Kai Treutler

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• Dr.-Ing.
• Group Leader at Clausthal University of Technology

Due to the inherent properties of the process, arc-based generative manufacturing offers the possibility, of specifically applying different material properties locally. One possibility to realize this is the use of different materials. Three approaches are presented to illustrate this option. First, anisotropic behavior in the welding direction is...

The supply and processing of materials for highly stressed components are usually cost-intensive. Efforts to achieve cost and resource efficiency lead to more complex structures and contours. Additive manufacturing steps for component repair and production offer significant economic advantages. Machining needs to be coordinated with additive manufa...

Nickel alloys are cost intensive materials and generally classified as difficult-to-cut material. However, machining of these materials is needed especially in case of alloy 36 (1.3912), which is commonly used in mould construction for the production of fibre-reinforced composites. With regard to repair, modification and manufacturing of such compo...

Arc based direct energy deposition combines the flexibility of additive manufacturing with high build rates and low investment costs. However, high geometric fidelity of manufactured components is not possible with state-of-the-art methods. Highly varying and geometry-dependent boundary conditions, e.g. heat dissipation and the interpass temperatur...

Today, arc-based additive manufacturing has great potential for industrial application due to new developments in robotics, welding technology, and computer-aided manufacturing. Two issues are currently the focus of research. One is the accurate generation of geometry with respect to the design, e.g., geometry fidelity, defined roughness, and shape...

Many metallic wear resistant alloys, which are applied by plasma powder cladding, use precipitated hard phases as a reinforcing element. The group of aluminides, in particular the iron aluminides, have an interesting application profile for various applications, generally high-temperature applications, and consist exclusively of an intermetallic ph...

The importance of technical gases has been increasing worldwide for several years. Liquefied natural gas for shipping and land-based transport are becoming increasingly important, especially as a result of political requirements to reduce emissions and climate targets. The significantly increased storage efficiency due to lower volumes means that t...

Wear-resistant coatings are required for highly efficient and economical steel components in equipment, process, and power plant engineering to withstand high corrosive, tribological, thermal, and mechanical stresses. Co-alloys are used as wear-resistant coatings for steel components, tailored to the specific application. The substitutability of Co...

The weldability of stainless steels is largely controlled by the chemical composition, and alloys with ferritic or ferritic-austenitic solidification show the highest resistance to hot cracking. As the resulting phase balance also affects the final properties, it may be beneficial to both foresee and measure the weld metal ferrite content. The WRC...

The welding of steel grades relies primarily on the interaction of the weld metal with doped oxygen components of the shielding gas. This mainly serves to decrease the viscosity and reduce the surface tension of the melt in order to achieve an adjusted material transition. Interference with the ambient atmosphere is undesirable in this context. In...

In the area of plant engineering, steel components are provided with a wear protection coating for efficient use to protect them against corrosive, tribological, thermal and mechanical stresses. The use of innovative ultrasound-assisted milling processes and plasma-welded nickel- and cobalt-based wear protection coatings are being investigated to d...

The reduction of ­CO2 emissions is closely linked to the development of highly efficient and economical steel components in plant and process engineering. To withstand the high combined corrosive, tribological, thermal, and mechanical stresses, wear-resistant coatings tailored to the application and steel grade are used. In addition to the increasi...

Zur Bestimmung der Geschwindigkeitsabhängigkeit des Haftreibungskoeffizienten µ in hochfest vorgespannten Verbindungen wurden quasistatische Gleitkraftversuche sowie Hochgeschwindigkeitszugversuche an schienenfahrzeugbautypischen Verschraubungsfällen durchgeführt und vergleichend gegenübergestellt. Dabei wurden die Einflussgrößen Klemmlängen-Durchm...

To determine the dependence of the test velocity on the friction coefficient (μ) in high-strength preloaded connections, experimental investigations are performed on bolted joints typical of rail vehicle construction. This is achieved through slip load tests following the procedure outlined in Annex G of EN 1090-2, well as high-speed tensile tests,...

During manufacturing of components using wire arc additive manufacturing, specific cooling times are required to prevent overheating of the structure and geometrical distortions. Currently, these cooling times are inserted based on experience at certain interlayer temperatures — which reduces the reproducibility, leads to unwanted component propert...

Increasing requirements in terms of weight, safety, and economy are leading to the use of high-strength steels in automotive construction. The focus is on advanced high-strength steels (AHSS). In chassis applications, complex-phase (CP) steels are frequently used and usually processed uncoated. But the demand for galvanized sheet steel is rising st...

The high corrosion resistance and good mechanical properties of duplex stainless steel (DSS) are due to its special chemical composition, which is a balanced phase ratio of ferrite (α) and austenite (γ). Many industrial applications require the integration of DSS components. For this, Gas tungsten arc welding (GTAW) is an excellent choice, as it al...

For several years, the significance of gaseous energy sources (e. g. liquified natural gas and hydrogen) has been increasing worldwide due to environmental and climate policy requirements. Storage and transportation of the liquids occur under cryogenic conditions. This results in specific requirements for the mechanical properties of the materials...

Die additive Fertigung mittels Schweißverfahren bietet große ökonomische Vorteile für eine ressourceneffiziente Bauteilherstellung. Offene Fragen bezüglich Homogenität, Anisotropie der Schweißgefüge und den damit verbundenen Bauteileigenschaften stehen einer wirtschaftlichen Verarbeitung oftmals im Wege. Finale Bauteilgeometrie und Oberflächengüte...

To produce additively manufactured components, various process advantages can be combined by using the tungsten inert gas (TIG) hot wire process with ohmic wire preheating. Unlike other various gas metal arc welding processes, with TIG, it is possible to influence the material properties by decoupling the energy supply and the welding filler materi...

The relevance of technical gases is constantly increasing due to environmental and climate policy requirements. The storage and transport of liquefied natural gas (LNG) takes place under cryogenic conditions with substantial volume reduction due to significant storage efficiency. Consequently, there are specific requirements for the mechanical prop...

Intermetallic alloys such as iron aluminides are of increasing interest for high-temperature applications due to their properties. However, their application potential is restricted by their limited machinability with conventional manufacturing methods such as milling. Arc-based additive manufacturing offers an approach to produce these materials t...

Die Verringerung der CO2-Emissionen ist eng mit der Entwicklung hocheffizienter und wirtschaftlicher Komponenten aus Stahl in der Anlagen- und Verfahrenstechnik verknüpft. Um den hohen kombinierten korrosiven, tribologischen, thermischen und mechanischen Beanspruchungen stand zu halten, werden auf Anwendungsfall und Stahlwerkstoff abgestimmte Versc...

Zur Bestimmung der Geschwindigkeitsabhängigkeit des Haftreibungskoeffizienten μ in hochfest vorgespannten Verbindungen werden experimentelle Untersuchungen an schienenfahrzeugbautypischen Verschraubungsfällen mithilfe von Gleitkraftversuchen in Anlehnung an den Anhang G der DIN EN 1090-2 sowie mittels Hochgeschwindigkeitszugversuchen (HGZV) durchge...

Die additive Fertigung (AM) durch schweißtechnische Verfahren eröffnet vielfach ökonomische Vorteile für eine ressourceneffiziente Bauteilherstellung. Gerade hinsichtlich der Homogenität und Anisotropie der resultierenden Schweißgefüge und den damit verbundenen Eigenschaften gibt es noch offene Fragestellungen. Die Einstellung der finalen Bauteilge...

Bereits seit einigen Jahren nimmt die Bedeutung technischer Gase weltweit immer weiter zu. Insbesondere in Folge politischer Vorgaben zur Emissionsreduktion und Einhaltung der Klimaziele werden verflüssigtes Erdgas (LNG) für Schifffahrt und landgestütztes Transportgewerbe, aber auch Wasserstoff immer wichtiger. Der Transport und die Lagerung erfolg...

Intermetallic alloys such as iron aluminides are of increasing interest for high temperature applications due to their properties. However, their application potential is limited by their limited machinability with conventional manufacturing methods such as milling. Arc-based additive manufacturing offers an approach to produce these materials to f...

Intermetallic alloys such as iron aluminides are of increasing interest for high-temperature applications due to their properties. However, their application potential is restricted by their limited machinability with conventional manufacturing methods such as milling. Arc-based additive manufacturing offers an approach to produce these materials t...

Alloy 36 (1.3912), also known as “Invar,” is an alloy with 36% nickel. The alloy has a remarkably low thermal expansion coefficient in certain temperature ranges. This peculiarity is called the invar effect, which was discovered in 1896 by the Swiss physicist Charles Édouard Guillaume Sahoo and Medicherla Mater today Proc 43:2242-2244, (2021). Ther...

Unter Berücksichtigung des Leichtbaugedankens werden in der Automobilindustrie hochfeste Stahlfeinbleche eingesetzt. Aufgrund der korrosionsschützenden Wirkung hat sich im Karosseriebau der Einsatz verzinkter Stähle schon lange durchgesetzt. Im Fahr-werk werden die Stahlwerkstoffe üblicherweise unbeschichtet verarbeitet. Auch für Fahrwerksanwendung...

Die Bedeutung technischer Gase nimmt weltweit immer weiter zu. Insbesondere in Folge politischer Vorgaben zur Emissionsreduktion und Einhaltung der Klimaziele wer-den verflüssigtes Erdgas (LNG) für Schifffahrt und landgestütztes Transportgewerbe aber auch Wasserstoff immer wichtiger. Auch die derzeitige weltpolitische Lage ver-deutlicht noch einmal...

Zur Bestimmung einer Geschwindigkeitsabhängigkeit des Haftreibungskoeffizienten µ in vorgespannten Verbindungen werden Haftreibungskoeffizienten für eine gestrahlte Oberfläche mithilfe von Gleitkraftversuchen in Anlehnung an DIN EN 1090-2 Anhang G sowie mittels Hochgeschwindigkeitszugversuche (HGZV) ermittelt und vergleichend gegenübergestellt. Dab...

Duplexstähle besitzen ein zweiphasiges Gefüge und werden aufgrund ihrer verbesserten Schweißeignung gegenüber den Vollausteniten häufig im Anlagen-bzw. Apparatebau eingesetzt. Aufgrund der hohen Abkühlgeschwindigkeit und dem Abbrand von Legie-rungselementen kommt es zu einer Ferritisierung des Schweißguts und damit zu einer Degradation der mechanis...

Manufacturers of welding wire electrodes for GMAW welding adapt the alloy compositions of welding wire electrodes in order to adjust the weld pool behavior and the properties of the weld. Additively manufactured components in various sizes and with complex structures and multi-axial stress states place diverse demands on the material. The filler wi...

Particularly in the automotive industry and the sector of liquid–gas storage, austenitic steels with a high energy absorption capacity are used. The light metals frequently used do not meet all requirements. Therefore, especially for components involved in crash situations, the cost-effective alternative with outstanding properties is used. In this...

Alloy 36 (1.3912) is an alloy with 36% nickel and 64% iron and is generally classified as a difficult-to-cut material. Increasingly complex structures and the optimization of resource efficiency are making additive manufacturing (AM) more and more attractive for the manufacture or repair of components. Subsequent machining of AM components is unavo...

This paper shed light on the kinetics of transformation and the developed microstructure during wire arc additive manufacturing (WAAM). Three microalloyed alloys, two of them are high strength low alloyed steel (HSLA) grades and the third is a Ni-Cr-Mo steel, from which the welding wires are being produced, were investigated. Repeated cycles around...

Die lichtbogenadditive Fertigung hat in den letzten Jahren wissenschaftlich und industriell gesehen einen großen Aufschwung erlebt. Insbesondere durch die Weiterentwicklung der Robotik und Automatisierungstechnik ist es möglich geworden auch große Bauteile wirtschaftlich und nach genauen Kundenspezifikationen herzustellen. Bei der Kavitationserosio...

Co-Cr alloys are frequently used for highly stressed components, especially in turbine and plant construction, due to their high resistance to thermal and mechanical stress, as well as to corrosive and abrasive loads. Furthermore, they are classified as difficult-to-cut materials because of their high strength and toughness as well as their low the...

Zur Überprüfung einer möglichen Geschwindigkeitsabhängigkeit des Haftreibungskoeffizienten in vorgespannten Verbindungen werden Gleitkraftversuche unter quasi-statischer Belastung sowie unter sehr hohen Geschwindigkeiten (v = 1 m/s) durchgeführt und die Ergebnisse miteinander verglichen. Dabei wird sich am stahl- baulich normativ geregelten Verfahr...

These days, additive manufacturing processes have a large representation in current research and in the field of industrial applications [...]

Hyperbaric welding is used for diferent steels in many underwater applications as a repair welding process. A diference between wet and dry welding processes can be made. Due to the increased ambient pressure, these processes have special features inherent in the process that infuence the cooling and penetration behaviour. The positive use of these...

Cobalt chromium alloys are often used in turbine and plant construction. This is based on their high thermal and mechanical stress resistance as well as their high wear resistance to corrosive and abrasive loads. However, cobalt is a cost-intensive material that is difficult to machine. Moreover, increasingly complex structures and the optimisation...

Featured Application Detection of stresses or stress peaks and potentially aging processes in the device. Abstract Resource-efficient manufacturing with a high degree of freedom in terms of component shape can be realised through additive manufacturing. The focus can lie not only on the manufacturing process in terms of geometrical correctness, st...

New alloys are needed to adapt the material properties and to improve the weldability of arc-based additive manufacturing processes. The classic development of welding filler materials is time-consuming and cost-intensive. For this reason, an alternative alloy concept is investigated and qualified here. This is based on the thin-film coating of wel...

Featured Application Wire Arc Additive Manufacturing of complex concentrated (high entropy alloys). Abstract The field of complex concentrated alloys offers a very large number of variations in alloy composition. The achievable range of properties varies greatly within these variants. The experimental determination of the properties is in many cas...

In additive manufacturing, knowledge of the geometry of the weld seam is crucial for the quality of the component. This is especially true for Wire and Arc Additive Manufacturing (WAAM) based on Gas Metal Arc Welding (GMAW). The length of the free wire electrode ("stickout") should be almost constant during the entire manufacturing process. In addi...

The aerospace industry uses nickel–iron alloys, e.g., FeNi36, to create moulding tools for composite materials, since these alloys have a low coefficient of thermal expansion. Nickel–iron alloys are hard-to-cut materials. The moulding tools are large in size and involve complex structures, making them cost-intensive and difficult to manufacture. Th...

High-strength steel sheets are used in the automotive industry to save weight. In particularly, in the chassis area, high-strength steels are constantly replacing the previously used strength classes of 440 - 590 MPa. In body in white construction, galvanized sheet steel has had long been established use due to its anti-corrosive effect. In chassis...

Voraussetzungen für den wirtschaftlichen Einsatz der Additiven Fertigung sind hohe Materialauftragsraten und eine durchgängige Prozesskette. Bei der lichtbogenbasierten Variante muss zunächst ein ganzheitlicher Ansatz entlang der Prozesskette des Bauteils implementiert werden. Zudem sind insbesondere die mechanischen Eigenschaften der dabei verarbe...

Featured Application Wire Arc Additive Manufacturing (WAAM). Abstract Wire arc additive manufacturing is currently rising as the main focus of research groups around the world. This is directly visible in the huge number of new papers published in recent years concerning a lot of different topics. This review is intended to give a proper summary o...

The quality of the material deposition and contour accuracy produced by WAAM (Wire Arc Additive Manufacturing) depends on process parameters such as the temperature and the volume of the weld pool. The control of the welding process can be substantially improved by obtaining real-time signals of the weld-pool temperature and volume. In this paper,...

High entropy alloys (HEAs) are among of the most promising new metal material groups. The achievable properties can exceed those of common alloys in different ways. Due to the mixture of five or more alloying elements, the variety of high entropy alloys is fairly huge. The presented work will focus on some first insights on the weldability and the...

The joining of components with as few weld layers as possible is an important aspect of weld seam design due to the resulting reduced manufacturing effort and reduced influence of thermal cycles on the base material as well as reduced distortion. For materials with good thermal conductivity, this is not easily possible. The energy density of the ar...

In der additiven Fertigung erschließen sich für das seit über 30 Jahren durchgeführte robotergestützte Metallschutzgasschweißen durch neue Technologien weitere Entwicklungsfelder. Stetig steigende Anforderungen an höhere Abschmelzleistungen und sicherheitsrelevante Bauteilkonzepte verstärken den Fokus auf die mechanischen Eigenschaften additiv gefe...

The lightweight construction of steel structures is often limited by the mechanical properties of the weld metal. The strength values of modern base materials are not achieved in the weld metal. There is a considerable need to develop welding consumables that allow the processing of modern fine-grained structural steels without limiting their poten...

Welding-related loss of strength, especially in the case of fatigue, significantly reduces the range of applications for high-strength fine-grained structural steels. In order to counteract this situation, the aim of the work is to increase the strength of welded joints made of high-strength fine-grained structural steels by using coated welding co...

In lightweight construction, light metals like aluminum are used in addition to high-strength steels. However, a welded joint of aluminum and steel leads to the precipitation of brittle, intermetallic phases and contact corrosion. Nevertheless, to use the advantages of this combination in terms of weight saving, composite hybrid forging has been de...

In this study, the monotonic and cyclic material properties of steel material of medium static strength produced additively in the wire arc additive manufacturing (WAAM) process were investigated. This investigated material is expected to be particularly applicable to the field of mechanical engineering, for which practical applications of the WAAM...

In Wire Arc Additive Manufactoring (WAAM), an object is welded from scratch. Finding feasible welding paths that make use of the potential of the technology is a computationally complex problem as it requires planning paths in 3D. All parts of the object to be manufactured have to be visited in few welding paths. The search for such welding paths i...

The present investigations on generative manufacturing using metallic materials pursue the idea of transferring the microscopic structural morphology of a dual-phase steel in modified form to the macroscopic level. The aim is to be able to join materials of different lattice modifications and to combine their positive properties. This applies in pa...

Brittle intermetallic phases are formed when steel and aluminum are joined. Therefore, it is difficult to use this combination of materials when applying the multimaterial design in the construction of load-adapted and weight-adapted structures. In order to largely avoid the formation of these brittle phases, joining processes based on diffusion pr...

Hybrid compound forging of aluminum bulk parts and steel sheet metals is a combination of material lightweight design and structural lightweight design. During this process, an aluminum bulk part and a steel sheet metal are combined and formed simultaneously. A material joint is generated by deforming, using zinc as solder material. This prevents t...

In diesem Beitrag werden die quasistatischen und Schwingfestigkeitseigenschaften von additiv mit dem WAAM-Verfahren gefertigtem Material der Werkstoffgruppe Stahl untersucht. Der Fokus der Untersuchung liegt dabei auf dem Einfluss der Beanspruchungsrichtung in Bezug zur Verarbeitungsrichtung und dem Einfluss zweier verschiedener bei der Herstellung...

Die generative Fertigung von Bauteilen gehört seit Jahren zum Stand der Technik. Der Trend geht zu höheren Fertigungsraten und belastungsgerechter Auslegung. Diese Anforderungen bedingen eine Notwendigkeit des Prozessverständnisses in Bezug auf die mechanischen Eigenschaften solcher Fertigungsverfahren. Durch den additiven Lagenaufbau von generativ...

The resilience of materials from the notch effect together with subsequent operating life and safety are important factors for the choice of material in industrial manufacture as well as for crash scenarios. The aim of this investigation is to study stress caused by the notch effect for HCT780XD and X5CrNi18-10 at different tensile test strain rate...

Die nachhaltige Nutzung von Bodenflächen in der Land- und Forstwirtschaft unter ökologischen Aspekten ist, ebenso wie die ökonomische Betriebsführung, eine der Kernanforderungen an die heutigen land- und forstwirtschaftlichen Betriebe. Die Fülle der Gesetze und Zertifizierungen, wie z.B. das FSC-Gütesiegel, führen heute dazu, dass die Anforderungen...

To find a quick method to quantify the depth of hardening in order to optimize the production process at thyssenkrupp Presta Schönebeck GmbH, micromagnetic characterization after surface heating is used. The difference between the following method and other proceedings is that the depth is measured on the opposite surface of the heated side. For th...

The development of high-strength and ultrahigh-strength fine-grain steels is especially enhanced due to requirements in the range of mobile crane construction, bridge construction, and general steel construction purposing a consistent utilization of lightweight construction and an increase of payloads. However, currently available filler metals lim...

Die nachfolgenden Ausführungen geben einen Überblick über die Vorgehensweise und Besonderheiten bei der Ermittlung von Werkstoffeigenschaften unter schlagartig-dynamischer Belastung. Darüber hinaus werden Ergebnisse zum Werkstoffverhalten des kerbbehafteten austenitschen Stahls 1.4301 unter schlagartig-dynamischer Last dargestellt.

Bauteile mit hochbelasteten Laufflächen wie zum Beispiel Muttern für Kugelumlauf-triebe werden meist randschichtgehärtet. Die charakteristische Einhärtungstiefe muss dabei einen Min-destwert erreichen, um den erforderlichen Verschleißschutz zu gewährleisten. Die ermittelte Tiefe muss jedoch unterhalb des Maximalwerts liegen, um einer Versprödung vo...

Im automobilen Leichtbau werden neben hochfesten Stählen zunehmend Leichtmetalle, wie z.B. Aluminium, verwendet. Die stoffschlüssige Verbindung von Aluminium und Stahl führt jedoch zur Ausscheidung spröder, intermetallischer Phasen und zu Kontaktkorrosion. Um dennoch durch die Kombination beider Werkstoffe Gewicht einsparen zu können, wurde das Ver...

In lightweight construction, light metals like aluminum are used in addition to high-strength steels. However, a welded joint of aluminum and steel leads to the precipitation of brittle, intermetallic phases and contact corrosion. Nevertheless, to use the advantages of this combination in terms of weight saving composite hybrid forging has been dev...

The increasing demand for high-strength fine-grain steels for the purpose of reducing the weight of steel structures and increasing payloads, is driving forward the development of fine-grain steels. However, with the currently available welding consumables, it is not possible to achieve the strengths of modern fine-grain steels with a grade of S130...

The increasing demand for high-strength fine-grain steels for the purpose of reducing the weight of steel structures and increasing payloads, is driving forward the development of fine-grain steels. However, with the currently available welding consumables, it is not possible to achieve the strengths of modern fine-grain steels with a grade of S130...