Katharina Frey’s research while affiliated with German Aerospace Center (DLR) and other places

Additive manufacturing with aluminum alloys is becoming increasingly important in the automotive industry to meet the growing demand for lightweight construction and flexibility. However, higher build rates and higher process efficiency are necessary for laser metal deposition (LMD) to be more economically competitive. The so called high-speed LMD allows high build rates by partial melting of the powder before it hits the melt pool but is currently limited to coatings of rotationally symmetrical parts. Our goal is to apply this process technology to the additive manufacturing of AlSi10Mg and thereby increase the build rate. In this work we demonstrate a successful build-up of cuboids manufactured with the alloy AlSi10Mg using feed rates ten times higher compared to state of the art. The tensile strength of these cuboids is in the range of 180 to 220 MPa.

Additive manufacturing with aluminum alloys is becoming increasingly important in the automotive industry to meet the growing demand for lightweight construction and flexibility. However, higher build rates and higher process efficiency are necessary for laser metal deposition (LMD) to be more economically competitive. The so called high-speed LMD allows high build rates by partial melting of the powder before it hits the melt pool but is currently limited to coatings of rotationally symmetrical parts. Our goal is to apply this process technology to the additive manufacturing of AlSi10Mg and thereby increase the build rate. In this work we demonstrate a successful build-up of cuboids manufactured with the alloy AlSi10Mg using feed rates ten times higher compared to state of the art. The tensile strength of these cuboids is in the range of 180 to 220 MPa.

Das FlexCAR besteht aus einer autonom gesteuerten Fahrzeugplattform für die Mobilität von morgen, welche Use-Case-gesteuert als Forschungsdemonstrator fungiert, um neue technologische Features unmittelbar aus dem Forschungsstadium nach dem Plug-and-Play-Prinzip gezielt zu implementieren. Damit kann eine frühzeitige Validierung im Hinblick auf ein künftiges Anwendungspotenzial ermöglicht werden. Offene Soft- und Hardwareschnittstellen sind hier berücksichtigt oder werden weiterentwickelt.

Das FlexCAR besteht aus einer autonom gesteuerten Fahrzeugplattform für die Mobilität von morgen, welche Use-Case-gesteuert als Forschungsdemonstrator fungiert, um neue technologische Features unmittelbar aus dem Forschungsstadium nach dem Plug-and-Play–Prinzip gezielt zu implementieren. Damit kann eine frühzeitige Validierung im Hinblick auf ein künftiges Anwendungspotenzial ermöglicht werden. Offene Soft- und Hardwareschnittstellen sind hier berücksichtigt oder werden weiterentwickelt. FlexCAR comprises an autonomously controlled vehicle platform for the mobility of tomorrow. Use case-guided as a research platform, it enables implementing new technological features according to the plug-and-play principle. It allows for an early validation concerning potential future applications. Open software and hardware interfaces are included and will be further developed.