| 1. |
- Eberle, Sebastian, et al.
(författare)
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Additive manufacturing of an AlSi40 mirror coated with electroless nickel for cryogenic space applications
- 2018
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Ingår i: International Conference on Space Optics—ICSO 2018. - : SPIE - International Society for Optical Engineering.
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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
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| 2. |
- Willner, Robin, et al.
(författare)
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Potential and challenges of additive manufacturing for topology optimized spacecraft structures
- 2020
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Ingår i: Journal of laser applications. - : American Institute of Physics (AIP). - 1042-346X .- 1938-1387. ; 32:3
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Tidskriftsartikel (refereegranskat)abstract
- This study focused on the potential of topology optimization (TO) for metallic tertiary structures of spacecrafts produced by the additive manufacturing (AM) technique laser powder bed fusion. First, a screening of existing conventionally manufactured products was carried out to evaluate the benefits of a redesign concerning product performance and the associated economic impact. As a result of the study, the most suitable demonstrator was selected. This reference structure was redesigned by TO taking into consideration the AM process constraints. Another major aim of this work was to evaluate the possibilities and challenges of AM (accuracies, surface quality, process parameters, postmachining, and mechanical properties) in addition to the redesign process. A comprehensive approach was implemented including detailed analysis of the powder, mechanical properties, in-process parameters, and nondestructive inspection (NDI). All measured values were used for a back loop to the design process, thereby providing a final robust redesign. Finally, the fine-tuned demonstrator was built up in an iterative process. The parts were tested under representative conditions for the application to verify the performance. The demonstrator qualification test campaign contained thermal cycling, vibration testing, static load testing, and NDI. Thus, an improvement in technology readiness level up to "near flight qualified" was reached.
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| 3. |
- Brandau, Benedikt, et al.
(författare)
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Absorbance study of powder conditions for laser additive manufacturing
- 2022
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Ingår i: Materials & design. - : Elsevier. - 0264-1275 .- 1873-4197. ; 216
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Tidskriftsartikel (refereegranskat)abstract
- Absorbance is often used for simulations or validation of process parameters for powder-based laser materials processing. In this work, the absorbance of 39 metal powders for additive manufacturing is determined at 20 laser wavelengths. Different grain sizes and aging states for: steels, aluminum alloys, titanium alloys, Nitinol, high entropy alloy, chromium, copper, brass and iron ore were analyzed. For this purpose, the absorbance spectrum of the powders was determined via a dual-beam spectrometer in the range of λ = 330 - 1560 nm. At the laser wavelengths of λ = 450 nm, 633 nm and 650 nm, the absorbance averaged over all materials was found to increase by a factor of 2.4 up to 3.3 compared to the usual wavelength of λ = 1070 nm, with minimal variations in absorbance between materials. In the investigation of the aged or used powders, a loss of absorbance was detectable. Almost no changes from the point of view of processing aged and new AlSi10Mg powders, is expected for laser sources with λ = 450 nm. The resulting measurements provide a good basis for process parameters for a variety of laser wavelengths and materials, as well as a data set for improved absorbance simulations.
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| 4. |
- Fedina, Tatiana, et al.
(författare)
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Laser-assisted reduction of iron ore using aluminum powder
- 2023
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Ingår i: Journal of laser applications. - : American Institute of Physics (AIP). - 1042-346X .- 1938-1387. ; 35:2
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Tidskriftsartikel (refereegranskat)abstract
- This study reports on the laser-assisted reduction of iron ore waste using Al powder as areducing agent. Due to climate change and the global warming situation, it has become ofparamount importance to search for and/or develop green and sustainable processes for ironand steel production. In this regard, a new method for iron ore utilization is proposed in thiswork, investigating the possibility of iron ore waste reduction via metallothermic reaction withAl powder. Laser processing of iron ore fines was performed, focusing on the Fe2O3-Alinteraction behavior and extent of the iron ore reduction. The reaction between the materialsproceeded in a rather intense uncontrolled manner which led to a formation of Fe-rich domainsand alumina as two separate phases. In addition, a combination of Al2O3 and Fe2O3 melts aswell as transitional areas such as intermetallics were observed, suggesting the occurrence ofincomplete reduction reaction in isolated regions. The reduced iron droplets were prone toacquire a sphere-like shape and concentrated mainly near the surface of the Al2O3 melt or at theinterface with the iron oxide. Both SEM, EDS and WDS analyses were employed to analyzechemical composition, microstructure and morphological appearances of the reaction products.High-speed imaging was used to study the process phenomena and observe differences in themovement behavior of the particles. Furthermore, the measurements acquired from X-raycomputed microtomography revealed that approximately 2.4 % of iron was reduced during thelaser processing of Fe2O3-Al powder bed, most likely due to insufficient reaction time orinappropriate equivalence ratio of the two components.
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