ACAM @Formnext 2019

Rendering-ACAM-Stand

Walbert–Schmitz GmbH & Co. KG

Visit us @Formnext at the booth H11 D48

The ACAM Team is happy to be a part of the Formnext, the internationally leading trade fair on Additive Manufacturing. Our cooperation enables us to be a part of an innovative platform for industrial production, which leverages an even wider range of topics along the relevant process chains, and key areas such as software, material, and pre-and post-processing.

Meet up with one of our experts to discuss the latest developments around Additive Manufacturing, to get to know about our community as well as learn about our professional education program.

At Formnext, ACAM showcases solutions along the entire AM value and process chain

We compiled innovative findings of the RWTH Aachen Campus, one of the most sophisticated environment for R & D in one substantial showcase especially for you at Formnext. You will find the latest activities of our research partners directly from Aachen. Our experts are eager to share insights and discuss industry trends with a non-biased view. We will be expecting you at our Booth H11 D48.

RWTH Aachen Chair for Digital Additive Production DAP

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Fraunhofer ILT, Volker Lannert

Current global political debates demand for the reduction of fine dust emissions and a new orientation in electromobility. Facing the present challenges in diminishing fine dust emissions resulting from brake disc wear, economical coating technologies for wear and corrosion protection in mass production applications present one essential approach: The Extreme High-Speed Laser Material Deposition (EHLA) process is a very promising solution in this context.

Characteristics:
  • Process speed: up to 500 m/min
  • Layer thickness: 20 to 350 μm, dense and metallurgical bonded layers
  • Material efficiency: up to 95%
Advantages:
  • Almost any alloy can be used for coatings (e.g., iron-, nickel-, aluminum-based alloys, Metal Matrix Composites (MMC))
  • It requires fewer process steps for brake disc coating
  • Reduces coating time and increases process efficiency in terms of energy and resources
  • It increases the life cycles of brake discs and brake drums
  • The downtimes, particularly in the transport sector, can be reduced due to less maintenance and replacement.
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Fraunhofer IPT, RWTH DAP

Innovative engine concepts directly influence resource conservation and, hence, have a major impact on economic efficiency. They often go hand in hand with complex design and geometries that challenge conventional manufacturing methods. Therefore, the experts Digital Additive Production DAP – RWTH Aachen and Fraunhofer IPT took a closer look at the process chain of blade integrated disks (BLISK) manufacturing, and considered the Additive Manufacturing technology Laser Powder Bed Fusion (LPBF) as a promising alternative manufacturing method.

  • State-of-the-art BLISKs are made from nickel-based superalloys such as IN 718. This material is hard to machine so that manufacturing the BLISK´s blade profile through established milling is time and cost consuming
  • Manufacturing the blade profiles using LPBF makes it possible to significantly reduce the material that has to be removed due to a near-net-shape build-up
  • Furthermore, the applied lattice structures support the component during build-up and avoid vibration during the milling process.
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RWTH DAP

Digital material is usually composed of only one material. However, its density distribution in a geometrical body can vary so that the component can have distinct mechanical properties in different sections. Utilizing this feature, different material distributions result in different local densities that meet loading and further boundary conditions.
Furthermore, the use of digital material can optimize components in terms of weight, cost, and production time. The RWTH Aachen Chair for Digital Additive Production DAP focuses on the development of new efficient algorithms for the generation of smart digital materials to advance its extraordinary potential for industrial applications. In the future, these algorithms shall integrate production and application requirements almost automatically during digital material generation.

Research areas:
  • Algorithmic lattice structure generation considering material producibility constraints such as critical overhang angle or minimum achievable feature size
  • Load-adaptive lattice structure generation based on loading and boundary conditions
  • Conformal lattice structure generation
  • Refinement algorithms for lattice structures, either locally or globally
  • Topology optimization algorithms
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 KEX Knowledge Exchange AG

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KEX AG

In close cooperation, KEX Knowledge Exchange AG and 16 well-known research partners such as Fraunhofer Gesellschaft, WZL and IKV are leveraging the unique experience in the field of Additive Manufacturing on a broad online knowledge base and tool suite. With KEX.net you can utilize our huge application finder landscape with hundreds of pre-evaluated parts and products and rely on a frequently updated, near-time technology monitoring. Our unique digital process chain tool, based on a comprehensive pool of material, technology and expert profiles enables you rapidly access relevant information and allows you to make a quick and data-driven decision. With our self-developed patent tool we offer you the possibility to create high-quality analyses within the scope of a bilateral consultation.

Characteristics:
  • Evaluation of the readiness and potential utilization of 3D-printing processes
  • Daily news regarding relevant processes, materials and software in the field of Additive Manufacturing
  • Comprehensive application landscape with hundreds of pre-evaluated parts, products and applications
  • Unique digital process chain tool, based on a comprehensive pool of material, technology and expert profiles
  • Frequently updated, near-time technology monitoring
Advantages:
  • Stay up to date with the latest news from the various industries and research activities in Additive Manufacturing
  • Get a comprehensive overview of Additive Manufacturing technologies, machines and materials
  • Benefit from our broadly-based expert network at the RWTH Aachen Campus
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RWTH Aachen Chair of Machine Tools and Production Engineering WZL

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RWTH WZL

The development of batteries is one of the biggest challenges in the rise of electric mobility. Short development cycles and new materials ask for new measures to limit costs.

Characteristics:
  • Enabling design for remanufacturing by new cell frame geometries allowing the exchange of cells
  • Assembly-integrated forming of the copper-made cell tabs
  • Additive injection molds for pre-series testing
  • Accelerating weld test by the use of welding jigs and design for process features in the cell frames
Advantages:
  • Functional integration of parts
  • Prototypes with close-to-series characteristics
  • Low invest process chain for certification and validation phases
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RWTH WZL

Hybrid welding jig is designed for pre-series body in white production of welded assemblies. The hybrid jig consists of polymer elements manufactured with the Polyjet process and standard elements such as a manual toggle clamp and location pins. The manufacturing costs of the hybrid jig are significantly lower than those of a conventional solution.

Characteristics:
  • Enabling design for remanufacturing by new cell frame geometries allowing the exchange of cells
  • Assembly-integrated forming of the copper-made cell tabs
  • Additive injection molds for pre-series testing
  • Accelerating weld test by the use of welding jigs and design for process features in the cell frames
Advantages:
  • Functional integration of parts
  • Prototypes with close-to-series characteristics
  • Low invest process chain for certification and validation phases
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RWTH Aachen Chair and Institute for Materials Applications in Mechanical Engineering IWM
RWTH Aachen Institute of Applied Powder Technology and Ceramics IAPK

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IWM/IAPK

AM components can be hot isostatically pressed (HIP) to improve their fatigue strength. AM and HIP can also be combined in a new way to produce wear-resistant or corrosion-resistant composite components that require virtually no finishing work. The cooperation between established production methods such as HIP and new Additive Manufacturing production processes promises exciting opportunities to develop new materials or to further develop known materials to achieve new top performance.
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Computer-aided simulation offers the opportunity to observe particle-mechanical processes at sites that are difficult or impossible to access in experiments. IWM / IAPK works with models that can describe powder technology manufacturing processes. The DEM simulation can be used to simulate the behavior of the powder in the powder bed, whereby different interactions of the powder particles are calculated based on the Newton equations of motion. Subsequently, the deformation and the shrinkage in the sintering process can be calculated by FEM simulations. Based on these simulations, the initial geometry can be adjusted with an optimization tool so that the desired geometry can be achieved after sintering.
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ACCESS e.V.

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Access

Electron beam melting (EBM) is the most advanced method for 3D printing of aero-engine components from intermetallic Titanium Aluminides, offering the lowest possible oxygen pickup and low residual stresses. The challenges are to meet the end-users requirements for microstructure homogeneity, which can be achieved by adequate heat treatment. The demonstrator low-pressure turbine blade from alloy GE4822 was used to optimize the heat treatment sequence as well as the final machining parameters.
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Access

Hybrid manufacturing offers new options to reduce production costs, whenever the part geometry calls for a hybrid solution.
Within a publicly funded research project Otto Fuchs KG, BTU Cottbus, Fraunhofer ILT Aachen, and Access e.V. joined forces to explore hybrid production routes for a bracket made from Ti-6Al-4V. The base part of the bracket is produced by forging, while the upper part is added by Laser deposition of powder or wire. The research focuses on heat treatment optimization to achieve well-balanced properties.
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AccessSimulation

Access

ACCESS provides numerical simulations along the process chains using the ICME-approach (Integrated Computational Materials Engineering). Diverse simulation tools can be operated on the Aachen Virtual Material Processing Platform – AixViPMaP® offering seamless data flow between them. Available simulation tools are ADD2MAN®, STAR-CCM+®, HOMAT®, MICRESS®, and Thermo-Calc®.

The current research topics are:

  • Melt pool dynamics incl. the gas phase
  • Microstructure – property relations
  • Residual stresses and strain
You can also find us every morning, from 9:30 to 11:00 on the AM4U area conducting the seminar series Discover3Dprinting.
Details Discover3Dprinting