Additive manufacturing and processing by forming of Al-Ti metallic composites

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The purpose of this project is a fundamental understanding of the production and formability of additive manufactured Al-Ti metallic composites. For the first time, such composites are produced from aluminum and titanium by cold gas spraying and are hot-formed by die forging. First of all, the spray parameters have to be determined that layers with low porosity can be produced. In order to correspond to the nature of an additive manufacturing of solids, a large layer thickness has to be realised. That means an extension beyond the limits of previously produced thermal sprayed layer thicknesses.Since no information is available on the forming of cold gas sprayed coatings, their forming behaviour under realistic conditions is to be characterized. Therefore, the sprayed composites are formed under different process parameters and stress conditions by die forging. The microstructure and mechanical properties are evaluated on both, the composites produced and the subsequently formed composites using different investigation techniques. This allows the determination and fundamental understanding of the microstructure-property relationship along the entire process chain. In order to transfer the findings to further investigations, the numerical modeling of the forming process is performed on the basis of the determined mechanical properties and considering the actual solid structure.