The “Simsalabim” project focuses on the development of an end-to-end process chain for the sinter-additive production of nickel-based alloys. The Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM in Dresden, the Dresden University of Applied Sciences (HTWD) and the Fraunhofer Institute for Material and Beam Technology IWS are working together to cover all steps – from design and sintering simulation to verification on real components. The Fraunhofer IWS led by Moritz Greifzu is primarily dedicated to sintering simulation, the Fraunhofer IFAM led by Dr. Thomas Studnitzky to the sintering process and the team led by Prof. Daniela HĂĽnert from the HTWD is concentrating on the optimization of materials and heat treatments. The aim is to gather industrial experience right from the start and incorporate it into the development goals. To this end, a network meeting was held with manufacturers and users and the current problems in simulation and material behavior were addressed.
Workshop and network
The project’s first network meeting took place on November 28. Industry representatives from start-ups to large listed companies, representatives of associations and researchers met to discuss the key challenges of sinter-based additive manufacturing. An open exchange of experiences and challenges helps to sharpen the project goals in a targeted manner. The focus was on topics such as simulation, materials and their properties. The findings from the numerous discussions will be incorporated into the next steps of the project in order to drive forward further developments in a targeted manner and create innovative solutions.
About the project
To date, the focus of metal additive manufacturing has been on laser-based processes. These are characterized by a high level of technical maturity, but do not meet all the challenges in terms of materials, geometries and productivity. The industry is therefore increasingly turning its attention to SBAM processes. In SBAM, metal powders are processed without complete melting, which reduces thermal gradients and the associated formation of residual stresses, susceptibility to cracking and the formation of harmful phases. Despite the existing demand, hardly any 3D-manufactured components made of poorly weldable alloys have been available to date, as these materials can only be realized to a very limited extent or not at all using laser processes. As SBAM does not have these process-related limitations, there is great economic potential. The successful processing of these materials would also represent a significant technological advance in terms of productivity and surface quality. In addition to a continuous process chain for nickel-based alloys, the aim is to further develop sintering and material simulations and to adapt these materials to SBAM requirements. Such alloys are characterized in particular by their high strength and corrosion resistance at high temperatures, which makes them the first choice in high-temperature applications in the energy, transport and hydrogen industries.
Networking as a success factor
The research work of the participating institutes is bundled in a regional network and is intended to promote and intensify the exchange between research and industry on sinter-based additive processes and materials. The aim is to jointly advance the cost-effective production of components using 3D printing. In the future, the network will make an important contribution to Saxony’s regional development.
The project is co-financed by tax funds on the basis of the budget approved by the Saxon state parliament and co-financed by the European Union.
Interested companies and associations can contact Prof. Daniela HĂĽnert (+49 351 462 2582).
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Further links
👉 www.htw-dresden.de
Photo: HTWD
