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This is what is meant by the "fourth dimension" in 3D printing

The possibility of integrating completely new material properties into the microstructure of materials in additive manufacturing, beyond the virtually freely selectable three-dimensional shape, is also referred to in the professional world as the fourth dimension in 3D printing. In the next five years, with the ERC Starting Grant "HeteroGenius4D," Haase intends to investigate this additional dimension. "The difficulty," he says, "is that the number of parameters that can be changed is very high. "The space of chemical compositions that can be worked with is extremely broad—even when limited to metallic materials," Haase explains. In addition, there are process parameters, such as the properties and guidance of the laser beam. So, there is a jungle of possible combinations from which the optimum must be identified.

Results through experiment plus material simulation

To tackle this challenge, Haase relies on computer simulations of new materials to predict their properties. "But this only works if the simulations are built on a solid data basis," says Haase. Therefore, the researchers also conduct so-called high-throughput experiments, in which sample bodies are created at high speed using laser deposition welding. Sample bodies are automatically measured for hardness and electron microscopy images are taken. "In the end, you have whole maps showing how the material properties depend on the chemical composition and, for example, the laser power. "On these maps, simulation programs can then conduct a refined search for the precisely desired material properties for a specific application," explains Haase.

These industries benefit from the insights

3D printing is traditionally used in industries where complex workpieces are needed in small quantities, the researchers further explain. This can include casting molds and specialized tools in production facilities, in the semiconductor industry, but also in aerospace. Additive manufacturing will also play a helpful role in the energy transition, as demonstrated by a research project conducted in the field of mobility. The project focused on high-strength aluminum alloys, aiming to replace the expensive and geopolitically critical element scandium. Using the combined approach of experiment and simulation, Haase's team identified the more affordable element zirconium as a substitute, which showed better properties in the alloy and also saved weight. Additionally, in the hot areas of gas turbines—whether in airplanes or for converting natural gas or hydrogen into electricity—3D printing can offer significant advantages. New geometries can enable entirely different cooling systems integrated into the turbine.

The new professorships at TU Berlin are funded by the State of Berlin with 1.5 million euros annually. The Werner-von-Siemens Centre for Industry and Science e.V. is supported within the framework of the joint task "Improvement of the regional economic structure" (GRW) with federal and state funds. The projects are co-financed by the European Regional Development Fund (ERDF).