Project Details
Projekt
First-time right manufacturing in laser-based powder bed fusion of polymers by in-situ process monitoring and spectral x-ray dark-field imaging
Subject Area
Primary Shaping and Reshaping Technology, Additive Manufacturing
Statistical Physics, Nonlinear Dynamics, Complex Systems, Soft and Fluid Matter, Biological Physics
Statistical Physics, Nonlinear Dynamics, Complex Systems, Soft and Fluid Matter, Biological Physics
Term
since 2024
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 531882042
Laser-based powder bed fusion of plastics (PBF-LB/P) is an additive manufacturing technology, which is up to now well established in the production environment due to its high maturity level. However, if a production process fails or is successful is evaluated subsequent to the PBF-LB/P process. This drawback of the otherwise mature technology is caused by the missing link between process information or rather a process signature and resulting part properties since there is no established process monitoring approach available. As soon as the porosity reaches a specific value the mechanical properties decrease due to the porosity-driven failure mechanism, which is why understanding the resulting mechanism for pore formation during processing is needed. On a part level, the residual porosity depends on the feature size and geometry. For real-world components away from simple test coupons the porosity distribution is unknown. Thus the project is underpinned by two technical innovations (i) an in-situ measurement system for PBF-LB/P, that is capable of predicting component properties during processing, and (ii) an X-ray inspection method based on a combination of spectral detection and dark-field imaging, that can quantify porosity in bulk materials below the resolution limit of the imaging system.
DFG Programme
Research Grants
