Project Details
Projekt
Sensor-based process development for laser-additive manufacturing of implants with complex outer geometries and inner structures
Applicant
Professor Dr.-Ing. Stefan Kaierle
Subject Area
Materials in Sintering Processes and Generative Manufacturing Processes
Biomaterials
Biomaterials
Term
since 2022
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 449916462
Subproject 1 of the research unit 5250 addresses the sensor-based additive manufacturing of implants with complex outer geometries and inner structures by means of laser-based powder bed fusion (PBF-LB/M). In the first funding period, extensive results regarding the fabrication of complex permanent titanium implants made of Ti-6Al-4V were already achieved. Based on this, the second funding period will focus on the processing of the magnesium alloy WE43 for the manufacturing of customised biodegradable implants. By addressing both process and system-related issues, a holistic research approach will be taken. In addition, the research regarding PBF-LB/M of titanium implants will be continued and intensified. The work will focus on the analyses of the reproducibility depending on external manufacturing boundary conditions, such as powder degradation. As part of a comprehensive process development for the fabrication of TPMS lattice structures made of WE43, the interactions between process parameters, component design and the resulting component and material properties are analysed in detail. Using an efficient design of experiment approach, empirical models will be derived to describe these interdependencies, resulting in a profound understanding of the process and its boundaries. The design and integration of a monitoring system adapted to the processing of magnesium alloys will allow the quantification of the thermal process boundary conditions and thus enable an analysis of the process-structure-property relationships regarding the production of complex magnesium structures. In particular, linking the process-specific microstructure with the mechanical properties, the corrosion resistance and the degradation behaviour of the manufactured structures is a fundamental aspect. Here, the interdisciplinary consortium's synergies enable the holistic process, component and material analysis. Based on the gained process understanding and the developed monitoring system, anomaly and defect detection during BF-LB/M of WE43 will be investigated. In addition to the additive processing itself, heat treatments will be analysed with respect to their suitability for additively processed WE43 and their influence on the mechanical properties and the corrosion behaviour. The combination of a profound process and material analysis regarding PBF-LB/M of complex implants, the development and testing of adapted monitoring concepts and the investigation of adapted heat treatments will provide an in-depth understanding of the overall process chain and build the foundation of future additive manufacturing of permanent and bioresorbable implants.
DFG Programme
Research Units
