Additive Manufacturing Microstructure on Demand

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How can components be manufactured in such a way that their internal structure specifically matches their subsequent function? The international ICON research project Ultra Grain of the Fraunhofer-Gesellschaft with Australian partners has shown that microstructures can be specifically and locally adjusted during laser-based deposition welding.

The project shows a practicable way to no longer leave microstructures to the process, but to adjust them where strength, service life or resilience are crucial. The Fraunhofer Institute for Material and Beam Technology IWS, the Fraunhofer Institute for Additive Production Technologies IAPT and RMIT University in Melbourne were involved in the project, which opens up new scope for industrial users in the design of additively manufactured metal components. Prof. Christoph Leyens, Director of the Fraunhofer IWS, explains: "Ultra Grain shows how we at the Fraunhofer IWS consistently develop new manufacturing technologies from the idea to industrial application. The results are scientifically highly interesting and form an excellent basis for future industrial transfer."

Reduction of the Grain Size By Up to 75 Percent

Initially, Ultra Grain used ultrasound to influence grain formation in the melt pool. In the course of the project, the consortium made a clear technological leap forward: the ultrasonic approach was replaced by pulsed, laser-induced excitation of the melt pool. This solution works without contact, is independent of the component geometry and meets the requirements of industrial production environments. pulse laser-induced direct weld pool excitation can be integrated into existing systems for laser-based deposition welding (DED-LB). Unlike the ultrasonic method, the pulsed laser can also be used to produce complex component geometries. In demonstrator components, the project achieved a reduction in grain size of up to 75 percent. This makes it possible for the first time to create microstructurally and functionally optimized zones directly during the manufacturing process. "We deliberately opted for a solution that works industrially," explains Jacob-Florian Mätje, main contact person for the project and research associate at the Fraunhofer IWS. "Laser-based excitation makes it possible to adjust microstructures specifically where they make a real difference to the component function."

A key unique selling point of Ultra Grain is the close integration of laser process, simulation, design methodology and material development. The Fraunhofer IWS integrated the pulse laser-induced melt pool excitation into real DED-LB systems and validated the technology under industrial conditions. Fraunhofer IAPT developed methods for segmentation, path planning and parameter assignment for components with locally varying microstructures. RMIT University complemented the project with multi-scale modelling, simulation-based process design and optimization concepts in the sense of integrated computational materials engineering.The results of Ultra Grain are relevant for industries with high demands on the mechanical properties and service life of components. These include mechanical engineering, aerospace, energy technology, turbomachinery, the automotive industry and tool and mold making. Companies benefit from components whose microstructure is specifically adapted to load and function. This reduces the amount of material used, increases the service life and improves the overall property profile of the component. Ultra Grain has shown that this structure can be adjusted during construction.

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