| 1. |
- Brueckner, Frank, et al.
(författare)
-
Enhanced manufacturing possibilities using multi-materials in laser metal deposition
- 2018
-
Ingår i: Journal of laser applications. - : American Institute of Physics (AIP). - 1042-346X .- 1938-1387. ; 26:2, s. 10-12
-
Tidskriftsartikel (refereegranskat)abstract
- Additive manufacturing (AM) addresses various benefits as the buildup of complex shaped parts, the possibility of functional integration, reduced lead times or the use of difficult machinable materials compared to conventional manufacturing possibilities. Beside these advantages, the use of more than one material in a component would strongly increase the field of applications in typical AM branches as energy, aerospace, or medical technology. By means of multi-material buildups, cost-intensive alloys could be only used in high-loaded areas of the part, whereas the remaining part could be fabricated with cheaper compositions. The selection of combined materials strongly depends on the requested thermophysical but also mechanical properties. Within this contribution, examples (e.g., used in the turbine business) show how alloys can be arranged to fit together, e.g., in terms of a well-chosen coefficient of thermal expansion. As can be seen in nature, the multi-material usage can be characterized by sharp intersections from one material to the other (e.g., in case of a thin corrosion protection), but also by graded structures enabling a smoother material transition (e.g., in case of dissimilar materials which are joined together without defects). The latter is shown for an example from aerospace within this paper. Another possibility is the simultaneous placement of several materials, e.g., hard carbide particles placed in a more ductile matrix composition. These particles can be varied in size (e.g., TiC versus WC). Also the ratio between carbides and matrix alloy can be adjusted depending on its application. Especially, nozzle-based free form fabrication technologies, e.g., laser metal deposition, enable the utilization of more than one material. Within this contribution, possibilities to feed more than one filler material are demonstrated. In addition, results of multi-material processes are shown. Finally, this work focuses on different (potential) applications, mainly on power generation, but also for medical technology or wear resistant components.
|
|
| 2. |
- Brueckner, Frank, et al.
(författare)
-
Fabrication of metallic multi-material components using Laser Metal Deposition
- 2017
-
Ingår i: Solid Freeform Fabrication 2017. - : The University of Texas at Austin. ; , s. 2530-2538
-
Konferensbidrag (övrigt vetenskapligt/konstnärligt)abstract
- Meanwhile, Laser Metal Deposition (LMD) is a well-known Additive Manufacturing technology used in various industrial branches as energy, tooling or aerospace. It can be used for the fabrication of new components but also repair applications. So far, volume build-ups were mostly carried out with one single material only. However, loading conditions may strongly vary and, hence, the use of more than one material in a component would yield major benefits. By means of multi-material build-ups, cost-intensive alloys could be used in highly-loaded areas of the part, whereas the remaining part could be fabricated with cheaper compositions. The selection of combined materials strongly depends on the requested thermo-physical and mechanical properties. Within this contribution, possibilities of material combinations by LMD and selected examples of beneficial multi-material use are presented.
|
|
| 3. |
- Eberle, Sebastian, et al.
(författare)
-
Additive manufacturing of an AlSi40 mirror coated with electroless nickel for cryogenic space applications
- 2018
-
Ingår i: International Conference on Space Optics—ICSO 2018. - : SPIE - International Society for Optical Engineering.
-
Konferensbidrag (refereegranskat)abstract
- Advanced Manufacturing (AM) has the potential to improve existing technologies and applications in terms of performance, light-weighting and costs. In the context of the SME4ALM initiative, launched by DLR and ESA, the company Kampf Telescope Optics GmbH (KTO) in cooperation with the Fraunhofer Institute for Material and Beam Technology (IWS) have assessed the feasibility of AM to build a high-performance optical mirror for space applications. For the assessment of the AM potentials, a mirror design concept for cryogenic instruments for observations in the IR and NIR range was baselined. In a second step, Nickel-Phosphorus (NiP) was selected as optical coating. The combination of coating and mirror material is a primary design driver for optical performance. Both materials must have a very similar CTE as well as be compliant to modern optical manufacturing (diamond turning, polishing). As a promising candidate for NiP coating the AlSi40 was selected for the mirror structure. The potential advantages of AM for optical mirrors in terms of mechanical performance, cost, and manufacturing time were exploited. The achievement of those objectives was / will be demonstrated by:1. verifying AM material properties and manufacturability of AM mirrors by material sample tests and subcomponent tests2. designing AM mirror demonstrator by structural, thermal, and optical performance analysis3. applying and elaborating AM specific design methods (topology optimization, sandwich structures with internal microstructures, monolithic design, etc.)4. manufacturing, assembling, and testing AM mirror demonstrator to verify manufacturability and optical performance5. comparing optical and mechanical performance of the AM mirror demonstrator to a conventional mirror by numerical analysis to exploit potential advantages of AM
|
|
| 4. |
- Franken, T., et al.
(författare)
-
Analysis of the Water Addition Efficiency on Knock Suppression for Different Octane Ratings
- 2020
-
Ingår i: SAE Technical Papers. - 400 Commonwealth Drive, Warrendale, PA, United States : SAE International. - 0148-7191 .- 2688-3627. ; 2020-April:April
-
Tidskriftsartikel (refereegranskat)abstract
- Water injection can be applied to spark ignited gasoline engines to increase the Knock Limit Spark Advance and improve the thermal efficiency. The Knock Limit Spark Advance potential of 6 °CA to 11 °CA is shown by many research groups for EN228 gasoline fuel using experimental and simulation methods. The influence of water is multi-layered since it reduces the in-cylinder temperature by vaporization and higher heat capacity of the fresh gas, it changes the chemical equilibrium in the end gas and increases the ignition delay and decreases the laminar flame speed. The aim of this work is to extend the analysis of water addition to different octane ratings. The simulation method used for the analysis consists of a detailed reaction scheme for gasoline fuels, the Quasi-Dimensional Stochastic Reactor Model and the Detonation Diagram. The detailed reaction scheme is used to create the dual fuel laminar flame speed and combustion chemistry look-up tables. The Detonation Diagram is used as a novel approach in the Quasi-Dimensional Stochastic Reactor Model to evaluate the auto-ignition characteristic in the end gas and determine if it is a harmless deflagration or developing detonation. First, the Quasi-Dimensional Stochastic Reactor Model is trained for three engine operating points and a RON95 E10 fuel. Its performance is evaluated based on experimental results of a single cylinder research engine. Subsequently, different spark timings and water-fuel ratios are investigated for different Primary Reference Fuels. The results outline that water addition can effectively reduce the strength of auto-ignition in the end gas for different Primary Reference Fuels. Thereby, it can be stated that the reduction of the auto-ignition strength through water addition by 50-80 % water-fuel ratio for high octane number fuels corresponds to the spark timing delay of 6 °CA or an increase of research octane number by 10 points.
|
|
| 5. |
- Franken, Tim, et al.
(författare)
-
Gasoline engine performance simulation of water injection and low-pressure exhaust gas recirculation using tabulated chemistry
- 2020
-
Ingår i: International Journal of Engine Research. - : SAGE Publications. - 1468-0874 .- 2041-3149. ; 21:10, s. 1857-1877
-
Tidskriftsartikel (refereegranskat)abstract
- This work presents the assessment of direct water injection in spark-ignition engines using single cylinder experiments and tabulated chemistry-based simulations. In addition, direct water injection is compared with cooled low-pressure exhaust gas recirculation at full load operation. The analysis of the two knock suppressing and exhaust gas cooling methods is performed using the quasi-dimensional stochastic reactor model with a novel dual fuel tabulated chemistry model. To evaluate the characteristics of the autoignition in the end gas, the detonation diagram developed by Bradley and co-workers is applied. The single cylinder experiments with direct water injection outline the decreasing carbon monoxide emissions with increasing water content, while the nitrogen oxide emissions indicate only a minor decrease. The simulation results show that the engine can be operated at lambda = 1 at full load using water-fuel ratios of up to 60% or cooled low-pressure exhaust gas recirculation rates of up to 30%. Both technologies enable the reduction of the knock probability and the decrease in the catalyst inlet temperature to protect the aftertreatment system components. The strongest exhaust temperature reduction is found with cooled low-pressure exhaust gas recirculation. With stoichiometric air-fuel ratio and water injection, the indicated efficiency is improved to 40% and the carbon monoxide emissions are reduced. The nitrogen oxide concentrations are increased compared to the fuel-rich base operating conditions and the nitrogen oxide emissions decrease with higher water content. With stoichiometric air-fuel ratio and exhaust gas recirculation, the indicated efficiency is improved to 43% and the carbon monoxide emissions are decreased. Increasing the exhaust gas recirculation rate to 30% drops the nitrogen oxide emissions below the concentrations of the fuel-rich base operating conditions.
|
|
| 6. |
- Franken, T., et al.
(författare)
-
Multi-objective optimization of water injection in spark-ignition engines using the stochastic reactor model with tabulated chemistry
- 2019
-
Ingår i: International Journal of Engine Research. - : SAGE Publications. - 1468-0874 .- 2041-3149. ; 20:10, s. 1089-1100
-
Tidskriftsartikel (refereegranskat)abstract
- Water injection is investigated for turbocharged spark-ignition engines to reduce knock probability and enable higher engine efficiency. The novel approach of this work is the development of a simulation-based optimization process combining the advantages of detailed chemistry, the stochastic reactor model and genetic optimization to assess water injection. The fast running quasi-dimensional stochastic reactor model with tabulated chemistry accounts for water effects on laminar flame speed and combustion chemistry. The stochastic reactor model is coupled with the Non-dominated Sorting Genetic Algorithm to find an optimum set of operating conditions for high engine efficiency. Subsequently, the feasibility of the simulation-based optimization process is tested for a three-dimensional computational fluid dynamic numerical test case. The newly proposed optimization method predicts a trade-off between fuel efficiency and low knock probability, which highlights the present target conflict for spark-ignition engine development. Overall, the optimization shows that water injection is beneficial to decrease fuel consumption and knock probability at the same time. The application of the fast running quasi-dimensional stochastic reactor model allows to run large optimization problems with low computational costs. The incorporation with the Non-dominated Sorting Genetic Algorithm shows a well-performing multi-objective optimization and an optimized set of engine operating parameters with water injection and high compression ratio is found.
|
|
| 7. |
- Haack, Maximilian, et al.
(författare)
-
Comprehensive study on the formation of grain boundary serrations in additively manufactured Haynes 230 alloy
- 2020
-
Ingår i: Materials Characterization. - : Elsevier. - 1044-5803 .- 1873-4189. ; 160
-
Tidskriftsartikel (refereegranskat)abstract
- Recently, grain boundary serrations have been introduced in conventionally processed Haynes 230 through a slow-cooling heat treatment. The aim of this work was to utilize these heat treatments to introduce serrations in additively manufactured (Laser Metal Deposition) Haynes 230. Contrary to expectations, serrations already formed during the fast-cooling of the Laser Metal Deposition process. Electron Backscatter Diffraction was used to elucidate the underlying phenomenon for the emergence of serrations during fast-cooling. As a result, a hypothesis regarding a new mechanism responsible for the formation of grain boundary serrations was formulated. Additionally, specific characteristics of the Laser Metal Deposition process have been identified. This includes a columnar-to-equiaxed transition (CET) for slower feed rates, leading to smaller grains despite lower cooling rates; the observation of an abrupt increase in grain growth for a raised solution annealing temperature; the fact that serrations hinder uncontrolled grain growth and finally that the LMD-process leads to a finer carbide morphology compared to conventional manufacturing methods, potentially leading to an increased precipitation strengthening effect.
|
|
| 8. |
- Hans, Andreas, et al.
(författare)
-
Optical Fluorescence Detected from X-ray Irradiated Liquid Water
- 2017
-
Ingår i: Journal of Physical Chemistry B. - : American Chemical Society (ACS). - 1520-6106 .- 1520-5207. ; 121:10, s. 2326-2330
-
Tidskriftsartikel (refereegranskat)abstract
- Despite its importance, the structure and dynamics of liquid water are still poorly understood in many apsects. Here, we report on the observation of optical fluorescence upon soft X-ray irradiation of liquid water. Detection of spectrally resolved fluorescence was achieved by a combination of the liquid microjet technique and fluorescence spectroscopy. We observe a genuine liquid-phase fluorescence manifested by a broad emission band in the 170-340 nm (4-7 eV) photon wavelength range. In addition, another narrower emission near 300 nm can be assigned to the fluorescence of OH (A state) in the gas phase, the emitting species being formed by Auger electrons escaping from liquid water. We argue that the newly observed broad-band emission of liquid water is relevant in search of extraterrestrial life, and we also envision the observed electron-ejection mechanism to find application for exploring solutes at liquid vapor interfaces.
|
|
| 9. |
- Hans, Andreas, et al.
(författare)
-
Soft X-ray induced ultraviolet fluorescence emission from bulk and interface of a liquid water microjet
- 2017
-
Ingår i: Journal of Physics, Conference Series. - : Institute of Physics Publishing (IOPP). - 1742-6588 .- 1742-6596. ; 875
-
Tidskriftsartikel (refereegranskat)abstract
- Tremendous progress has been made in the research on the structure and dynamics of liquids due to the development of advanced experimental techniques such as liquid microjets, enabling investigations on volatile samples in ultrahigh vacuum environments. The spectroscopy of charged particles, e.g. photoelectron or Auger electron spectroscopy on liquids, is an established field by now. Here, we report on the successful application of a fluorescence spectrometer to measure optical emission spectra from liquids irradiated with soft X-ray synchrotron radiation.
|
|
| 10. |
- Lopez, Elena, et al.
(författare)
-
Evaluation of 3D-printed parts by means of high-performance computer tomography
- 2018
-
Ingår i: Journal of laser applications. - : American Institute of Physics (AIP). - 1042-346X .- 1938-1387. ; 30:3
-
Tidskriftsartikel (refereegranskat)abstract
- Conventional tactile and optical testing methods are not capable to detect complex inner geometries or complex surface shapes. Detecting porosities in parts is also not possible with those nondestructive methods. Among other material parameters, geometrical accuracy is essential to determine part's quality. Additive manufacturing processes also have to be optimized regarding geometry deviations caused by distortion or unfavorable orientation in the build chamber. For additive manufactured parts that incorporate previously mentioned features, high-performance computer tomography is the more suitable nondestructive testing method. Components of different materials such as plastics, ceramics, composites, or metals can be completely characterized. This nondestructive testing method was used for porosity analysis regarding the shape and local distribution of pores in an additive manufactured part to find correlations concerning the most suitable process conditions. The measured part data were also compared to original CAD files to determine zones of deviation and apply specific process strategies to avoid distortion. This paper discusses the results of integrating high-performance computer tomography (power: 500 W, max. part size: Ø 300 mm, 300 × 430 mm2) in a productionlike environment of additively manufactured parts for a wide range of technologies (i.e., electron beam melting and selective laser melting). I. INTRODUCTION
|
|
