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Available online at www.sciencedirect.com
Available online at www.sciencedirect.com
ScienceDirect
Procedia CIRP 00 (2017) 000–000
www.elsevier.com/locate/procedia
2212-8271 © 2017 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 28th C IRP Design Conference 2018.
28th CIRP Design Conference, May 2018, Nantes, France
A new methodology to analyze the functional and physical architecture of
existing products for an assembly oriented product family identification
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu
Abstract
In today’s business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of
agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production
systems as well as to choose the optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to
analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and
nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production
system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster
these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable
assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and
a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the
similarity between product families by providing design support to both, production system planners and product designers. An illustrative
example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
© 2017 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
Keywords: Assembly; Design method; Family identification
1. Introduction
Due to the fast development in the domain of
communication and an ongoing trend of digitization and
digitalization, manufacturing enterprises are facing important
challenges in today’s market environments: a continuing
tendency towards reduction of product development times and
shortened product lifecycles. In addition, there is an increasing
demand of customization, being at the same time in a global
competition with competitors all over the world. This trend,
which is inducing the development from macro to micro
markets, results in diminished lot sizes due to augmenting
product varieties (high-volume to low-volume production) [1].
To cope with this augmenting variety as well as to be able to
identify possible optimization potentials in the existing
production system, it is important to have a precise knowledge
of the product range and characteristics manufactured and/or
assembled in this system. In this context, the main challenge in
modelling and analysis is now not only to cope with single
products, a limited product range or existing product families,
but also to be able to analyze and to compare products to define
new product families. It can be observed that classical existing
product families are regrouped in function of clients or features.
However, assembly oriented product families are hardly to find.
On the product family level, products differ mainly in two
main characteristics: (i) the number of components and (ii) the
type of components (e.g. mechanical, electrical, electronical).
Classical methodologies considering mainly single products
or solitary, already existing product families analyze the
product structure on a physical level (components level) which
causes difficulties regarding an efficient definition and
comparison of different product families. Addressing this
Procedia CIRP 74 (2018) 196–200
2212-8271 © 2018 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review under responsibility of the Bayerisches Laserzentrum GmbH.
10.1016/j.procir.2018.08.093
© 2018 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review under responsibility of the Bayerisches Laserzentrum GmbH.
Available online at www.sciencedirect.com
ScienceDirect
Procedia CIRP 00 (2018) 000–000
www.elsevier.com/locate/procedia
2212-8271 © 2018 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
Peer-review under responsibility of the Bayerisches Laserzentrum GmbH.
10th CIRP Conference on Photonic Technologies [LANE 2018]
Laser additive manufacturing of oxide dispersion strengthened steels using
laser-generated nanoparticle-metal composite powders
Markus B. Wilmsa, RenéStreubelb, Felix Frömelc, Andreas Weisheita, Jochen Tenkampc,
Frank Waltherc,Stephan Barcikowskib,Johannes Henrich Schleifenbauma, Bilal Gökceb,*
aChair for Digital Additive Production (DAP), RWTH Aachen University and Fraunhofer Institue of Laser Technology (ILT), 52074 Aachen, Germany
bTechnical Chemistry I and Center for Nanointegration Duisburg-Essen (CENIDE), University Duisburg-Essen, 45141 Essen, Germany
cTU Dortmund University, Department of Materials Test Engineering (WPT), Baroper Str. 303, D-44227 Dortmund, Germany
* Corresponding author. Tel.: +49-201-183-3146; fax: +49-201-183-3049.E-mail address: bilal.goekce@uni-due.de
Abstract
A new route for the synthesis of powder composites suitable for processing with laser additive manufacturing is demonstrated. The powder
composites, consisting of micrometer-sized stainless steel powder, homogenously decorated with nano-scaled Y2O3powder particles, are
manufactured by laser processing of colloids and electrostatic deposition. Consolidated by laser metal deposition and selective laser melting,
the resulting specimens show superior mechanical properties at elevated temperatures, caused by the nano-sized, homogenously distributed
dispersoids.
© 2018 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
Peer-review under responsibility of the Bayerisches Laserzentrum GmbH.
Keywords: Oxide dispersion strengthened materials; ODS; Laser additive manufacturing; Pulsed laser ablation in liquids; Selective Laser Melting
1. Introduction
Oxide dispersion steels are a promising structural material
class for GenIV nuclear reactorsas well as future fusion
reactors [1, 2]. This material class is typically composed of a
ferritic/martensitic steel matrix, alloyed with high amounts of
chromium (9-20%) to exhibit corrosion resistance. The steel
matrix is additionally reinforced with nanometer-sized
dispersoids, composed of titanium-containing yttrium-based
oxides [3,4], exhibiting low solubility in the steel matrix
offering only low potential for coarsening by Ostwald
ripening [5]. The homogeneously distributed dispersoids
increase material strength in particular at high temperatures,
such as creep resistance [8,9]. Additionally, theyact as sinks
for defects, induced by high-energy neutron or ion irradiation,
and therefore increase the resistance against macroscopic
material degradation, such as swelling [10-12].
The main fabrication route for ODS steels is the powder
metallurgy route, consisting of a long-term (up to 48h), batch-
wise mechanical alloying process that uses metal matrix alloy
powder and a nanometer-sized yttrium oxide powder [13-15].
By ball milling in planetary or high-energy attritor type mills
powder composites of metal and oxide particles are formed.
This process is characterized by the dissolution of oxide
particles into the metal powders, since the peak of yttrium
oxide in XRD disappears with prolonged milling times [16].
The ball milling process is subsequently followed by various
types of consolidation processes, such as hot-isostatic pressing
or hot extrusion as well as various thermomechanical
treatments in order to adjust the final microstructure of the
alloy. The complex and expensive fabrication route for ODS
Available online at www.sciencedirect.com
ScienceDirect
Procedia CIRP 00 (2018) 000–000
www.elsevier.com/locate/procedia
2212-8271 © 2018 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
Peer-review under responsibility of the Bayerisches Laserzentrum GmbH.
10th CIRP Conference on Photonic Technologies [LANE 2018]
Laser additive manufacturing of oxide dispersion strengthened steels using
laser-generated nanoparticle-metal composite powders
Markus B. Wilmsa, RenéStreubelb, Felix Frömelc, Andreas Weisheita, Jochen Tenkampc,
Frank Waltherc,Stephan Barcikowskib,Johannes Henrich Schleifenbauma, Bilal Gökceb,*
aChair for Digital Additive Production (DAP), RWTH Aachen University and Fraunhofer Institue of Laser Technology (ILT), 52074 Aachen, Germany
bTechnical Chemistry I and Center for Nanointegration Duisburg-Essen (CENIDE), University Duisburg-Essen, 45141 Essen, Germany
cTU Dortmund University, Department of Materials Test Engineering (WPT), Baroper Str. 303, D-44227 Dortmund, Germany
* Corresponding author. Tel.: +49-201-183-3146; fax: +49-201-183-3049.E-mail address: bilal.goekce@uni-due.de
Abstract
A new route for the synthesis of powder composites suitable for processing with laser additive manufacturing is demonstrated. The powder
composites, consisting of micrometer-sized stainless steel powder, homogenously decorated with nano-scaled Y2O3powder particles, are
manufactured by laser processing of colloids and electrostatic deposition. Consolidated by laser metal deposition and selective laser melting,
the resulting specimens show superior mechanical properties at elevated temperatures, caused by the nano-sized, homogenously distributed
dispersoids.
© 2018 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
Peer-review under responsibility of the Bayerisches Laserzentrum GmbH.
Keywords: Oxide dispersion strengthened materials; ODS; Laser additive manufacturing; Pulsed laser ablation in liquids; Selective Laser Melting
1. Introduction
Oxide dispersion steels are a promising structural material
class for GenIV nuclear reactorsas well as future fusion
reactors [1, 2]. This material class is typically composed of a
ferritic/martensitic steel matrix, alloyed with high amounts of
chromium (9-20%) to exhibit corrosion resistance. The steel
matrix is additionally reinforced with nanometer-sized
dispersoids, composed of titanium-containing yttrium-based
oxides [3,4], exhibiting low solubility in the steel matrix
offering only low potential for coarsening by Ostwald
ripening [5]. The homogeneously distributed dispersoids
increase material strength in particular at high temperatures,
such as creep resistance [8,9]. Additionally, theyact as sinks
for defects, induced by high-energy neutron or ion irradiation,
and therefore increase the resistance against macroscopic
material degradation, such as swelling [10-12].
The main fabrication route for ODS steels is the powder
metallurgy route, consisting of a long-term (up to 48h), batch-
wise mechanical alloying process that uses metal matrix alloy
powder and a nanometer-sized yttrium oxide powder [13-15].
By ball milling in planetary or high-energy attritor type mills
powder composites of metal and oxide particles are formed.
This process is characterized by the dissolution of oxide
particles into the metal powders, since the peak of yttrium
oxide in XRD disappears with prolonged milling times [16].
The ball milling process is subsequently followed by various
types of consolidation processes, such as hot-isostatic pressing
or hot extrusion as well as various thermomechanical
treatments in order to adjust the final microstructure of the
alloy. The complex and expensive fabrication route for ODS
10th CIRP Conference on Photonic Technologies [LANE 2018]
Markus B. Wilms et al. / Procedia CIRP 74 (2018) 196–200 197
2Author name /Procedia CIRP 00 (2018) 000–000
steels still poses the main drawback for widespread industrial
applications of these type of materials. Also, conventional
techniques do not offer the possibility of near net shaped
manufacturing. An alternative manufacturing method is Laser
Additive Manufacturing (LAM), which is principally capable
of producing ODS materials by offering high solidification
rates in combination with strong Maragoni forces within small
scaled melt pools. The principalcapability of the LAM
processes Laser Metal Deposition (LMD) [17]and Selective
Laser Melting (SLM) [18-20]to produce ODS materials has
been showed in various studies. However, in all cases
mechanically alloyed powder has been utilized.In this study
the feasibility of nanoparticle-metal powder composites,
fabricated by a new route consisting of laser processing of
colloids (LPC) and subsequent adsorption by pH-controlled
electrostatic interaction on steel powders [21] for the LAM
production of ODS materials is demonstrated. Mechanical
characterization is performed by compression tests of
specimens manufactured by LMD [22]. Additionally the
powder was used to manufacture bulk specimens via SLM.
2. Materials and Methods
Ferritic, stainless steel powder (Nanoval) consisting of
21.03 wt% Cr, 4.67 wt% Al and 0.47 wt% Ti and with two
powder particle fractions of < 45 μm for SLM and 45-90 μm
for LMD was used for laser-based processing of colloids with
0.3 wt% commercial Y2O3nanopowder (Sigma Aldrich).
2.1 Production of composite powders
A 10 ps laser (EdgeWave) with a wavelength of 355 nm
was used with a laser power of 20 W and a repetition rate of
80 kHz to deagglomerate dispersed Y2O3nanoparticles in an
aqueous solution by laser processing of colloids (LPC)
[23,24]via a flow jet configuration [25,26] (Fig. 1) for five
passage cycles. The nanoparticles are adsorbed via
electrostatic interaction by adjusting the pH value of the
aqueous solution [25].
Fig. 1 Schematic drawing of the LPC process and the electrostatic deposition
process in aqueous suspension
2.2 Consolidation via LAM
LMD is conducted on a three-axis handling system
(Schuler-Held) equipped with a diode laser system (Laserline
LDF 2000-30) emitting at wavelengths of 1025 and 1064 nm.
Using a special optical setup a focal spot diameter of approx.
0.6 mm is generated. The powderis injected via a coaxial
powder feed nozzle (Fraunhofer ILT) and a disc-based
feeding system (GTV Verschleißschutz PF2/2) using Ar gas.
Argon is fed through the beam path for additional shielding
from the surrounding atmosphere.
Bulk samples were produced using a laser power of 370 W,
a deposition speed of 2,000 mm/min and a powder feed rate of
1.3 g/min on a water-cooled plate to ensure rapid heat transfer
to the substrate. A two directional deposition pattern,
maintaining constant track offset of 350 μm and height offset
of 210 μm, is used to manufacture bulk samples with 40
layers.
Fig. 2 Schematic drawing of LMD (left) and SLM (right)
SLM is conducted on a laboratory SLM machine (Aconity
MIDI) equipped with a 1kW fiber laser (IPG YLR-1000-WC-
Y14) emitting a wavelength of 1070 nm. The laser scanner is
used to generate a focal spot diameter of approx. 80 μm.
Cubic bulk samples (5 mm3) were manufactured using a
chess-like pattern with a constant layer height of 30 μm, a
scanning speed of 800 mm/s and a laser power of 160 W.
2.3 Microstructural characterization
Microstructural characterization is conducted using light
optical microscopy (LOM) after standard metallographic
preparation of cross sections perpendicular to building
direction and etching with “Nital” agent (3 Vol.% HNO3
(aq.)). Additionally the samples are examined using a
scanning electron microscope (Zeiss Leo 1455EP) in SE-
mode.
2.4 Mechanical characterization
For mechanical characterization quasistatic compression
tests with constant speed (vc=0.0833 mm/min) at room
temperature and at 600°C were performed. A servohydraulic
testing system (Schenck PC63M, Instron 8800 controller)
with a 63kN load cell, equipped with a high temperature
furnace (MTS 653) was used to test cylindrical water-jet cut
specimens (diameter 4 mm, height 5-6 mm). Lubrication
agent (Molykote) was used to minimize friction between the
specimens and the compression dies.
198 Markus B. Wilms et al. / Procedia CIRP 74 (2018) 196–200
Author name /Procedia CIRP 00 (2018) 000–000 3
3. Results
The laser processing (dispersion) of colloidal aqueous
suspension of Y2O3nanoparticles resulted in a significant
reduction of the agglomerates (Fig. 3).
Figures 3a-c) show the presence of agglomerated Y2O3
nanoparticles in dependence of the used treatment method as
imaged by SEM.While ultrasonication of the suspension
already leads to deagglomeration, dispersion by means of
LPC evidently leads to less agglomerates.
Fig.3 Deagglomeration of Y2O3nanoparticles by different treatment methods.
(a-c) SEM images. (D) UV-Vis extinction spectra. (E) Measurement of the
fraction of Y2O3nanoparticles with hydrodynamic diameters >100nm by
dynamic light scattering.
This conclusion is also supported by UV-Vis extinction
spectroscopy (Fig. 3d)) where the extinction is increased by a
better dispersion of the nanoparticles (at the same
concentration). Fig. 3e shows the fraction of particles larger
than 100 nm for different dispersion methods as extracted
from dynamic light scattering measurements. This method
which is dominated by large scatting entities additionally
supports the above observation, i.e.,only laser dispersion by
LPC leads to a significant reduction of the agglomerates.
The subsequent adsorption of laser-irradiated nanoparticles on
raw steel powder, which is also performed in aqueous
suspension, resultsin homogeneous distribution of
nanoparticles on the steel raw powders surface (Fig. 4).
Fig.4 SEM image of raw steel powder (a) and decorated steel powder with
0.3wt% Y2O3(b)
The nanoparticle deposition is achieved by
dielectrophoretic interaction between nanoparticle and
micropowder. For the suspension apH of 6is adjusted
leading to negatively charged steel powder particles and
positively charged nanoparticles. After deposition the
suspension is dried in a furnace (50°C) for several hours. The
steel powder does not additionally oxidize during its transient
immersion time in water as confirmed by REM-EDX
analysis.
The manufactured powder composites are processed with
LMD with the setup described in 2.2. In contrast to non-
reinforced steel powder the melt pool during processing
becomes more turbulent, which is also indicated by increased
spark formation. However, specimens with porosities of
approx. 0.5% could be manufactured and no further
adjustments of process parameters had to be performed. No
cracks could be observed in the manufactured specimens. The
microstructure is characterized by large elongated grains,
which exceed the distance between interlayer boundaries and
therefore indicate epitaxial grain growth (Fig. 5). The grains
are oriented in building direction with asubtle inclination of a
few degrees caused the curvature of the solidification front in
combination with the used building strategy.Grain refinement
by heterogeneous nucleation on dispersed nanoparticles is not
observed. This may be related to the poor wettability of
yttrium oxide by iron-chromium melts. Vickers hardness
measurements (HV10) further confirm that (within the error
of the measurement) the distributed nano-scaled oxides have
no influence on hardness of the material (data not shown).
Fig.5 Light optical microscope image (a) of the microstructure of LMD
produced sample,(b)SEM image revealing the presence of homogenously
distributed oxide particles
A more critical test for ODS steels are compression tests at
high temperatures, since these materials are typically used in
high-temperature environments. The performed compression
tests reveal decreasing mechanical strength with increasing
testing temperature, which is expected and typical for steels.
However, the mechanical properties of steel, reinforced with
nano-scaled Y2O3(labelled in Fig. 6as “Y2O3”), are superior
compared to the unreinforced material. Whereas the increase
of compression stress at room temperature for reinforced steel
is rather small, the increase at higher testing temperatures
(600°C) becomes significantly more pronounced, which can
be explained by impairment of climb or glide motion of
dislocations by dispersed nanoparticles.
Fig.6 Averaged compression behavior at room temperature (a) and 600°C (b)
Markus B. Wilms et al. / Procedia CIRP 74 (2018) 196–200 199
4Author name /Procedia CIRP 00 (2018) 000–000
To test the SLM-processability of the powder composites,
further specimens are built by SLM (Fig. 7). These specimens
exhibit porosities of approx. 0.8%. The microstructure is
characterized by elongated grains in building direction. The
width of these grains is considerably smaller than the grains
observed in LMD specimens, which may be caused by the
utility of a smaller beam diameter and therefore higher
solidification rates. Additionally, no inclination of the growth
direction of the grains is visible. However, epitaxial grain
growth can be observed.
Fig. 7 Photograph of the SLM specimen on a316L substrate material (a),
SEM image of homogenously distributed oxides in SLM built specimen (b)
A large number of “spots” indicate the presence of sub-100
nm-sized dispersoids(Fig. 7 right). These small populations
of dispersoids cannot be resolved by the resolution of the used
SEM system. Detailed analysis of these areasrequire
transmission electron microscopy but are not within the scope
of this study.
4. Conclusions and Outlook
The feasibility of a novel powder synthesis route,
consisting of LPC and subsequent electrophoretic deposition
is demonstrated in this study. Powder composites, which are
characterized by ahomogenous distribution of Y2O3-
nanoparticles on the surface of micrometer-sized stainless
steel particles, could be synthesized.The powder composites
were successfully processed by the two LAM processes of
LMD and SLM, leading to bulk specimens with low
porosities and homogenous distribution of nanoscale
dispersoids. Compression tests at elevated temperatures
demonstrate the superior performance of reinforced material
compared to raw stainless steel specimens.
Future investigations will focus on the mechanical
characterization of the SLM processed material as well as the
microstructural characterization by TEM. In order to qualify
these materials for industrial application further mechanical
tests such as long-term creep tests and evaluation of high
energy neutron resistance need to be performed.
Acknowledgments
We thank Veronica Rocio Molina Ramirez for conducting
SEM analysis and Mareen Goßling for her contribution in
performing SLM experiments.
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