Results and Conclusions on Metallic Materials Made by AM within the Austrian Leader Project “addmanu”
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The paper provides a selection of manifold results and findings gained within a national research and leader project, called “addmanu”, which has motivated a lot of other researchers and companies to go into this interesting field of metallic additive manufacturing. New material developments, lightweight AM-concepts, hybrids, components having a very complex geometry, production of very small channels, reduction of surface roughness, and the production of a series of parts in high-tech application areas are demonstrated.
KeywordsSelective laser melting (SLM) Addmanu Metallic components Topology optimization Hybrids Advanced applications
Erkenntnisse aus dem nationalen Projekt „addmanu“ über die Additive Fertigung von metallischen Werkstoffen
In diesem Artikel wird ein Auszug der vielfältigen Ergebnisse und Erkenntnisse aus dem nationalen Leader-Projekt „addmanu“ wiedergegeben, die viele Forscher und Unternehmen auch dazu ermuntert haben, in das interessante Gebiet der Additiven Fertigung metallischer Komponenten einzusteigen. Neue Werkstoffentwicklungen, AM-gestützter Leichtbau, Hybridanwendungen, Bauteile mit sehr komplexer Geometrie, die Fertigung von sehr engen Kühlkanälen, Maßnahmen zur Reduktion der Oberflächenrauheit und die Produktion einiger Teile für High-Tech-Anwendungen werden dargestellt.
SchlüsselwörterSelektives Laserschmelzen (SLM) Addmanu Metallische Komponenten Topologieoptimierung Hybride Moderne Anwendungen
In order to foster the market potential and to concentrate on problematic issues of additive manufacturing, an Austrian leader project was established. The project was sponsored by The Austrian Research Promotion Agency (FFG) over a period of three years with more than 20 research partners coming from universities, R&D firms, and industry. In mid 2018, the project called “addmanu” was successfully completed. The project structure covered aspects of design, processing, and applications of components made from metals, polymers, ceramics, and hybrids. In this paper, only metallic systems are considered, with special emphasis on new powder materials, hybrids, topology optimization and joints between dissimilar materials, fabrication of small channels and surface modifications. Regarding potential application fields, demonstrator examples for mechanical engineering, tools for injection moulding, lightweight automotive components, nozzles for aerospace technology, and composites with special properties for satellites are shown. Basics, classifications, process descriptions, economical aspects, and typical applications are not considered in this paper but can be found in the available literature [1, 2, 3, 4, 5, 6, 7, 8, 9, 10].
2 Structure of Leader Project “addmanu”
3 New Metallic Materials and Hybrids Made by SLM
4 Topology and Shape Optimization of AM-Parts
5 AM-Process Development for Metallic Structures
To find out the geometrical process limits of SLM and other AM technologies, special trials were carried out to define the smallest channel diameters and very fine surface structures. The smallest diameter factor to build very fine structures was found to be about 0.3 mm.
6 New SLM-Applications of Metallic Components in Mechanical Engineering
7 Dissemination of the Results
According to the leader project character, a very broad dissemination was aimed for from the beginning on in various forms: in almost 50 presentations at conferences and special events (e. g. Alpbach in August 2017), participation at fairs (e. g. at Rapidtech2017), workshops (e. g. ERFA-round in Leoben), and many publications, some of which are listed below. As far as academia is concerned, three PhD theses and six master’s theses were completed, focussing on metallic components only. Two patents were submitted. Some more information is given on our website www.addmanu.at. In a joint action between ASMET and AIT, a roadmap for additive manufacturing is currently being prepared and will be available 2019. In February 2018, most of the participants of the “addmanu” leader project became members of the newly established Austrian platform “AM Austria” (www.am-austria.com).
It is worth mentioning that, due to this open knowledge transfer to scientists as well as to companies, additive manufacturing has entered into the curricula of Austrian universities and new business areas have been established in Austria. As a rough number, about 20 companies have invested in this new disruptive business field, which demonstrates the overall success of the leader project “addmanu”.
The Austrian FFG leader project “addmanu” with about 20 partners was a great success not only for the participants but also for other interested companies, which could benefit from the knowledge and findings gained. Critical aspects for further use of the disruptive technology of selective laser melting could be clarified and new ideas for more projects could be obtained. The information of the most important findings were spread out in various forms in order to foster further developments in this field.
Finally, we would like to thank the Austrian research funding society FFG for their financial support.
Open access funding provided by Montanuniversität Leoben.
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