SPP 2122:  Materials for Additive Manufacturing

• Subject Area: Materials Science and Engineering ; Chemistry ; Mechanical and Industrial Engineering ; Physics ; Thermal Engineering/Process Engineering
• Term: since 2018
• Website: Homepage
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 359962234

Lasers in production are becoming increasingly powerful and brilliant, but the materials available are often completely inadequate for the processing tasks currently required. To date, metal powders are used in additive manufacturing that were developed over 50 years ago for a completely different process - thermal spraying. However, in modern laser-based additive processes, these powders lead to process instabilities, porosities, and defects in the component. In the field of polymer powders, there is also a lack of a wide range of materials. Therefore, there is an urgent need to adapt the materials to these widespread production processes, as laser-based processes will dominate important production processes in the long term due to their throughput and precision. In fact, a fundamental research approach already at the beginning of the process chain, the material, is required. Therefore, there is an urgent need for action to defend and further expand Germany's leading position worldwide in photonics and materials science. A coordinated, coherent research program combining materials development and photonics research for the first time, starting at the materials synthesis stage, should help exploit this considerable potential. To ensure feedback between process behavior and material properties, the SPP will fund tandem projects from the fields of "materials" and "laser process", which will cooperate across projects in thematic clusters. The scientific questions will be formulated across materials and focused on the photonic process of additive laser manufacturing. With this, for the first time, chemical, as well as metallurgical and additive-based modifications, will be developed specifically for photonic production. Such a large-scale interdisciplinary study requires targeted coordination and enables a unique Interlaboratory Study (Round Robin), including Research Data Management. Only by this, is it possible to generate an inter-laboratory scientific exchange, which guarantees reproducibility and statistical robustness.

• DFG Programme: Priority Programmes

Projects

• Contamination tolerant hypo- and hypereutectic Al-Si-alloys for additive manufacturing (Applicants Ellendt, Nils ;  Tönjes, Anastasiya )
• Coordination Funds (Applicant Barcikowski, Stephan )
• Development of a method for carbide additivation on tool steel powders via a functional polymer binder to enhance the processability, microstructural isotropy, and strength of hard ferrous alloys (Applicants Broeckmann, Christoph ;  Pich, Andrij )
• Development of surface tailored metal powders for increased production efficiency at the laser powder-bed fusion additive manufacturing process (Applicants Kwade, Arno ;  Sehrt, Jan T. )
• Disentangled UHMWPE composites for warp-free SLS parts (Applicants Imgrund, Philipp ;  Luinstra, Gerrit A. )
• Dispersion effects of nanocomposites to improve melting and resolidification behavior during PBF-LB/P with near-infrared diode lasers (Applicants Barcikowski, Stephan ;  Schmidt, Michael )
• Eutectic Al alloys with tailored solidification path to probe fundamental aspects of solidification in laser-based AM II (Applicants Apel, Markus ;  Schmidt, Michael )
• Generation of polyethylene powder for the fiber laser based Direct Energy Deposition process: Parametric studies, microstructure and mechanical properties (Applicants Luinstra, Gerrit A. ;  Ostendorf, Andreas )
• High Pressure Spray Process for Polymer Particles applicable for Laser Polymer Deposition (LPD) (Applicants Ostendorf, Andreas ;  Petermann, Marcus )
• Influence of Si3N4 powder additivation on PBF-LB processability of stainless steels and microstructural evolution during PBF-LB and a subsequent HIP-URQ densification process (Applicants Broeckmann, Christoph ;  Weber, Sebastian )
• Inoculation of Aluminium Powders for Additive Manufacturing guided by Differential Fast Scanning Calorimetry (Applicants Keßler, Olaf ;  Schaper, Mirko ;  Zhuravlev, Evgeny )
• Nanoparticle additivation of powders for laser additive manufacturing of oxide-dispersion strengthened steels: a joint experimental and numerical study (Applicants Gökce, Bilal ;  Xu, Bai-Xiang )
• New high stiffness materials for light weight constructions using ultrafast additive manufacturing (Applicants Lippmann, Stephanie ;  Nolte, Stefan )
• Numerical and experimental investigations of dimensionless material parameters in laser additive manufacturing of polymers for accelerated material development and process optimization – Phase 2: Expansion of the application field optimization (Applicants Bierwisch, Claas ;  Rudloff, Johannes )
• Production of SLS particles via liquid-liquid phase separation and precipitation (Applicant Schmidt, Jochen )
• Qualification of new steel-alloying strategies for LAM powders by combined in-situ additivation, agglomeration and in-/post-process treatments (Applicants Fechte-Heinen, Rainer ;  Theisen, Werner ;  Walther, Frank )
• Tailor made Magnesium Alloy for Selective Laser Melting: Material Development and Process Modelling (Applicants Maier, Hans Jürgen ;  Overmeyer, Ludger )

• Spokesperson: Professor Dr.-Ing. Stephan Barcikowski