Development, manufacturing, characterisation and modelling of lightweight structures prepared by selective laser melting

• Subject Area: Materials in Sintering Processes and Generative Manufacturing Processes ; Mechanical Properties of Metallic Materials and their Microstructural Origins
• Term: since 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 498036830

The objective of the project is to strengthen the research area of lightweight design by acquiring and scientifically developing an L-PBF (Laser-Powder Bed Fusion) system for the near-net-shape manufacturing of metallic structures in powder beds. The embedding of such a facility into the existing infrastructure enables the expansion of the research area and provides additional opportunities for follow-up projects. Consequently, the existing infrastructure for the analysis of the microstructure and mechanical testing can be better utilised within the framework of scientific projects.The project aims on the development and additive manufacturing of stiffness- and strength-optimized lattice plate structures based on the Al-alloy AlSi10Mg. The focus is on lattice topologies that can achieve high specific macroscopic stiffnesses as well as buckling stability of the cell walls and specific strengths for the basic stress types of tension, compression and shear. For this purpose, a thin cell wall thickness of 0.2 to 0.3 mm with as little wall thickness variation as possible is aspired. The analysis of the generated lattice plate structures is performed by CT and SEM. For the mechanical investigations on these structures, cyclic shear tests with a specially developed shear field test facility for pure and homogeneous shear loads are planned in addition to the usual compression tests. The research activities on the basis of the L-PBF system will be carried out at the Competence Center of Lightweight Design (LLK) by bundling the competences from structural and modeling competence, materials competence and design and manufacturing competence. Existing know-how on cellular structures and sandwich structures can be used, whereby lattice plate structures can be produced in a much more reproducible and force-flow-oriented manner. The possibility of additive manufacturing of lightweight structures and components on a metallic basis represents an important prerequisite for the consistent further development of the research area of lightweight design at the Landshut University of Applied Sciences. The device will be made available to other research areas at the university for their scientific activities during the project period.

• DFG Programme: Major Instrumentation Initiatives
• Major Instrumentation: L-PBF Anlage
• Instrumentation Group: 5740 Laser in der Fertigung
• Applicant Institution: Hochschule für angewandte Wissenschaften Landshut
• Leader: Professor Dr.-Ing. Holger Saage
• Co-Investigator: Professor Dr.-Ing. Otto Huber