Conventional manufacturing technologies, such as milling or casting, are limited in terms of the manufacturable complexity of the parts to be produced. They are also restricted in terms of the local modifiability of the mechanical properties. Additive manufacturing, specifically the Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M), is a novel method, which is capable of addressing both limitations. However, the resulting parts are often prone to cracking during PBF-LB/M and in the service afterward because of high thermally induced local stress intensities. Selectively modifying the process parameters during the fabrication can be a suitable strategy to locally reduce the failure susceptibility. Over the course of this study, samples made from the nickel-based superalloy Inconel 718 were manufactured with varying laser powers, hatch distances, and scan speeds. The samples were divided into stress crack specimens as well as static and dynamic tensile test specimens. The grain structure was investigated, and correlations between the microstructure and the cracking susceptibility were determined. It was found out that variations in the laser power had the most pronounced effect on the grain structure and the failure behavior. An increasing grain size enhanced the fracture resistance in the stress crack samples while the static and dynamic mechanical properties deteriorated. Based on these results, the application area of PBF-LB/M could potentially be widened due to the manufacturability of parts otherwise susceptible to stress-induced cracking. The mechanical properties of as-built parts can remain unchanged utilizing a local process parameter adaption.

In binder jetting (BJ), an ink is inserted layerwise into a powder bed to selectively bond the particles in the cross-section of a part. By predicting the penetration depth of the ink, the ideal layer thickness for BJ can be set. Each layer should be penetrated with ink. Insufficient penetration will result in a poor layer bond and a low strength of the part; over-penetration will impede a dimensionally accurate production, as the ink will leak from the sides of the part and unintentionally solidify the powder in these areas. The Washburn equation has been used for the calculation of the penetration depth in various fields, such as hydrology or with loose powders. However, a transfer to the BJ process is difficult due to the preferably compact powder bed and the fine particles. In more compact powder beds, the small radii with their greater capillary pressure and their distribution in the layer have a high influence on the penetration depth. This work shows an adaptation of the Washburn equation for powder beds in BJ and a new approach to determine the effective pore radius for calculating the penetration depth. A weighted pore radius was introduced, which accounts for the spatial distribution of the pores in the powder bed and the acting capillary pressure. The validation was performed with two different powders by experimentally simulating the BJ process through the infiltration of a drop into a powder bed. The weighted radius was used in the Washburn equation to calculate the penetration depth. The results were compared with those models from the literature and experimental data, and a good agreement between the calculation and the experiment was found.

Due to the tool-less fabrication of parts and the high degree of geometric design freedom, additive manufacturing is experiencing increasing relevance for various industrial applications. In particular, the powder bed fusion of metals using a laser beam (PBF-LB/M) process allows for the metal-based manufacturing of complex parts with high mechanical properties. However, residual stresses form during PBF-LB/M due to high thermal gradients and a non-uniform cooling. These lead to a distortion of the parts, which reduces the dimensional accuracy and increases the amount of post-processing necessary to meet the defined requirements. To predict the resulting residual stress state and distortion prior to the actual PBF-LB/M process, this paper presents the finite-element-based simulation tool AscentAM with its core module and several sub-modules. The tool is based on open-source programs and utilizes a sequentially coupled thermo-mechanical simulation, in which the significant influences of the manufacturing process are considered by their physical relations. The simulation entirely emulates the PBF-LB/M process chain including the heat treatment. In addition, algorithms for the part pre-deformation and the export of a machine-specific file format were implemented. The simulation results were verified, and an experimental validation was performed for two benchmark geometries with regard to their distortion. The application of the optimization sub-module significantly minimized the form deviation from the nominal geometry. A high level of accuracy was observed for the prediction of the distortion at different manufacturing states. The process simulation provides an important contribution to the first-time-right manufacturing of parts fabricated by the PBF-LB/M process.

Binders play a pivotal role in the production and the operation of lithium-ion batteries. They influence a number of key dispersion characteristics and battery parameters. In the light of growing interest in additive manufacturing technologies, binders were found to decisively govern the processability due to the induced complex non-Newtonian behavior. This paper examines the relevance of various binder derivatives for aqueous graphite dispersions that can be employed in inkjet printing. Two different carboxymethyl cellulose (CMC) derivatives with strongly deviating molecular weights were employed. The impact of the inherent polymer characteristics on the processability and the electrode characteristics were explored. Therefore, miscellaneous studies were carried out at the dispersion, the electrode, and the cell levels. The results revealed that the CMC with the lower molecular weight affected most of the studied characteristics more favorably than the counterpart with a higher molecular weight. In particular, the processability, encompassing drop formation and drop deposition, the cohesion behavior, and the electrochemical characteristics, were positively impacted by the low-molecular-weight CMC. The adhesion behavior was enhanced using the high-molecular-weight CMC. This demonstrates that the selection of a suitable binder derivative merits close attention.

Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) has proven to be a competitive manufacturing technology to produce customized parts with a high geometric complexity. Due to process-specific characteristics, such as high cooling rates, the microstructural features can be tailored. This offers the possibility to locally control the mechanical properties. Therefore, the grain structure has to be reliably predicted at first. The starting point of the grain formation and the growth process is characterized by the nucleation. Over the course of this study, various nucleation theories were applied to the PBF-LB/M process and their suitability was evaluated. The two Sc-modified aluminum alloys Scalmalloy^® and Scancromal^® were processed with a novel experimental PBF-LB/M setup. By performing melt pool simulations based on the Finite Element Method (FEM), the input data for the nucleation models were obtained. The simulatively predicted nucleation zones based on the different theories were compared to real metallographic images and to literature results. It was found that the phenomenological approach should be used whenever no first-time-right prediction of the simulation is necessary. The physically based models with the heterogeneous nucleation should be applied if a first-time-right prediction is striven for. For applications in PBF-LB/M, the nucleation models should be extended in terms of the influence of precipitates and the high cooling rates during the manufacturing process. The presented approach may be used to further assess grain nucleation models for various additive manufacturing processes.