due to handling operations is one of the most critical aspects of powder quality. In order to investigate the influences of powder humidity on LPBF processing, four materials (AlSi10Mg, Ti6Al4V, 316L and IN718) are chosen for this study. The powder material is artificially humidified, subsequently characterized, manufactured into cubic samples in a miniaturized process chamber and analyzed for their relative density. The results indicate that the processability and reproducibility of parts made of AlSi10Mg and Ti6Al4V are susceptible to humidity, while IN718 and 316L are barely influenced.
Selective Laser Melting (SLM) is one of the Additive Manufacturing (AM) technologies applicable for producing complex geometries which are typically expensive or difficult to fabricate using conventional methods. This process has been extensively investigated experimentally for various metals and the fabrication process parameters have been established for different applications; however, fabricating 3D glass objects using SLM technology has remained a challenge so far although it could have many applications. This paper presents a summery on various experimental evaluations of a material database incorporating the build parameters of glass powder using the SLM process for jewelry applications.
The laser beam-submerged arc hybrid welding method originates from the knowledge that, with increasing penetration depth, the laser beam process has a tendency to pore formation in the lower weld regions. The coupling with the energy-efficient submerged-arc process improves degassing and reduces the tendency to pore formation. The high deposition rate of the SA process in combination with the laser beam process offers, providing the appropriate choice of weld preparation, the possibility of welding plates with a thickness larger than 20° mm in a single pass, and also of welding thicker plates with the double-sided single pass technique.
Laserwelding with fillerwire
(2001)
The main objective of our ROS Summer School series is to introduce MA level students to program mobile robots with the Robot Operating System (ROS). ROS is a robot middleware that is used my many research institutions world-wide. Therefore, many state-of-the-art algorithms of mobile robotics are available in ROS and can be deployed very easily. As a basic robot platform we deploy a 1/10 RC cart that is wquipped with an Arduino micro-controller to control the servo motors, and an embedded PC that runs ROS. In two weeks, participants get to learn the basics of mobile robotics hands-on. We describe our teaching concepts and our curriculum and report on the learning success of our students.
Password necessarily. Access only for Students by Prof. Dr. Klaus-Peter Kämper. Winter semester 2007/2008. Version 2007-08-30. 472 pages (pdf) Contents 1. Introduction 2. Introduction to Sensors 3. Introduction to Microfabrication 4. Pressure Sensors 5. Acceleration Sensors 6. Angular Rate Sensors 7. Position Sensors 8. Flow Sensors 9. Piezoelectric Actuators 10. Magnetostrictive Actuators 11. Actuators based on Shape Memory Alloys 12. Actuators based on Electrorheological Fluids 13. Actuators based on Magnetorheological Fluids
Password necessarily. Access only for Students by Prof. Dr. Klaus-Peter Kämper. Winter semester 2008/2009. 488 pages (pdf) Contents 1. Introduction 2. Introduction to Sensors 3. Introduction to Microfabrication 4. Pressure Sensors 5. Acceleration Sensors 6. Angular Rate Sensors 7. Position Sensors 8. Flow Sensors 9. Piezoelectric Actuators 10. Magnetostrictive Actuators 11. Actuators based on Shape Memory Alloys 12. Actuators based on Electrorheological Fluids 13. Actuators based on Magnetorheological Fluids 14. Index
Electron beam plasma measurement was realised by means of DIABEAM system invented by ISF RWTH Aachen. The Langmuir probe method is used for measurement. The relative simplicity of the method and the possibility of dispersion of high power on the probe allow its application for the investigation of high-power electron beams. The key element of the method is a rotating thin tungsten wire, which intersects the beam transversely on its axis and collects part of the current by itself. The signals, which are registered in the DIABEAM as a voltage, were taken in the form of amplitude. The conversion of the probe current into the distribution along the beam radius was realised using the Abel’s method. A voltage-current characteristic was built for the beam current. The local electron density as well as the electron temperature, the floating potential and the plasma potential were measured and calculated by means of this characteristic.
Additive Manufacturing (AM) of metallic workpieces faces a continuously rising technological relevance and market size. Producing complex or highly strained unique workpieces is a significant field of application, making AM highly relevant for tool components. Its successful economic application requires systematic workpiece based decisions and optimizations. Considering geometric and technological requirements as well as the necessary post-processing makes deciding effortful and requires in-depth knowledge. As design is usually adjusted to established manufacturing, associated technological and strategic potentials are often neglected. To embed AM in a future proof industrial environment, software-based self-learning tools are necessary. Integrated into production planning, they enable companies to unlock the potentials of AM efficiently. This paper presents an appropriate methodology for the analysis of process-specific AM-eligibility and optimization potential, added up by concrete optimization proposals. For an integrated workpiece characterization, proven methods are enlarged by tooling-specific figures.
The first stage of the approach specifies the model’s initialization. A learning set of tooling components is described using the developed key figure system. Based on this, a set of applicable rules for workpiece-specific result determination is generated through clustering and expert evaluation. Within the following application stage, strategic orientation is quantified and workpieces of interest are described using the developed key figures. Subsequently, the retrieved information is used for automatically generating specific recommendations relying on the generated ruleset of stage one. Finally, actual experiences regarding the recommendations are gathered within stage three. Statistic learning transfers those to the generated ruleset leading to a continuously deepening knowledge base. This process enables a steady improvement in output quality.
Numerical algorithms with C
(1996)
Numerical and experimental investigation of tensile behavior of laser beam welded TRIP700 steel
(2011)
This paper aims to evaluate the formability of tailor welded blanks of dual phase (DP600)/transformation induced plasticity (TRIP700) steel sheets. In this work, bead on plate butt joints of 2·5 mm DP600 and 1·2 mm TRIP700 steel sheets were performed using CO2 laser beam welding. Microhardness measurements and transverse tensile testing were carried out to characterise the welds. The formability of base metals and welds were investigated by standard Erichsen test. In a perpendicular tensile test to the weld line, all specimens were fractured at the TRIP base metal, and the strengths were somewhat higher than those of base metal. There was a significant reduction in formability caused by welding of the DP600/TRIP700 steel sheets, and the formability increased with increasing welding speed.
Laser-based Additive Manufacturing (AM) processes for the use of metals out of the powder bed have been investigated profusely and are prevalent in industry. Although there is a broad field of application, Laser Powder Bed Fusion (LPBF), also known as Selective Laser Melting (SLM) of glass is not fully developed yet. The material properties of glass are significantly different from the investigated metallic material for LPBF so far. As such, the process cannot be transferred, and the parameter limits and the process sequence must be redefined for glass. Starting with the characterization of glass powders, a parameter field is initially confined to investigate the process parameter of different glass powder using LPBFprocess. A feasibility study is carried out to process borosilicate glass powder. The effects of process parameters on the dimensional accuracy of fabricated parts out of borosilicate and hints for the post-processing are analysed and presented in this paper.
Generally, the quality of a weld joint is directly influenced by the welding input parameter settings. Selection of proper process parameters is important to obtain the desired weld bead profile and quality. In this research work, numerical and graphical optimization techniques of the CO2 laser beam welding of dual phase (DP600)/transformation induced plasticity (TRIP700) steel sheets were carried out using response surface methodology (RSM) based on Box–Behnken design. The procedure was established to improve the weld quality, increase the productivity and minimize the total operation cost by considering the welding parameters range of laser power (2–2.2 kW), welding speed (40–50 mm/s) and focus position (−1 to 0 mm). It was found that, RSM can be considered as a powerful tool in experimental welding optimization, even when the experimenter does not have a model for the process. Strong, efficient and low cost weld joints could be achieved using the optimum welding conditions.
Particle-Image-Velocimetry (PIV) in rotierenden Maschinen / Dues, M. ; Kallweit, S. ; Siekmann, H.
(1994)
We prove characterizations of the existence of perfect ƒ-matchings in uniform mengerian and perfect hypergraphs. Moreover, we investigate the ƒ-factor problem in balanced hypergraphs. For uniform balanced hypergraphs we prove two existence theorems with purely combinatorial arguments, whereas for non-uniform balanced hypergraphs we show that the ƒ-factor problem is NP-hard.
The fourth industrial revolution introduces disruptive technologies to production environments. One of these technologies are multi-agent systems (MASs), where agents virtualize machines. However, the agent's actual performances in production environments can hardly be estimated as most research has been focusing on isolated projects and specific scenarios. We address this gap by implementing a highly connected and configurable reference model with quantifiable key performance indicators (KPIs) for production scheduling and routing in single-piece workflows. Furthermore, we propose an algorithm to optimize the search of extrema in highly connected distributed systems. The benefits, limits, and drawbacks of MASs and their performances are evaluated extensively by event-based simulations against the introduced model, which acts as a benchmark. Even though the performance of the proposed MAS is, on average, slightly lower than the reference system, the increased flexibility allows it to find new solutions and deliver improved factory-planning outcomes. Our MAS shows an emerging behavior by using flexible production techniques to correct errors and compensate for bottlenecks. This increased flexibility offers substantial improvement potential. The general model in this paper allows the transfer of the results to estimate real systems or other models.
Establishing high-performance polymers in additive manufacturing opens up new industrial applications. Polyetheretherketone (PEEK) was initially used in aerospace but is now widely applied in automotive, electronics, and medical industries. This study focuses on developing applications using PEEK and Fused Filament Fabrication for cost-efficient vulcanization injection mold production. A proof of concept confirms PEEK’s suitability for AM mold making, withstanding vulcanization conditions. Printing PEEK above its glass transition temperature of 145 °C is preferable due to its narrow process window. A new process strategy at room temperature is discussed, with micrographs showing improved inter-layer bonding at 410°C nozzle temperature and 0.1 mm layer thickness. Minimizing the layer thickness from 0.15 mm to 0.1 mm improves tensile strength by 16%.
This paper presents the laser-based powder bed fusion (L-PBF) using various glass powders (borosilicate and quartz glass). Compared to metals, these require adapted process strategies. First, the glass powders were characterized with regard to their material properties and their processability in the powder bed. This was followed by investigations of the melting behavior of the glass powders with different laser wavelengths (10.6 µm, 1070 nm). In particular, the experimental setup of a CO2 laser was adapted for the processing of glass powder. An experimental setup with integrated coaxial temperature measurement/control and an inductively heatable build platform was created. This allowed the L-PBF process to be carried out at the transformation temperature of the glasses. Furthermore, the component’s material quality was analyzed on three-dimensional test specimen with regard to porosity, roughness, density and geometrical accuracy in order to evaluate the developed L-PBF parameters and to open up possible applications.
As researchers continue to seek the expansion of the material base for additive manufacturing, there is a need to focus attention on the Ni–Cu group of alloys which conventionally has wide industrial applications. In this work, the G-NiCu30Nb casting alloy, a variant of the Monel family of alloys with Nb and high Si content is, for the first time, processed via the laser powder bed fusion process (LPBF). Being novel to the LPBF processes, optimum LPBF parameters were determined, and hardness and tensile tests were performed in as-built conditions and after heat treatment at 1000 °C. Microstructures of the as-cast and the as-built condition were compared. Highly dense samples (99.8% density) were achieved after varying hatch distance (80 µm and 140 µm) with scanning speed (550 mm/s–1500 mm/s). There was no significant difference in microhardness between varied hatch distance print sets. Microhardness of the as-built condition (247 HV0.2) exceeded the as-cast microhardness (179 HV0.2.). Tensile specimens built in vertical (V) and horizontal (H) orientations revealed degrees of anisotropy and were superior to conventionally reported figures. Post heat treatment increased ductility from 20% to 31% (V), as well as from 16% to 25% (H), while ultimate tensile strength (UTS) and yield strength (YS) were considerably reduced.
For smaller railway operators or those with a diverse fleet, it can be difficult to collect sufficient data to improve maintenance programs. At the same time, new rules such as entity in charge of maintenance – ECM – regulations impose an additional workload by requiring a dedicated maintenance management system and specific reports. The RailCrowd platform sets out to facilitate compliance with ECM and similar regulations while at the same time pooling anonymised fleet data across operators to form virtual fleets, providing greater data insights.
Rapid Prototyping
(2003)
Rapid Prototyping
(2004)
Rapid Prototyping and PIV
(2001)
The development of protype applications with sensors and actuators in the automation industry requires tools that are independent of manufacturer, and are flexible enough to be modified or extended for any specific requirements. Currently, developing prototypes with industrial sensors and actuators is not straightforward. First of all, the exchange of information depends on the industrial protocol that these devices have. Second, a specific configuration and installation is done based on the hardware that is used, such as automation controllers or industrial gateways. This means that the development for a specific industrial protocol, highly depends on the hardware and the software that vendors provide. In this work we propose a rapid-prototyping framework based on Arduino to solve this problem. For this project we have focused to work with the IO-Link protocol. The framework consists of an Arduino shield that acts as the physical layer, and a software that implements the IO-Link Master protocol. The main advantage of such framework is that an application with industrial devices can be rapid-prototyped with ease as its vendor independent, open-source and can be ported easily to other Arduino compatible boards. In comparison, a typical approach requires proprietary hardware, is not easy to port to another system and is closed-source.
Rapid Tooling
(2019)
Rare event simulation to optimise maintenance intervals of safety critical redundant subsystems
(2018)
The radio-based wireless data communication has made the realization of new technical solutions possible in many fields of the automation technology (AT). For about ten years, a constant disproportionate growth of wireless technologies can be observed in the automation technology.
However, it shows that especially for the AT, conventional technologies of office automation are unsuitable and/or not manageable. The employment of mobile services in the industrial automation technology has the potential of significant cost and time savings. This leads to an increased productivity in various fields of the AT, for example in the factory and process automation or in production logistics. In this paper technologies and solutions for an automation-suited supply of mobile wireless services will be introduced under the criteria of real time suitability, IT-security and service orientation.
Emphasis will be put on the investigation and development of wireless convergence layers for different radio technologies, on the central provision of support services for an easy-to-use, central, backup enabled management of combined wired / wireless networks and on the study on integrability in a Profinet real-time Ethernet network.
In the face of the current trend towards larger and more complex production tasks in the SLM process and the current limitations in terms of maximum build space, the welding of SLM components to each other or to conventionally manufactured parts is becoming increasingly relevant. The fusion welding of SLM components made of 316L has so far been rarely investigated and if so, then for highly specialised laser welding processes. When welding with industrial gas welding processes such as MIG/MAG or TIG welding, distortions occur which are associated with the resulting residual stresses in the components. This paper investigates process-side influencing factors to avoid resulting residual stresses in SLM components made of 316L. The aim is to develop a strategy to build up SLM components as stress-free as possible in order to join them as profitably as possible with a downstream welding process. For this purpose, influencing parameters such as laser power, scan speed, but also scan vector length and different scan patterns are investigated with regard to their influence on residual stresses.
This work demonstrates how the interaction between particle image velocimetry (PIV) and robotics can massively increase measurement efficiency. The interdisciplinary approach is shown using the complex example of an automated, large scale, industrial environment: a typical automotive wind tunnel application. Both the high degree of flexibility in choosing the measurement region and the complete automation of stereo PIV measurements are presented. The setup consists of a combination of three robots, individually used as a 6D traversing unit for the laser illumination system as well as for each of the two cameras. Synchronised movements in the same reference frame are realised through a master-slave setup with a single interface to the user. By integrating the interface into the standard wind tunnel management system, a single measurement plane or a predefined sequence of several planes can be requested through a single trigger event, providing the resulting vector fields within minutes.
In this paper, a brief overview on the demands of large scale industrial PIV and the existing solutions is given. Afterwards, the concept of RoboPIV is introduced as a new approach. In a first step, the usability of a selection of commercially available robot arms is analysed. The challenges of pose uncertainty and importance of absolute accuracy are demonstrated through comparative measurements, explaining the individual pros and cons of the analysed systems. Subsequently, the advantage of integrating RoboPIV directly into the existing wind tunnel management system is shown on basis of a typical measurement sequence. In a final step, a practical measurement procedure, including post-processing, is given by using real data and results. Ultimately, the benefits of high automation are demonstrated, leading to a drastic reduction in necessary measurement time compared to non-automated systems, thus massively increasing the efficiency of PIV measurements.
The production and assembly of customized products increases the demand for flexible automation systems. One approach is to remove the safety fences that separate human and industrial robot to combine their skills. This collaboration possesses a certain risk for the human co-worker, leading to numerous safety concepts to protect him. The human needs to be monitored and tracked by a safety system using different sensors. The proposed system consists of a RGBD camera for surveillance of the common working area, an array of optical distance sensors to compensate shadowing effects of the RGBD camera and a laser range finder to detect the co-worker when approaching the work cell. The software for collision detection, path planning, robot control and predicting the behaviour of the co-worker is based on the Robot Operating System (ROS). A first prototype of the work cell shows that with advanced algorithms from the field of mobile robotics a very flexible safety concept can be realized: the robot not simply stops its movement when detecting a collision, but plans and executes an alternative path around the obstacle.
Transgenic plants have the potential to produce recombinant proteins on an agricultural scale, with yields of several tons per year. The cost-effectiveness of transgenic plants increases if simple cultivation facilities such as greenhouses can be used for production. In such a setting, we expressed a novel affinity ligand based on the fluorescent protein DsRed, which we used as a carrier for the linear epitope ELDKWA from the HIV-neutralizing antibody 2F5. The DsRed-2F5-epitope (DFE) fusion protein was produced in 12 consecutive batches of transgenic tobacco (Nicotiana tabacum) plants over the course of 2 years and was purified using a combination of blanching and immobilized metal-ion affinity chromatography (IMAC). The average purity after IMAC was 57 ± 26% (n = 24) in terms of total soluble protein, but the average yield of pure DFE (12 mg kg−1) showed substantial variation (± 97 mg kg−1, n = 24) which correlated with seasonal changes. Specifically, we found that temperature peaks (>28°C) and intense illuminance (>45 klx h−1) were associated with lower DFE yields after purification, reflecting the loss of the epitope-containing C-terminus in up to 90% of the product. Whereas the weather factors were of limited use to predict product yields of individual harvests conducted for each batch (spaced by 1 week), the average batch yields were well approximated by simple linear regression models using two independent variables for prediction (illuminance and plant age). Interestingly, accumulation levels determined by fluorescence analysis were not affected by weather conditions but positively correlated with plant age, suggesting that the product was still expressed at high levels, but the extreme conditions affected its stability, albeit still preserving the fluorophore function. The efficient production of intact recombinant proteins in plants may therefore require adequate climate control and shading in greenhouses or even cultivation in fully controlled indoor farms.
Selective laser melting of metals: desktop machines open up new chances even for small companies
(2012)
Additive manufacturing (AM) of metal parts by using Selective Laser Melting (SLM) has become a powerful tool mostly in the area of automotive, aerospace engineering and others. Especially in the field of dentistry, jewelry and related branches that require individualized or even one-of-a-kind products, the direct digital manufacturing process opens up new ways of design and manufacturing. In these fields, mostly small and medium sized businesses (SME) are operating which do not have sufficient human and economic resources to invest in this technology. But to stay competitive, the application of AM can be regarded as a necessity. In this situation a new desktop machine (Realizer SLM 50) was introduced that cost about 1/3 of a shop floor SLM machine and promises small quality parts. To find out whether the machine really is an alternative for SMEs the University of Applied Science, Aachen, Germany, designed, build and optimized typical parts from the dentistry and the jewelry branches using CoCr and silver material, the latter being new with this application. The paper describes the SLM procedure and how to find and optimize the most important parameters. The test is accompanied by digital simulation in order to verify the build parameters and to plan future builds. The procedure is shown as well as the resulting parts made from CoCr and silver material.
The aim of this work was to perform a detailed investigation of the use of Selective Laser Melting (SLM) technology to process eutectic silver-copper alloy Ag 28 wt. % Cu (also called AgCu28). The processing occurred with a Realizer SLM 50 desktop machine. The powder analysis (SEM-topography, EDX, particle distribution) was reported as well as the absorption rates for the near-infrared (NIR) spectrum. Microscope imaging showed the surface topography of the manufactured parts. Furthermore, microsections were conducted for the analysis of porosity. The Design of Experiments approach used the response surface method in order to model the statistical relationship between laser power, spot distance and pulse time.