The potential of an optimization process with respect to reduced mass can be used to the full extent by utilizing a high-strength material as it is, among others, strength-dependent. For the additive manufacturing process, Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M), 316L is commonly used. PBF-LB/M/316L has its benefits, like good material properties, such as availability, corrosion resistance, strength, and ductility. Nevertheless, a higher-strength material is required to fully take advantage of the optimization process and achieve a greater reduction in the mass of manufactured parts. The high-strength austenitic stainless steel investigated in this study is Printdur^® HSA. Its main alloying elements are manganese, chromium, molybdenum, carbon, and nitrogen. The steel obtains its high strength properties from the alloyed carbon and nitrogen via solid solution hardening and improving the austenite stability. Therefore, it is defined as (C+N) steel. The datasheet of the powder manufacturer describes a yield strength (R_p0.2; 0.2% offset proof stress) of 915 MPa, an ultimate tensile strength of 1120 MPa, and an elongation at fracture of 30%. These are clear benefits in comparison to PBF-LB/M/316L. Since there are no further investigations made on Printdur^® HSA, a thorough investigation of material behavior, fatigue life, and microstructure is needed.

In this study, the implementation of the PBF-LB/M process into the construction design and building process was investigated. To this purpose, a tensegrity-tower was designed, planned, and built. The nodes between the compression rods and the tension cables were manufactured by PBF-LB/M/AlSi10Mg. Four different nodes were designed and shape-optimized by vertex-morphing. In order to qualify the tensegrity nodes according to the German regulations, mechanical as well as microstructural evaluations were conducted. Tensile tests of a manufactured tensegrity node in a fully hinged setup were carried out. Additionally, fatigue testing was conducted. The tensegrity nodes were heat-treated (T6) and subsequently vibratory ground to reduce the surface roughness. The results indicate that it is feasible to integrate the PBF-LB/M process into the design and construction process. The tower is now a permanent and tangible exhibit in the Deutsches Museum in Munich.

The newly introduced high manganese high strength (C + N) steel Printdur HSA was developed for the additive manufacturing process PBF‐LB/M. It consists of a fully austenitic grain structure. This study aims to evaluate the cyclic plastic material behavior of this (C + N) steel. Therefore, tensile tests and strain‐controlled low‐cycle fatigue tests were conducted. Strain amplitudes between 0.5% and 3.0% were applied. Furthermore, the microstructure was examined. In particular, electron backscatter diffraction and scanning transmission electron microscopy were applied. For all strain amplitudes, a general softening behavior is visible. The strain amplitude of 0.5% results in primary hardening within the first 30 cycles. Therefore, a dependency of the cyclic material behavior on the applied strain amplitude can be assumed. This behavior correlates with the investigated characteristics of the microstructure. The observed mechanical behavior is linked to microstructural mechanisms, including dislocation rearrangement, persistent slip band formation, and grain boundary interactions. A comparison with conventionally used PBF‐LB/M/316L highlights the superior static mechanical and fatigue performance of Printdur HSA. These results improve the understanding of the cyclic deformation mechanisms of this material and support its structural application under fatigue loading at high strains.

Aluminium cast components have become increasingly important in overhead line construction, particularly for parts such as cantilevers, tensioning devices, and connectors. Since the 1950s and 1960s, the transition from steel and iron castings to aluminium has enabled significant weight reductions, simplified assembly processes, and improved corrosion resistance—key advantages for enhancing the operational safety and service life of overhead line systems. However, the lower operational and fatigue strength of aluminium castings compared to steel imposes stringent demands on design, material selection, and quality assurance. A thorough understanding of fatigue mechanisms and constraint-induced stresses under cyclic loads from wind and tensile forces is essential to preventing crack initiation and component failure. This paper demonstrates how material analyses, experimental testing, and the targeted application of relevant standards can ensure the operational reliability of aluminium cast components. Furthermore, existing gaps in current standards are identified, whose closure is vital to fully exploiting the potential of aluminium castings for durable, lightweight, and low-maintenance overhead line elements.