Subject area:
High temperature materials
Responsible Employees:
PD Dr. Steffen Neumeier
Benno Schönleber (M. Sc.)
This project is being carried out by the MSE I Chair at FAU Erlangen-Nuremberg in collaboration with the Heinz Maier-Leibnitz Zentrum FRM II at the TU Munich and Concept Laser GmbH Lichtenfels. The main objective of the project is to bring new, high-strength aluminium alloys for aerospace applications to maturity in the laser powder bed fusion process (LPBF).
During the LPBF process, thin powder layers are selectively welded using a laser, enabling near-net-shape manufacturing. High-strength aluminium alloys are often unsuitable for the LPBF process due to their susceptibility to hot cracking. The novel aluminium alloys contain additional alloying elements that react during the process to form fine ceramic particles, which both supply energy and have a grain-refining effect. This reduces susceptibility to cracking and makes the material suitable for the LPBF process.
A deep understanding of the relationships between process parameters and the resulting microstructure, as well as the microstructure-property correlation, is necessary for the successful application of the manufacturing process for the new alloys. During the research project, the laser-welded materials will be examined in detail in order to achieve a homogeneous, defect-free microstructure and to optimize the mechanical properties in subsequent heat treatments. The correlations between process parameters and microstructure and, based on this, the mechanical properties will be investigated. Furthermore, the effects of powder aging as a result of repeated use in the process will be considered.
The knowledge gained will allow the potential of the materials to be made use of in an economical and sustainable manner using the LPBF process.
The research project Aluminium from Additive Manufacturing – AlaAF is funded by the German Federal Ministry of Research, Technology, and Space under the funding code 05K25WEA.