Additive Manufacturing


The Group Additive Manufacturing (AM) is concerned with innovative methods of powder- and beam-based AM, the further development of AM processes and the development of special AM alloys. The focus is on selective electron beam melting (SEBM), selective laser melting (SLM) and laser metal deposition (LMD).
Various Arcam electron beam machines for powder bed based additive manufacturing are available. In addition, there is a new in-house developed electron beam machine (Athene) equipped with a 6 kW electron beam gun. The vacuum-based electron beam technology allows building temperatures over 1000 ° C. These process conditions enable the processing of high performance materials such as intermetallic alloys or superalloys.





Term: 1. July 2020 - 30. June 2024
Funding source: Bundesministerium für Forschung, Technologie und Raumfahrt (BMFTR)
Acronym: Track-AM
Project leader:

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Term: 1. January 2012 - 31. December 2023
Funding source: DFG / Sonderforschungsbereich / Transregio (SFB / TRR)
Acronym: SFB/TRR 103 (B02)
Project leader: ,

Project B2 explores selective electron beam melting, which belongs to the additive manufacturing technologies, for the processing of single-crystalline superalloys. Especially the potential of the inherent high cooling rates is investigated. These lead to an ultra-fine and directional solidified microstructure. The main challenge of this project is to develop innovative processing strategies based on a sound theoretical process understanding in order to produce crack-free and preferably single c…

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Term: 1. October 2020 - 30. September 2023
Funding source: DFG-Einzelförderung / Sachbeihilfe (EIN-SBH)
Project leader: ,

Cellular structures represent a promising alternative to classical randomly packed bed reactors owing to their very good heat transport characteristics. A key challenge of using cellular structures as catalyst carriers in tubular reactors is the contact of the structure with the tube wall, which in many cases is not sufficient and thus downgrades the overall heat transfer performance. Especially with strongly exo- or endothermic reactions, this inhibition of heat transfer leads to undesirable te…

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Term: 1. December 2020 - 30. November 2023
Funding source: Bundesministerium für Wirtschaft und Energie (BMWE)
Acronym: SAPHIR
Project leader:

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Term: 1. January 2018 - 30. June 2022
Funding source: DFG / Sonderforschungsbereich (SFB)
Acronym: SFB 814 (T2)
Project leader: ,

The aim of this project is to facilitate additive manufacturing of bulk metallic components by selective laser melting based on predictive numerical simulations. There should be developed suitable process strategies to ensure the amorphous material state preferably without aging effects in the bulk as well as for complex geometries. Therefore, clear statements using the numerical simulation has to be made exceeding the temperature field and the material consolidation during manufacturing towards…

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Term: 1. July 2011 - 30. June 2023
Funding source: DFG / Sonderforschungsbereich (SFB)
Acronym: SFB 814 (B2)
Project leader: ,

This sub-project aims to automate the development of process strategies for selective electron beam melting. The integration of the innovative electron optics in the process cycle allows an in situ quality control and in combination with the findings from the first funding periods, the active control of the process. Finally, a self-learning system should be able to manufacture arbitrary parts of even novel alloys by a process database optimization.

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Term: 1. January 2019 - 31. December 2022
Funding source: BMFTR / Verbundprojekt
Acronym: Tubulyze
Project leader: ,

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Term: 1. October 2018 - 30. September 2022
Funding source: EU - 8. Rahmenprogramm - Horizon 2020
Acronym: MANUELA
Project leader:

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Term: 1. April 2019 - 30. September 2021
Funding source: DFG-Einzelförderung / Sachbeihilfe (EIN-SBH)
Project leader:

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Term: 1. July 2011 - 30. June 2019
Funding source: DFG / Sonderforschungsbereich (SFB)
Acronym: SFB 814 (B04)
Project leader:

The basic mechanisms that are essential in the powder based selective beam melting process are poorly understood. Most of the existing analytical and numerical models describing the process of consolidation in a homogenized image, i.e. individual powder particles are not resolved. This approach is suitable for information on averages, but cannot capture the local influence of the powder, i.e. the powder size distribution, the stochastic effect of the powder bed, the wetting of the powder by the…

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Term: 1. July 2011 - 30. June 2023
Funding source: DFG / Sonderforschungsbereich (SFB)
Acronym: SFB 814 (B5)
Project leader: ,

Fundamental understanding of a new and innovative process combining sheet metal forming with additive manufacturing is the main goal of this research work.

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Term: 1. May 2018 - 30. April 2021
Funding source: andere Förderorganisation
Project leader:

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Term: 1. April 2019 - 31. March 2021
Funding source: Bundesministerium für Wirtschaft und Energie (BMWE)
Project leader:

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Term: 1. August 2019 - 31. July 2020
Funding source: andere Förderorganisation
Project leader:

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Term: since 1. November 2017
Project leader:

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Term: 1. October 2016 - 30. September 2019
Funding source: Industrie
Project leader:

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Term: 1. September 2016 - 31. August 2019
Funding source: DFG-Einzelförderung / Sachbeihilfe (EIN-SBH)
Project leader: ,

Raney-copper is a catalyst made from a copper base alloy containing at least one less noble element than copper (e.g. zinc). After fabricating the base material via a casting process consisting of a melt and a quenching step the alloy can be converted into a nanoporous and catalytically active structure using an alkaline solution. During this project a Raney-copper type alloy will be processed using the selective electron beam melting process (SEBM). The main goal of this project is to utilize t…

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Term: 1. April 2017 - 1. April 2019
Funding source: andere Förderorganisation
Project leader: ,

Ziel dieses Projektes ist es, die Einschränkungen der bisherigen Elektronenstrahlkanone und eingeschränkten Prozesskontrolle zu überwinden, um damit einen großen Entwicklungsschritt in dieser Technologie zu vollziehen. Dazu ist geplant, die Elektronenstrahlkanone einer bei WTM vorhandenen Arcam S12 (diese wird geopfert) durch eine erheblich leistungsfähigere Elektronenstrahlkanone zu ersetzen. Auf dem Markt sind Kanonen mit sehr viel höherer Leistung bei gleichbleibend guter Strahlqualität vorha…

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Term: 1. August 2015 - 31. July 2018
Funding source: Siemens AG
Project leader:

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Term: 1. November 2007 - 31. October 2017
Funding source: DFG / Exzellenzcluster (EXC)
Acronym: EXC15 EAM (E2)
Project leader:

Metamaterials are artificial structures with extraordinary properties as result of their internal architecture. We are investigating mechanical metamaterials manufactured by SEBM. We investigate auxetic materials characterized by a negative Poisson’s ratio as well as phononic band gap materials. Structure design rests upon basic knowledge about mechanisms generated by numerical simulation.

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Term: 1. October 2010 - 30. June 2017
Funding source: DFG-Einzelförderung / Sachbeihilfe (EIN-SBH)
Project leader:

Additive manufacturing of components is a key technology of the future. The powder bed based selective electron beam melting process allows to produce complex components from high performance alloys. Nevertheless, the highly dynamic melting process is not fully understood and suffers from binding faults, changes of the alloy composition and process instabilities. Aim of the project is to understand the basic mechanisms during selective electron beam melting and to use this knowledge to predict a…

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Term: 1. April 2016 - 31. October 2017
Funding source: DFG / Exzellenzcluster (EXC)
Acronym: EXC15 EAM
Project leader:

Target oriented material development has to be based on a profound understanding of process-inherent mechanisms. This project aims on in-situ observation of the material consolidation process during additive manufacturing. This includes particular phase transformations and the nucleation and growth of precipitates. The observation of these phenomena is a big challenge due to their high temporal dynamics. New experimental environments allow the observation of the formation of the microstructure o…

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Term: 1. January 2013 - 30. June 2017
Funding source: EU - 7. RP / Cooperation / Verbundprojekt (CP)
Acronym: AMAZE
Project leader:

The overarching goal of AMAZE is to rapidly produce large defect-free additively-manufactured (AM) metallic components up to 2 metres in size, ideally with close to zero waste, for use in the following high-tech sectors namely: aeronautics, space, automotive, nuclear fusion and tooling. Four pilot-scale industrial AM factories will be established and enhanced, thereby giving EU manufacturers and end-users a world-dominant position with respect to AM production of high-value metallic parts, by 20…

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Term: 1. January 2014 - 31. December 2016
Funding source: EU - 7. RP / Capacities / Forschung für spezielle Gruppen (insbesondere KMU) (SME)
Acronym: FastEBM
Project leader:

Electron beam melting additive manufacturing is used to produce successive layers of a part in a powder bed and offers the ability to produce components closest to their final dimensions, with good surface finish. At this time the process is faster than any other technique of comparable quality, however the parts are not produced at sufficient rate to make them economically viable for any but very high value specific applications. One key output of the project will be the knowledge surrounding t…

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Term: 1. July 2013 - 30. June 2016
Funding source: Sonstige EU-Programme (z. B. RFCS, DG Health, IMI, Artemis)
Acronym: SIMCHAIN
Project leader:

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Term: 6. May 2015 - 1. August 2015
Funding source: Siemens AG
Project leader:

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Term: 1. April 2011 - 30. April 2013
Funding source: DFG-Einzelförderung / Sachbeihilfe (EIN-SBH)
Project leader:

Titanaluminde haben durch das Ersetzen deutlich schwererer Nickelbasislegierungen großes Potential für Kraftstoffeinsparungen in zukünftige Generationen von Flugzeug- und Kraftwerksturbinen. Die Verarbeitung dieser Materialien gestaltet sich allerdings äußerst schwierig, da die Materialeigenschaften stark von der Mikrostruktur und chemischen Homogenität des Endproduktes abhängen. Im vorliegenden Vorhaben soll ein Rapid Manufacturing Prozess, das selektive Elektronenstrahlschmelzen, zur Verarbeit…

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Term: since 1. January 2000
Project leader:

The electron beam offers the potential for innovative selective beam melting process strategies due its inertia-free deflection at extremely high speed. A deep understanding of the process is developed with the help of different methods of in-situ process monitoring (thermal imaging and high speed camera). In particular, the potential to tailor the microstructure, grain structure and texture of the material with the help of the extremely high beam velocity is explored. In addition, we investigat…

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Term: since 1. January 2000
Project leader:

We investigate the potential of SEBM for processing of technical alloys based on Iron Aluminides, Nickel and Copper as well as amorphous metals. For Iron aluminides, the focus is on the influence of additional elements such as Boron and Titanium on the workability, the microstructure and the resulting properties.   Concerning pure Copper and Copper alloys our focus is on the influence of minor elements or contaminations such as Oxygen or Phosphorus on the resulting properties, in particular the…

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Term: since 1. January 2016
Project leader:

Commercial available EBSM machines show strong limitations with respect to the beam power, beam quality and beam control. To overcome these limitations, the electron gun and control system of an Arcam S12 System was renewed. The resulting machine is equipped with a 6 kW electron beam gun and a backscattering electron detector for process monitoring. This is the first electron beam AM machine where the electron beam serves for both, processing and analyzing.

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Term: since 1. January 2010
Project leader:

We investigate new alloys for structural catalysts that serve as carrier material and simultaneously as catalytically active material in structured reactors. The active catalyst (Raney copper type) develops from the AM manufactured structure by leaching. Thus, geometric restrictions of complex coating processes for catalytic functionalization disappear. The direct generation of the catalytically active material on the carrier structure is expected to show advantages with respect to thermal manag…

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Term: since 1. January 2015
Project leader:

We use combinatorial methods for the development of new alloys that allow the creation of large material libraries based on thermodynamic predictions. To do this, the Chair of WTM is currently establishing a laser metal deposition machine from the company InssTek. This machine is equipped with four powder hoppers in a glove box with inert gas atmosphere. Besides materials libraries we are also able to realize multi-material and graded components.

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Term: since 1. January 2015
Project leader:

Target oriented material development has to be based on a profound understanding of process-inherent mechanisms. This project aims on in-situ observation of the material consolidation process during additive manufacturing. This includes particular phase transformations and the nucleation and growth of precipitates. The observation of these phenomena is a big challenge due to their high temporal dynamics. New experimental environments allow the observation of the formation of the microstructure o…

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Term: since 1. January 2000
Project leader:

We examine the possibility to process high performance alloys such as non-weldable Nickel-base alloys or special Copper alloys by means of SEBM. There are also experiences in the processing of Titanium alloys, in particular for medical applications, Titanium aluminides and steels.

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Term: 1. July 2019 - 31. December 2020
Funding source: Industrie
Project leader:

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Term: 1. July 2019 - 30. June 2023
Funding source: DFG - Sonderforschungsbereiche
Acronym: SFB 814 (C5)
Project leader: ,

Based on the gained knowledge of projects B4 and C5, the aim of this project is to account for the influence of part borders on the resulting material/part-mesostructure for powder- and beam-based additive manufacturing technologies of metals and to model the resulting meso- and macroscopic mechanical properties. The mechanical behavior of these mesostructures and the influence of the inevitable process-based geometrical uncertainties is modelled, verified, quantified and validated especially fo…

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