@article{MishurovaCabezaArtztetal.2017, author = {Mishurova, Tatiana and Cabeza, Sandra and Artzt, Katia and Haubrich, Jan and Klaus, Manuela and Genzel, Christoph and Requena, Guillermo and Bruno, Giovanni}, title = {An Assessment of Subsurface Residual Stress Analysis in SLM Ti-6Al-4V}, series = {Materials}, volume = {10}, journal = {Materials}, publisher = {MDPI}, address = {Basel}, issn = {1996-1944}, doi = {10.3390/ma10040348}, pages = {14}, year = {2017}, abstract = {Ti-6Al-4V bridges were additively fabricated by selective laser melting (SLM) under different scanning speed conditions, to compare the effect of process energy density on the residual stress state. Subsurface lattice strain characterization was conducted by means of synchrotron diffraction in energy dispersive mode. High tensile strain gradients were found at the frontal surface for samples in an as-built condition. The geometry of the samples promotes increasing strains towards the pillar of the bridges. We observed that the higher the laser energy density during fabrication, the lower the lattice strains. A relief of lattice strains takes place after heat treatment.}, language = {en} } @article{ThiedeCabezaMishurovaetal.2018, author = {Thiede, Tobias and Cabeza, Sandra and Mishurova, Tatiana and Nadammal, Naresh and Kromm, Arne and Bode, Johannes and Haberland, Christoph and Bruno, Giovanni}, title = {Residual Stress in Selective Laser Melted Inconel 718}, series = {Materials performance and characterization}, volume = {7}, journal = {Materials performance and characterization}, number = {4}, publisher = {American Society for Testing and Materials}, address = {West Conshohocken}, issn = {2379-1365}, doi = {10.1520/MPC20170119}, pages = {717 -- 735}, year = {2018}, abstract = {The residual stress distribution in IN718 elongated prisms produced by selective laser melting was studied by means of neutron (bulk) and laboratory X-ray (surface) diffraction. Two deposition hatch lengths were considered. A horizontal plane near the top surface (perpendicular to the building direction) and a vertical plane near the lateral surface (parallel to the building direction) were investigated. Samples both in as-built (AB) condition and removed from the base plate (RE) were characterized. While surface stress fields seem constant for the AB condition, X-ray diffraction shows stress gradients along the hatch direction in the RE condition. The stress profiles correlate with the distortion maps obtained by tactile probe measurements. Neutron diffraction shows bulk stress gradients for all principal components along the main sample directions. We correlate the observed stress patterns with the hatch length, i.e., with its effect on temperature gradients and heat flow. The bulk stress gradients partially disappear after removal from the base plate.}, language = {en} } @misc{MuellerKupschLaquaietal.2018, author = {M{\"u}ller, Bernd Randolf and Kupsch, Andreas and Laquai, Rene and Nellesen, Jens and Tillmann, Wolfgang and Kasperovich, Galina and Bruno, Giovanni}, title = {Microstructure Characterisation of Advanced Materials via 2D and 3D X-Ray Refraction Techniques}, series = {Materials Science Forum}, volume = {941}, journal = {Materials Science Forum}, publisher = {Trans Tech Publications Ltd}, address = {Zurich}, isbn = {978-3-0357-1208-7}, issn = {0255-5476}, doi = {10.4028/www.scientific.net/MSF.941.2401}, pages = {2401 -- 2406}, year = {2018}, abstract = {3D imaging techniques have an enormous potential to understand the microstructure, its evolution, and its link to mechanical, thermal, and transport properties. In this conference paper we report the use of a powerful, yet not so wide-spread, set of X-ray techniques based on refraction effects. X-ray refraction allows determining internal specific surface (surface per unit volume) in a non-destructive fashion, position and orientation sensitive, and with a nanometric detectability. We demonstrate showcases of ceramics and composite materials, where microstructural parameters could be achieved in a way unrivalled even by high-resolution techniques such as electron microscopy or computed tomography. We present in situ analysis of the damage evolution in an Al/Al2O3 metal matrix composite during tensile load and the identification of void formation (different kinds of defects, particularly unsintered powder hidden in pores, and small inhomogeneity's like cracks) in Ti64 parts produced by selective laser melting using synchrotron X-ray refraction radiography and tomography.}, language = {en} } @phdthesis{Thiede2019, author = {Thiede, Tobias}, title = {A multiscale analysis of additively manufactured lattice structures}, doi = {10.25932/publishup-47041}, url = {http://nbn-resolving.de/urn:nbn:de:kobv:517-opus4-470418}, school = {Universit{\"a}t Potsdam}, pages = {xi, 97, LIII}, year = {2019}, abstract = {Additive Manufacturing (AM) in terms of laser powder-bed fusion (L-PBF) offers new prospects regarding the design of parts and enables therefore the production of lattice structures. These lattice structures shall be implemented in various industrial applications (e.g. gas turbines) for reasons of material savings or cooling channels. However, internal defects, residual stress, and structural deviations from the nominal geometry are unavoidable. In this work, the structural integrity of lattice structures manufactured by means of L-PBF was non-destructively investigated on a multiscale approach. A workflow for quantitative 3D powder analysis in terms of particle size, particle shape, particle porosity, inter-particle distance and packing density was established. Synchrotron computed tomography (CT) was used to correlate the packing density with the particle size and particle shape. It was also observed that at least about 50\% of the powder porosity was released during production of the struts. Struts are the component of lattice structures and were investigated by means of laboratory CT. The focus was on the influence of the build angle on part porosity and surface quality. The surface topography analysis was advanced by the quantitative characterisation of re-entrant surface features. This characterisation was compared with conventional surface parameters showing their complementary information, but also the need for AM specific surface parameters. The mechanical behaviour of the lattice structure was investigated with in-situ CT under compression and successive digital volume correlation (DVC). The deformation was found to be knot-dominated, and therefore the lattice folds unit cell layer wise. The residual stress was determined experimentally for the first time in such lattice structures. Neutron diffraction was used for the non-destructive 3D stress investigation. The principal stress directions and values were determined in dependence of the number of measured directions. While a significant uni-axial stress state was found in the strut, a more hydrostatic stress state was found in the knot. In both cases, strut and knot, seven directions were at least needed to find reliable principal stress directions.}, language = {en} } @article{MishurovaArtztHaubrichetal.2019, author = {Mishurova, Tatiana and Artzt, Katia and Haubrich, Jan and Requena, Guillermo and Bruno, Giovanni}, title = {Exploring the correlation between subsurface residual stresses and manufacturing parameters in laser powder bed fused Ti-6Al-4V}, series = {Metals}, volume = {9}, journal = {Metals}, number = {2}, publisher = {MDPI}, address = {Basel}, issn = {2075-4701}, doi = {10.3390/met9020261}, pages = {13}, year = {2019}, abstract = {Subsurface residual stresses (RS) were investigated in Ti-6Al-4V cuboid samples by means of X-ray synchrotron diffraction. The samples were manufactured by laser powder bed fusion (LPBF) applying different processing parameters, not commonly considered in open literature, in order to assess their influence on RS state. While investigating the effect of process parameters used for the calculation of volumetric energy density (such as laser velocity, laser power and hatch distance), we observed that an increase of energy density led to a decrease of RS, although not to the same extent for every parameter variation. Additionally, the effect of support structure, sample roughness and LPBF machine effects potentially coming from Ar flow were studied. We observed no influence of support structure on subsurface RS while the orientation with respect to Ar flow showed to have an impact on RS. We conclude recommending monitoring such parameters to improve part reliability and reproducibility.}, language = {en} } @article{MishurovaSydowThiedeetal.2020, author = {Mishurova, Tatiana and Sydow, Benjamin and Thiede, Tobias and Sizova, Irina and Ulbricht, Alexander and Bambach, Markus and Bruno, Giovanni}, title = {Residual stress and microstructure of a Ti-6Al-4V Wire Arc Additive Manufacturing hybrid demonstrator}, series = {Metals}, volume = {10}, journal = {Metals}, number = {6}, publisher = {MDPI}, address = {Basel}, issn = {2075-4701}, doi = {10.3390/met10060701}, pages = {15}, year = {2020}, abstract = {Wire Arc Additive Manufacturing (WAAM) features high deposition rates and, thus, allows production of large components that are relevant for aerospace applications. However, a lot of aerospace parts are currently produced by forging or machining alone to ensure fast production and to obtain good mechanical properties; the use of these conventional process routes causes high tooling and material costs. A hybrid approach (a combination of forging and WAAM) allows making production more efficient. In this fashion, further structural or functional features can be built in any direction without using additional tools for every part. By using a combination of forging basic geometries with one tool set and adding the functional features by means of WAAM, the tool costs and material waste can be reduced compared to either completely forged or machined parts. One of the factors influencing the structural integrity of additively manufactured parts are (high) residual stresses, generated during the build process. In this study, the triaxial residual stress profiles in a hybrid WAAM part are reported, as determined by neutron diffraction. The analysis is complemented by microstructural investigations, showing a gradient of microstructure (shape and size of grains) along the part height. The highest residual stresses were found in the transition zone (between WAAM and forged part). The total stress range showed to be lower than expected for WAAM components. This could be explained by the thermal history of the component.}, language = {en} } @phdthesis{Baeckemo2022, author = {B{\"a}ckemo, Johan Dag Valentin}, title = {Digital tools and bioinspiration for the implementation in science and medicine}, doi = {10.25932/publishup-57145}, url = {http://nbn-resolving.de/urn:nbn:de:kobv:517-opus4-571458}, school = {Universit{\"a}t Potsdam}, pages = {xiv, 108}, year = {2022}, abstract = {Diese Doktorarbeit untersucht anhand dreier Beispiele, wie digitale Werkzeuge wie Programmierung, Modellierung, 3D-Konstruktions-Werkzeuge und additive Fertigung in Verbindung mit einer auf Biomimetik basierenden Design\-strategie zu neuen Analysemethoden und Produkten f{\"u}hren k{\"o}nnen, die in Wissenschaft und Medizin Anwendung finden. Das Verfahren der Funkenerosion (EDM) wird h{\"a}ufig angewandt, um harte Metalle zu verformen oder zu formen, die mit normalen Maschinen nur schwer zu bearbeiten sind. In dieser Arbeit wird eine neuartige Kr{\"u}mmungsanalysemethode als Alternative zur Rauheitsanalyse vorgestellt. Um besser zu verstehen, wie sich die Oberfl{\"a}che w{\"a}hrend der Bearbeitungszeit des EDM-Prozesses ver{\"a}ndert, wurde außerdem ein digitales Schlagmodell erstellt, das auf einem urspr{\"u}nglich flachen Substrat Krater auf Erhebungen erzeugte. Es wurde festgestellt, dass ein Substrat bei etwa 10.000 St{\"o}ßen ein Gleichgewicht erreicht. Die vorgeschlagene Kr{\"u}mmungsanalysemethode hat das Potenzial, bei der Entwicklung neuer Zellkultursubstrate f{\"u}r die Stammzellenforschung eingesetzt zu werden. Zwei Arten, die in dieser Arbeit aufgrund ihrer interessanten Mechanismen analysiert wurden, sind die Venusfliegenfalle und der Bandwurm. Die Venusfliegenfalle kann ihr Maul mit einer erstaunlichen Geschwindigkeit schließen. Der Schließmechanismus kann f{\"u}r die Wissenschaft interessant sein und ist ein Beispiel f{\"u}r ein so genanntes mechanisch bi-stabiles System - es gibt zwei stabile Zust{\"a}nde. Der Bandwurm ist bei S{\"a}ugetieren meist im unteren Darm zu finden und heftet sich mit seinen Saugn{\"a}pfen an die Darmw{\"a}nde. Wenn der Bandwurm eine geeignete Stelle gefunden hat, st{\"o}ßt er seine Haken aus und heftet sich dauerhaft an die Wand. Diese Funktion k{\"o}nnte in der minimalinvasiven Medizin genutzt werden, um eine bessere Kontrolle der Implantate w{\"a}hrend des Implantationsprozesses zu erm{\"o}glichen. F{\"u}r beide Projekte wurde ein mathematisches Modell, das so genannte Chained Beam Constraint Model (CBCM), verwendet, um das nichtlineare Biegeverhalten zu modellieren und somit vorherzusagen, welche Strukturen ein mechanisch bi-stabiles Verhalten aufweisen k{\"o}nnten. Daraufhin konnten zwei Prototypen mit einem 3D-Drucker gedruckt und durch Experimente veranschaulicht werden, dass sie beide ein bi-stabiles Verhalten aufweisen. Diese Arbeit verdeutlicht das hohe Anwendungspotenzial f{\"u}r neue Analysenmethoden in der Wissenschaft und f{\"u}r neue Medizinprodukte in der minimalinvasiven Medizin.}, language = {en} } @article{LogesTiberius2022, author = {Loges, Klara and Tiberius, Victor}, title = {Implementation Challenges of 3D Printing in Prosthodontics}, series = {Materials}, volume = {15}, journal = {Materials}, publisher = {MDPI}, address = {Basel}, issn = {1996-1944}, doi = {10.3390/ma15020431}, pages = {10}, year = {2022}, abstract = {The reduction in cost and increasing benefits of 3D printing technologies suggest the potential for printing dental prosthetics. However, although 3D printing technologies seem to be promising, their implementation in practice is complicated. To identify and rank the greatest implementation challenges of 3D printing in dental practices, the present study surveys dentists, dental technicians, and 3D printing companies using a ranking-type Delphi study. Our findings imply that a lack of knowledge is the most crucial obstacle to the implementation of 3D printing technologies. The high training effort of staff and the favoring of conventional methods, such as milling, are ranked as the second and third most relevant factors. Investment costs ranked in seventh place, whereas the lack of manufacturing facilities and the obstacle of print duration ranked below average. An inclusive implementation of additive manufacturing could be achieved primarily through the education of dentists and other staff in dental practices. In this manner, production may be managed internally, and the implementation speed may be increased.}, language = {en} } @misc{LogesTiberius2022, author = {Loges, Klara and Tiberius, Victor}, title = {Implementation Challenges of 3D Printing in Prosthodontics}, series = {Postprints der Universit{\"a}t Potsdam Wirtschafts- und Sozialwissenschaftliche Reihe}, journal = {Postprints der Universit{\"a}t Potsdam Wirtschafts- und Sozialwissenschaftliche Reihe}, doi = {10.25932/publishup-54402}, url = {http://nbn-resolving.de/urn:nbn:de:kobv:517-opus4-544024}, pages = {12}, year = {2022}, abstract = {The reduction in cost and increasing benefits of 3D printing technologies suggest the potential for printing dental prosthetics. However, although 3D printing technologies seem to be promising, their implementation in practice is complicated. To identify and rank the greatest implementation challenges of 3D printing in dental practices, the present study surveys dentists, dental technicians, and 3D printing companies using a ranking-type Delphi study. Our findings imply that a lack of knowledge is the most crucial obstacle to the implementation of 3D printing technologies. The high training effort of staff and the favoring of conventional methods, such as milling, are ranked as the second and third most relevant factors. Investment costs ranked in seventh place, whereas the lack of manufacturing facilities and the obstacle of print duration ranked below average. An inclusive implementation of additive manufacturing could be achieved primarily through the education of dentists and other staff in dental practices. In this manner, production may be managed internally, and the implementation speed may be increased.}, language = {en} } @phdthesis{Schroeder2024, author = {Schr{\"o}der, Jakob}, title = {Fundamentals of diffraction-based residual stress and texture analysis of laser powder bed fused Inconel 718}, doi = {10.25932/publishup-62197}, url = {http://nbn-resolving.de/urn:nbn:de:kobv:517-opus4-621972}, school = {Universit{\"a}t Potsdam}, pages = {XVII, 135}, year = {2024}, abstract = {Additive manufacturing (AM) processes enable the production of metal structures with exceptional design freedom, of which laser powder bed fusion (PBF-LB) is one of the most common. In this process, a laser melts a bed of loose feedstock powder particles layer-by-layer to build a structure with the desired geometry. During fabrication, the repeated melting and rapid, directional solidification create large temperature gradients that generate large thermal stress. This thermal stress can itself lead to cracking or delamination during fabrication. More often, large residual stresses remain in the final part as a footprint of the thermal stress. This residual stress can cause premature distortion or even failure of the part in service. Hence, knowledge of the residual stress field is critical for both process optimization and structural integrity. Diffraction-based techniques allow the non-destructive characterization of the residual stress fields. However, such methods require a good knowledge of the material of interest, as certain assumptions must be made to accurately determine residual stress. First, the measured lattice plane spacings must be converted to lattice strains with the knowledge of a strain-free material state. Second, the measured lattice strains must be related to the macroscopic stress using Hooke's law, which requires knowledge of the stiffness of the material. Since most crystal structures exhibit anisotropic material behavior, the elastic behavior is specific to each lattice plane of the single crystal. Thus, the use of individual lattice planes in monochromatic diffraction residual stress analysis requires knowledge of the lattice plane-specific elastic properties. In addition, knowledge of the microstructure of the material is required for a reliable assessment of residual stress. This work presents a toolbox for reliable diffraction-based residual stress analysis. This is presented for a nickel-based superalloy produced by PBF-LB. First, this work reviews the existing literature in the field of residual stress analysis of laser-based AM using diffraction-based techniques. Second, the elastic and plastic anisotropy of the nickel-based superalloy Inconel 718 produced by PBF-LB is studied using in situ energy dispersive synchrotron X-ray and neutron diffraction techniques. These experiments are complemented by ex situ material characterization techniques. These methods establish the relationship between the microstructure and texture of the material and its elastic and plastic anisotropy. Finally, surface, sub-surface, and bulk residual stress are determined using a texture-based approach. Uncertainties of different methods for obtaining stress-free reference values are discussed. The tensile behavior in the as-built condition is shown to be controlled by texture and cellular sub-grain structure, while in the heat-treated condition the precipitation of strengthening phases and grain morphology dictate the behavior. In fact, the results of this thesis show that the diffraction elastic constants depend on the underlying microstructure, including texture and grain morphology. For columnar microstructures in both as-built and heat-treated conditions, the diffraction elastic constants are best described by the Reuss iso-stress model. Furthermore, the low accumulation of intergranular strains during deformation demonstrates the robustness of using the 311 reflection for the diffraction-based residual stress analysis with columnar textured microstructures. The differences between texture-based and quasi-isotropic approaches for the residual stress analysis are shown to be insignificant in the observed case. However, the analysis of the sub-surface residual stress distributions show, that different scanning strategies result in a change in the orientation of the residual stress tensor. Furthermore, the location of the critical sub-surface tensile residual stress is related to the surface roughness and the microstructure. Finally, recommendations are given for the diffraction-based determination and evaluation of residual stress in textured additively manufactured alloys.}, language = {en} }