Research into additively manufactured steel
Why additively manufactured steel requires special attention
How does additively manufactured steel behave in combination with traditionally manufactured steel? How can they be optimally processed together?
Research into additively manufactured steel
A doctoral student at Osnabrück University of Applied Sciences is researching this. She is investigating the weldability of additively manufactured and cast steel. Not only products and components made of plastic can be manufactured using additive manufacturing processes such as 3D printing. Metals such as steel can also be printed.
Advantages of additively manufactured steel
Additively manufactured steel is already being used in a wide range of applications, particularly in medical technology and aviation. The advantages are convincing: "It is an excellent way of producing individual parts or small batches cost-effectively," explains Julianna Posey, a doctoral student at Osnabrück University of Applied Sciences and the University of Maryland Baltimore County (UMBC), USA.
"It also enables customized production, such as implants in medical technology. Repairs can also be carried out more easily and cost-effectively, as only the defective area needs to be replaced.
Different manufacturing processes lead to varying microstructures
So far, however, there have only been a few studies on how additively manufactured steel behaves in combination with traditionally manufactured steel. Posey is devoting her doctorate to the welded joints between cast and additively manufactured steel.
"My focus is on the fatigue phenomena of printed steel after welding - in particular the microstructure and its changes due to the welding process. Additively manufactured steel has a different microstructure due to its manufacturing process," explains the US-American, who came to Germany for her doctorate.
The reason for this is the heat flow during production. This powder is melted using a laser, building up the component or product layer by layer. The heat flow varies greatly during this process. This is why the microstructure is not uniform at first. Only through subsequent heat treatment does it become uniform and the steel can be used.
For the engineer, it is particularly exciting to be working in such a new field of research: "The results and information from such an unexplored area make you a kind of specialist. Of course, it was unusual at first. But I could always count on the support of my supervisors, Prof. Dr. Javad Mola from Osnabrück University of Applied Sciences and Dr. Marc Zupan from UMBC, as well as my colleagues." She also received support from industry: the samples Posey used for her experiments were specially produced by trained welders at the Volkswagen plant in Osnabrück.
Welded joints often break with additively manufactured steel
The samples were subjected to various tests, including tensile tests and hardness tests. They were then analyzed.
Posey experimented both with and without filler metals. "My investigations have shown that the welded joint often breaks on the side of the additively manufactured steel." This shows that the welding process needs to be adapted and that additively manufactured steel cannot be processed like cast steel.
However, tests with welding additives have proven to be promising. The additional material fills the welding gap and absorbs heat, reducing the size of the heat-affected zone.
Source: Osnabrück University of Applied Sciences
You might also be interested in
Fast spare parts production for rail vehicles
To ensure a reliable supply of spare parts even after decades, Alstom is relying on a new production process. With WAAM (Wire Arc Additive Manufacturing), components for rail vehicles can be manufactured flexibly, in a resource-saving manner and at...
read more...Large-format metal printing for industrial applications
Gefertec is presenting its latest developments in the field of Wire Arc Additive Manufacturing (WAAM) at this year's Formnext. The process pushes the boundaries of 3D printing of metallic components. With WAAM, large and complex components can be...
read more...Additive manufacturing for series production
As a full-liner in the additive manufacturing of metallic components, DMG Mori will be demonstrating how these processes can be further optimized at the upcoming Formnext from 18 to 21 November 2025 in Frankfurt.
read more...Rotating multi-metal 3D printing
Students accelerate the production of rocket parts
Students at ETH Zurich have built a new type of laser melting machine that prints cylindrical components from two metals simultaneously. Thanks to the rotating platform, the production time is significantly reduced, which is particularly interesting...
read more...Heat transfer and additive manufacturing
Conflux Technology enters the hypercar sector
Pagani has announced the signing of a six-year contract with Conflux to integrate Conflux heat exchangers into the transmission of its latest exclusive model, the Pagani Utopia, further advancing additive manufacturing in the hypercar industry.
read more...Technology with a promising future
Additive manufacturing with metals
Metals are used in a wide range of industries due to their material properties such as strength, temperature resistance, durability, biocompatibility, chemical resistance and conductivity. The question arises as to what possibilities additive...
read more...Martin Thiel joins the Kemper Management Board
As of January 1, 2020, Martin Thiel is a member of the management board of Gebr. Thiel is taking over the Rolled Products division as part of a future-oriented reorganization.
read more...Stratasys takes over MarkForged
Stratasys is acquiring MarkForged from Nano Dimension for USD 42.5 million, thereby expanding its portfolio in the field of fiber-reinforced composites. The acquisition also strengthens the company's software and materials expertise in industrial 3D...
read more...Timo Göbel, Head of BMW Additive Manufacturing
"Clearly on course for broad industrialization"
The BMW Group's Additive Manufacturing Campus (AMC) is setting the course for the next stage of industrialization. Under the leadership of Timo Göbel, additive manufacturing is being further integrated into all stages of the vehicle life cycle. In...
read more...