Design, calculation and manufacturing of filigree structures with laser beam melting

增材制造工艺，如激光束熔化，提供了经济有效地制造金属材料复杂几何形状的可能性。虽然为生产固体部件而建立的工艺链已经可靠地提供了良好的结果，但花丝晶格结构可能会显示出显著的几何和质量偏差。到目前为止，这些差异阻碍了在承重部件中增材制造晶格的生产使用。在最初的研究项目中，申请人已经开发了一种替代工艺链，可以将精细的晶格结构直接集成到cad环境中的组件中，然后使用适当的暴露策略，在尺寸上精确地生产它们。为此，已经开发了诸如CAD插件和切片算法等软件组件以及Ti6Al4V材料的曝光策略和激光参数等制造基础。然而，几何和定性的优势仅限于周期性格，并且需要大量的人工努力来确定。这些赤字将在拟议的项目中消除。其目的是调查质量标准的依赖性，通常与结构部件相关，与几何和技术规格比在最初的项目中可能更紧密。在本课程中，将制定一个实验计划，通过该计划可以减少适应特定制造场景的必要个体实验的数量。通过单独考虑和改进单个支柱和节点之间过渡的机械决定性区域，将进一步提高点阵结构的力学性能。在软件方面，不规则晶格结构的集成是目标，因为这允许组件对单个应用程序和负载情况进行理想的适应。重点继续是自相似和共形不规则格，由模拟结果产生。要调查的制造问题的各个方面集中在已开发的暴露策略的演变上。一方面，通过开发和测试适合的扫描策略和参数，进一步提高晶格质量，特别是增加表面质量和减少粉末粘附到支柱上的问题。另一方面，减少为新的生产场景限定工作流所需的工作是一个概念问题。

Additve manufacturing processes such as laser beam melting offer the possibility of cost-efficiently manufacturing complex geometries from metallic materials. While the process chain established for the production of solid components already reliably delivers good results, filigree lattice structures can show significant geometric andqualitative deviations. These discrepancies have so far hindered the productive use of additively manufactured lattices in load-bearing components. In the initial research project, the applicants have developed an alternative process chain which makes it possible to integrate fine lattice structures directly into components in the CADenvironment and then produce them dimensionally accurate, using appropriate exposure strategies. For this purpose, software components such as a CAD plug-in and slicing algorithms as well as manufacturing fundamentals like exposure strategies and laserparameters for the material Ti6Al4V have been developed. However, the geometric and qualitative advantages are limited to periodic lattices and require a considerable manual effort for qualification. These deficits are to be eliminated in the proposed project. The aim is to investigate the dependency of the quality criteria, typically relevant for structural components, on the geometric and technological specifications more closely than it was possible in the initial project. In this course, an experimental plan is to be developed by which the number of necessary individual experiments for the adaption ofspecific manufacturing scenarios can be reduced. By a separate consideration and improvement of the mechanically decisive area at the transition between the individual struts and the nodes, the mechanical performance of the lattice structures shall be further increased. On the software side, an integration of non-regular lattice structures is aimed at, as this allows an ideal adaptation of the component to the individual application and load case. The focus continues to be on self-similar and also conformal irregular lattices, generated from simulation results. Aspects of manufacturing issues tobe investigated focus on the evolution of the developed exposure strategies. On the one hand, it is a matter of further improving the lattice quality, in particular an increase of the surface quality and a reduction of the powder adhesion to the struts by developing andtesting adapted scan strategies and parameters. On the other hand it is a matter of a concept to reduce the effort required to qualify the workflow for new production scenarios.