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Matthias Schmitt
Department of Processing Technologies, Fraunhofer Institute for Casting, Composite and Processing Technology IGCV, 86159 Augsburg, Germany

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Journal article
Published: 09 August 2021 in Applied Sciences
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Through its unique characteristics, additive manufacturing yields great potential for designing fluid components with increased performance characteristics. These potentials in advanced design, functional structure, and manufacturing are not easily realized. Therefore, the present study proposes a holistic development methodology for fluid components with a specific focus on hydraulic manifolds. The methodology aims to lead the designer from the specification of the task, through a step-by-step embodied design, to a technical and economic evaluation of the optimized, first-time manufactured part. A case study applies the proposed methodology to a part of a rail-vehicle braking application. Through its application, a significant reduction in weight, size, as well as significant contributions to the company’s AM strategy can be assigned to the part. At the same time, increased direct manufacturing costs are identified. Based on the increased performance characteristics of the resulting design and the holistic foundation of the subsequent economic decisions, a satisfying efficiency can be allocated to the proposed methodology.

ACS Style

Nicolas Rolinck; Matthias Schmitt; Matthias Schneck; Georg Schlick; Johannes Schilp. Development Workflow for Manifolds and Fluid Components Based on Laser Powder Bed Fusion. Applied Sciences 2021, 11, 7335 .

AMA Style

Nicolas Rolinck, Matthias Schmitt, Matthias Schneck, Georg Schlick, Johannes Schilp. Development Workflow for Manifolds and Fluid Components Based on Laser Powder Bed Fusion. Applied Sciences. 2021; 11 (16):7335.

Chicago/Turabian Style

Nicolas Rolinck; Matthias Schmitt; Matthias Schneck; Georg Schlick; Johannes Schilp. 2021. "Development Workflow for Manifolds and Fluid Components Based on Laser Powder Bed Fusion." Applied Sciences 11, no. 16: 7335.

Journal article
Published: 31 May 2021 in Metals
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The carbon content of steel affects many of its essential properties, e.g., hardness and mechanical strength. In the powder bed fusion process of metals using a laser beam (PBF-LB/M), usually, pre-alloyed metal powder is solidified layer-by-layer using a laser beam to create parts. A reduction of the carbon content in steels is observed during this process. This study examines adding carbon particles to the metal powder and in situ alloying in the PBF-LB/M process as a countermeasure. Suitable carbon particles are selected and their effect on the particle size distribution and homogeneity of the mixtures is analysed. The workability in PBF-LB is then shown. This is followed by an evaluation of the resulting mechanical properties (hardness and mechanical strength) and microstructure in the as-built state and the state after heat treatment. Furthermore, potential use cases like multi-material or functionally graded parts are discussed.

ACS Style

Matthias Schmitt; Albin Gottwalt; Jakob Winkler; Thomas Tobie; Georg Schlick; Karsten Stahl; Ulrich Tetzlaff; Johannes Schilp; Gunther Reinhart. Carbon Particle In-Situ Alloying of the Case-Hardening Steel 16MnCr5 in Laser Powder Bed Fusion. Metals 2021, 11, 896 .

AMA Style

Matthias Schmitt, Albin Gottwalt, Jakob Winkler, Thomas Tobie, Georg Schlick, Karsten Stahl, Ulrich Tetzlaff, Johannes Schilp, Gunther Reinhart. Carbon Particle In-Situ Alloying of the Case-Hardening Steel 16MnCr5 in Laser Powder Bed Fusion. Metals. 2021; 11 (6):896.

Chicago/Turabian Style

Matthias Schmitt; Albin Gottwalt; Jakob Winkler; Thomas Tobie; Georg Schlick; Karsten Stahl; Ulrich Tetzlaff; Johannes Schilp; Gunther Reinhart. 2021. "Carbon Particle In-Situ Alloying of the Case-Hardening Steel 16MnCr5 in Laser Powder Bed Fusion." Metals 11, no. 6: 896.

Journal article
Published: 22 September 2020 in Procedia CIRP
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Additive manufacturing, especially laser powder bed fusion (LPBF), allows the build-up of complex parts and is, therefore, used in various industries. In order to exploit the potential in the automotive industry, the range of materials must be extended to include case-hardening steels, which are used in drivetrain parts. This paper examines the distortion of samples manufactured of the case-hardening steel 16MnCr5 (1.7131) via LPBF at varied baseplate temperatures and shielding gases, and also closely evaluates the resulting microstructure and hardness. Depending on the baseplate temperature, tempering or stress-relief annealing effects can be observed. For further insights into the process chain, dependencies between case hardening properties and manufacturing parameters are described.

ACS Style

Matthias Schmitt; Bernhard Kempter; Syed Inayathulla; Albin Gottwalt; Max Horn; Maximilian Binder; Jakob Winkler; Georg Schlick; Thomas Tobie; Karsten Stahl; Gunther Reinhart. Influence of Baseplate Heating and Shielding Gas on Distortion, Mechanical and Case hardening Properties of 16MnCr5 fabricated by Laser Powder Bed Fusion. Procedia CIRP 2020, 93, 581 -586.

AMA Style

Matthias Schmitt, Bernhard Kempter, Syed Inayathulla, Albin Gottwalt, Max Horn, Maximilian Binder, Jakob Winkler, Georg Schlick, Thomas Tobie, Karsten Stahl, Gunther Reinhart. Influence of Baseplate Heating and Shielding Gas on Distortion, Mechanical and Case hardening Properties of 16MnCr5 fabricated by Laser Powder Bed Fusion. Procedia CIRP. 2020; 93 ():581-586.

Chicago/Turabian Style

Matthias Schmitt; Bernhard Kempter; Syed Inayathulla; Albin Gottwalt; Max Horn; Maximilian Binder; Jakob Winkler; Georg Schlick; Thomas Tobie; Karsten Stahl; Gunther Reinhart. 2020. "Influence of Baseplate Heating and Shielding Gas on Distortion, Mechanical and Case hardening Properties of 16MnCr5 fabricated by Laser Powder Bed Fusion." Procedia CIRP 93, no. : 581-586.

Journal article
Published: 15 September 2020 in Procedia CIRP
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Additive manufacturing, especially laser powder bed fusion (LPBF), enables the build-up of complex parts. LPBF is a technology with high geometric degrees of freedom, but there are production restrictions, e.g. with regard to overhangs. One strategy to produce these components despite the restrictions is the use of support structures. Parameter determination for support structures is strongly neglected in contrast to component parameters. In this paper, a methodology for determining parameters for support structures is presented. Test geometries for the determination of mechanical properties (tensile and torsional properties) are developed. Subsequently, the influence of the manufacturing parameters (e.g. laser power) on the properties of the widely used lattice support are determined for the case-hardening steel 16MnCr5. It can be shown that shear and tensile strength of the support structures are influenced by the applied manufacturing parameters. Furthermore, the influence of geometrical parameters such as grid spacing and perforation on the tensile strength is investigated.

ACS Style

Matthias Schmitt; Bernhard Kempter; Georg Schlick; Gunther Reinhart. Parameter identification approach for support structures in laser powder bed fusion and analysis of influencing factors. Procedia CIRP 2020, 94, 260 -265.

AMA Style

Matthias Schmitt, Bernhard Kempter, Georg Schlick, Gunther Reinhart. Parameter identification approach for support structures in laser powder bed fusion and analysis of influencing factors. Procedia CIRP. 2020; 94 ():260-265.

Chicago/Turabian Style

Matthias Schmitt; Bernhard Kempter; Georg Schlick; Gunther Reinhart. 2020. "Parameter identification approach for support structures in laser powder bed fusion and analysis of influencing factors." Procedia CIRP 94, no. : 260-265.

Journal article
Published: 16 June 2020 in Additive Manufacturing
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Laser-based Powder Bed Fusion (LPBF) has evolved to a manufacturing technology for prototype and small scale production of gears. The case hardening steel 16MnCr5 is typically used and its material properties are well known and understood. However, the resulting material properties following the post-LPBF process sequence such as residual stress annealing, case hardening and hard finishing are widely unknown. This paper presents a study of processing 16MnCr5 with an EOS M270 LPBF-machine reaching 99.5 % relative density and above. The resulting microstructure and hardness of the material is examined. Furthermore, the tensile strength as well as the gear-specific tooth root carrying capacity are studied. The results are compared to a conventionally processed material via continuous casting. It is shown that residual stress annealing widely compensates material anisotropy following the LPBF process. Material hardness in the as-built condition is increased up to 21 % compared to a conventional material. The case hardening behavior shows a difference in the resulting case hardening depth in comparison to conventional material. The residual stresses measured at the surface after the case hardening show compressive stresses. Pulsator tests deliver a stress-cycle (S-N) curve from which the tooth root carrying capacity can be derived.

ACS Style

Matthias Schmitt; Tobias Kamps; Felix Siglmüller; Karl Jakob Winkler; Georg Schlick; Christian Seidel; Thomas Tobie; Karsten Stahl; Gunther Reinhart. Laser-based powder bed fusion of 16MnCr5 and resulting material properties. Additive Manufacturing 2020, 35, 101372 .

AMA Style

Matthias Schmitt, Tobias Kamps, Felix Siglmüller, Karl Jakob Winkler, Georg Schlick, Christian Seidel, Thomas Tobie, Karsten Stahl, Gunther Reinhart. Laser-based powder bed fusion of 16MnCr5 and resulting material properties. Additive Manufacturing. 2020; 35 ():101372.

Chicago/Turabian Style

Matthias Schmitt; Tobias Kamps; Felix Siglmüller; Karl Jakob Winkler; Georg Schlick; Christian Seidel; Thomas Tobie; Karsten Stahl; Gunther Reinhart. 2020. "Laser-based powder bed fusion of 16MnCr5 and resulting material properties." Additive Manufacturing 35, no. : 101372.

Journal article
Published: 13 June 2020 in Procedia CIRP
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Additive manufacturing gives new freedom to part design by enabling the manufacturing of complex structures. Mastering this degree of freedom poses challenges for product developers with experience from conventional manufacturing. In order to meet this challenge in a structured manner, a practical method is presented in which creative idea development is combined with software-based design optimization. First, optimization goals are defined. Then a baseline design is developed through a creative ideation process. Variants are derived from the baseline design, evaluated according to simulation results and selected. The method is illustrated by the development of a lightweight and function-integrated gear wheel.

ACS Style

Matthias Schmitt; Marco Michatz; Alexander Frey; Max Lutter-Guenther; Georg Schlick; Gunther Reinhart. Methodical software-supported, multi-target optimization and redesign of a gear wheel for additive manufacturing. Procedia CIRP 2020, 88, 417 -422.

AMA Style

Matthias Schmitt, Marco Michatz, Alexander Frey, Max Lutter-Guenther, Georg Schlick, Gunther Reinhart. Methodical software-supported, multi-target optimization and redesign of a gear wheel for additive manufacturing. Procedia CIRP. 2020; 88 ():417-422.

Chicago/Turabian Style

Matthias Schmitt; Marco Michatz; Alexander Frey; Max Lutter-Guenther; Georg Schlick; Gunther Reinhart. 2020. "Methodical software-supported, multi-target optimization and redesign of a gear wheel for additive manufacturing." Procedia CIRP 88, no. : 417-422.

Journal article
Published: 03 September 2018 in Procedia CIRP
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Additive manufacturing, especially Laser Powder Bed Fusion (LPBF), allows the build-up of complex parts. Therefore, LPBF is already used in multiple fields, such as automotive or aerospace industry. To promote the wide spread use of AM within the automotive sector materials such as case hardening steels have to be available due to their use in drivetrain parts e.g. gears and shift forks. In this contribution, the processing capability of case hardening steel 16MnCr5 (1.7131) via LPBF is examined. Results of parameter variations are presented. Analyses show that relative densities of above 99.5 % are achievable. The interlayer bonding of specimen manufactured with varied laser power at a constant energy density and with varied scan patterns was investigated. Occurring surface roughness was derived from tilted specimen and contour exposure variants were compared.

ACS Style

Matthias Schmitt; Georg Schlick; Christian Seidel; Gunther Reinhart. Examination of the processability of 16MnCr5 by means of laser powder bed fusion. Procedia CIRP 2018, 74, 76 -81.

AMA Style

Matthias Schmitt, Georg Schlick, Christian Seidel, Gunther Reinhart. Examination of the processability of 16MnCr5 by means of laser powder bed fusion. Procedia CIRP. 2018; 74 ():76-81.

Chicago/Turabian Style

Matthias Schmitt; Georg Schlick; Christian Seidel; Gunther Reinhart. 2018. "Examination of the processability of 16MnCr5 by means of laser powder bed fusion." Procedia CIRP 74, no. : 76-81.