Mechanical Properties of Laser Beam Melting Components Depending on Various Process Errors
Additive Manufacturing processes are constantly gaining more influence. The layer-wise creation of solid components by joining formless materials allows tool-free generation of parts with very complex geometries. Laser Beam Melting is one possible Additive Manufacturing process which allows the production of metal components with very good mechanical properties suitable for industrial applications. These are for example located in the field of medical technologies or aerospace. Despite this potential a breakthrough of the technology has not occurred yet. One of the main reasons for this issue is the lack of process stability and quality management. Due to the principle of this process, mechanical properties of the components are strongly depending on the process parameters being used for production. As a consequence incorrect parameters or process errors will influence part properties. For that reason possible process errors were identified and documented using high resolution imaging. In a next step tensile test specimens with pre-defined process errors were produced. The influence of these defects on mechanical properties were examined by determining the tensile strength and the elongation at break. The results from mechanical testing are validated with microscopy studies on error samples and tensile specimens. Finally this paper will give a summary of the impact of process errors on mechanical part quality. As an outlook the suitability of high resolution imaging for error detection is discussed. Based on these results a future contribution to quality management is aspired.
Design of an Optical system for the In Situ Process Monitoring of Selective Laser Melting (SLM)
Selective Laser Melting (SLM) is an Additive Manufacturing technology that enables the production of complex shaped individual parts with series identical mechanical properties. Areas of improvement are up to now quality and reproducibility of parts made by SLM due to different kinds of errors. Therefore the integration of a monitoring and control module into a SLM-machine is aspired. The design of such an optical system capable of monitoring high scanning velocities and melt pool dynamics is introduced as a first step.
Ignition and burning rates of segregated waste combustion in packed beds.
Recent developments in national recycling and re-use programmes for municipal waste have led to segregation of an increasing proportion of waste to enhance material recovery. Several of the segregated streams contain materials that can not viably be re-used or recycled but can be used for energy recovery. In this study, the combustion of cardboard and waste wood was investigated in a small-scale packed bed reactor in order to provide fundamental data for the design/operation of moving bed furnaces. Key parameters of combustion including the ignition and burning rates were evaluated for various air flowrates and compared to the modelling results. Two successive stages of combustion were identified for both samples: the propagation of ignition front into the bed and combustion of the fuel above the ignition front. The burning rate of cardboard reached a peak of about 300 kg/m(2)h at the air flowrate of 936 kg/m(2)h and decreased at higher air flowrates. For waste wood, both the ignition and burning rates increased in the tested range of the air flowrate up to 702 kg/m(2)h, of which the values were very close to those for the cardboard. The model prediction was in good agreement with the test results for waste wood. However, the burning rate for cardboard was under-predicted due to strongly irregular shapes of the fuel.