Innovative Lasertechnik für hohe PBF-Effizienz und kosteneffiziente Produktion in der Additiven Fertigung/Innovative Laser Techniques for High PBF Efficiency and Cost-Effective Productionin Additive Manufacturing

Institut

Professur für Laserbasierte Additive Fertigung

Typ

Bachelorarbeit / Masterarbeit /

Inhalt

 

Beschreibung

(English is bellow)

German:

Motivation: The research team of the Professorship for Laser-Based Additive Manufacturing (LBAM) is working on novel and innovative concepts for additive manufacturing processes, in particular powder bed-based laser beam melting of metals (PBF-LB/M). Due to their versatility, these processes offer extensive application possibilities in aerospace, medical technology and robotics.

Aim of the Master Thesis Project: The aim of this master thesis is to increase the productivity of the PBF-LB/M process and to achieve microstructural properties that can compete with conventional cast components. The state of the art primarily shows the use of single lasers, which is why novel technologies such as beam shaping and beam splitting are to be used to increase productivity. The project aims in particular to investigate the application of laser beam splitting to increase the build-up rate of the PBF process. The distribution of the laser power over several spots is to be optimized for effective melting and solidification in order to achieve a fine microstructure with minimal defect densities. These specifications are to be achieved by controlling the cooling rate and the solidification processes as well as controlling the laser-smoke interaction. In addition, the grain structure will be adjusted as part of the project so that the material behavior is as isotropic as possible and the components produced have high mechanical strength and a specified fatigue resistance. Material characterization, including observation of phase precipitation and texture characteristics, can be performed using metallographic analyses such as scanning electron microscopy (SEM/electron backscatter diffraction (EBSD)). The results of the beam splitting method and the single laser will be compared. A potential outlook for saving material, energy and possible post-processing steps resulting from the new application will be evaluated. By achieving these goals, the project will help establish an economically viable AM ​​process that is able to replace conventional cast components and thus promote progress in high-performance industries such as aerospace.

The Master Thesis project is divided into the following work packages: 

WP1: Conducting a literature review on PBF-LB/M of the IN718 alloy, solidification process in PBF-LB/M, laser beam modifications in PBF-LB/M processes and adaptation of microstructure and mechanical properties

WP2: Experimental investigation of the effect of laser beam splitting on the melt pool shape and the resulting microstructure including the effect of defect density and the influence of laser-smoke interaction.

WP3: Testing of the mechanical properties of the manufactured samples to ensure the required standards.

WP4: Comprehensive documentation and presentation of research results.

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English:

Motivation: The research team at the Professorship of Laser based Additive Manufacturing (LBAM) focuses on novel and innovative concepts for additive manufacturing processes, particularly laser and powder bed-based melting of metals. These processes offer extensive applications in aerospace, medical technology, and robotics due to their versatility.

Goal of the Master Thesis Project: The goal of this master thesis project is to significantly enhance the productivity of the Powder Bed Fusion (PBF) process while achieving microstructural properties similar to those obtained with single-spot laser printing. This is crucial for making the technology more economically viable and competitive with traditional casting methods. Specifically, the project aims to develop a laser beam splitting technique to increase the build rate of the PBF process, optimize the distribution of laser power among multiple spots for effective melting and solidification, and achieve a fine microstructure with minimal defects by managing cooling rates and solidification processes. Additionally, the project will tailor the grain structure to minimize columnar grain growth, ensure the produced components exhibit high mechanical strength and fatigue resistance, and compare the mechanical properties of parts produced with laser beam splitting to those produced with a single-spot laser. The project will involve analyzing the effect of the beam splitting technique on the material properties, including the cooling rate, phase distribution, and microstructure, and will utilize advanced material characterization techniques such as Electron Backscatter Diffraction (EBSD). Finally, the project will evaluate the economic benefits of using the enhanced PBF process compared to traditional casting, considering material savings, energy efficiency, and potential reduction in post-processing steps. By achieving these goals, the project will contribute to establishing a economically viable AM ​​process capable of substituting traditional cast components, supporting advancements in high performance industries such as aerospace. 

The Master Thesis Project is divided into the following work packages:

WP1: Conducting a literature review on PBF LB/M of IN718 alloy, solidification process in PBF-LB/M, laser beam modifications in PBF LB/M processes and tailoring microstructure and mechanical properties

WP2: Experimentally study the effect of using laser beam splitting on the cooling rate and resulting microstructure.

WP3: Test the mechanical properties of printed samples to ensure they meet the desired standards.

WP4: Document and present the research results comprehensively.

Voraussetzungen

(English is bellow)

German: 

Requirements :

- Strong knowledge of materials science with basic knowledge of material properties such as microstructure characteristics (solidification behaviour, grain growth, phase precipitation, texture characteristics) in metal alloys, especially IN718

- Basic understanding of material characterization methods such as EBSD and XRD desired

- Good data analysis skills

- Interest in additive manufacturing

 

Please send your application with a short letter of motivation and a current certificate to:

Contact person: Josip Vincic, Ph.D.

josip.vincic@tum.de

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English:

Requirements:

- Strong background in material science with basic understanding on material properties such phase, solidification process in metal alloys specially IN718

- Basic understanding of material characterization method such as EBSD and XRD

- Good data analysis skills

- Interest in Additive Manufacturing

 

Please send your application with a short letter of motivation and current transcript of records to:

Contact Person: Josip Vincic, Ph.D.

josip.vincic@tum.de

Möglicher Beginn

sofort/immediately

Kontakt

Josip Vincic
Raum: B2.2.12
Tel.: +49 89 289 55351
josip.vincictum.de

Ausschreibung