Research
Research is at the heart of everything we do at the Materials Science Group. It's what drives our commitment to teaching and scholarship.
Our group researches materials and processes for powder bed additive manufacturing - also known as 3D printing - of metallic materials. In these manufacturing processes, metal powder is selectively melted by a laser or electron beam in a layer-by-layer buildup process. This enables the resource-efficient production of customized components with complex, highly functional geometries. In addition, the exceptional process conditions can be used to create new materials with unique microstructures and improved mechanical properties.
Our research focuses on alloy development, i.e. the development of new, customized materials based on thermodynamic calculations, and on simulation-based process development, i.e. the development of process strategies for the defect-free processing of new materials. We work with refractory materials such as molybdenum and tungsten, titanium and aluminum alloys, and steels. Our application-oriented research projects are conducted in close cooperation with partners from academia and industry.
Alloy Development
Powder bed additive manufacturing is a technology in which metallic materials solidify under extreme temperature gradients and high cooling rates. During the build process, the solidified material is reheated, resulting in very complex temperature curves. Materials originally developed to meet the requirements of conventional manufacturing processes are often difficult to process additively. Further and new development of alloys for powder bed additive manufacturing is therefore essential to achieve simplified processability and improved material properties.
Process Development
The goal of process development for powder-bed additive manufacturing of new and existing materials is to understand and master the material-specific interactions between process parameters, process conditions and material properties. Process development is simulation-based and is performed both on the basis of sensor data from process monitoring tools, such as an inline pyrometer or high-speed camera, and on the basis of results from microstructural and mechanical component analysis.
Modeling and Simulation
Modeling and FEM and VOF simulation of additive manufacturing aims to improve our understanding of the interactions between the many manufacturing parameters and the process and material properties in this dynamic and physically highly complex process. For example, we study the factors that influence melt pool dynamics or the role of process atmosphere and powder quality in minimizing the formation of defects such as pores. We also study solidification conditions and temperature history to control and optimize the microstructure and mechanical properties of our materials.
