While significant progress has been made in laser powder bed fusion (L-PBF) for metal additive manufacturing (AM), there is still limited large scale adoption of this advanced manufacturing techniq

Laser powder bed fusion for metal additive manufacturing: perspectives on recent developments

On the fatigue strength enhancement of additive manufactured AlSi10Mg parts by mechanical and thermal post-processing

Aircraft electrification is currently the best alternative to address the rising demand for more air transportation and deal with anticipated economic and environmental impacts. Although the all-electric-aircraft (AEA) concept is not yet a feasible solution, the more-electric aircraft (MEA) is gaining significant attention. Electrical systems either partially or entirely replace the large and inefficient hydraulic, pneumatic, and mechanical conventional aircraft actuating systems. The upgrade could also encompass the propulsion system, as in hybrid- and turbo-electric aircraft. This upgrade reduces the aircraft weight, reduces the usage of pollutant fluids, increases fuel efficiency, reduces carbon emissions, and increases aircraft controllability and reliability. This article reviews various application areas of electric machines in electrified aircraft, such as actuation, taxiing, propulsion, and generation. Moreover, it reviews the main types of currently/to be utilized electric machines and the critically required specifications. Finally, a comparison between the different considered machines and potential future research is discussed.

Review of Electric Machines in More-/Hybrid-/Turbo-Electric Aircraft

Additive manufacturing of magnetic materials

The thorough description of the peculiarities of additively manufactured (AM) structures represents a current challenge for aspiring freeform fabrication methods, such as selective laser melting (SLM). These methods have an immense advantage in the fast fabrication (no special tooling or moulds required) of components, geometrical flexibility in their design, and efficiency when only small quantities are required. However, designs demand precise knowledge of the material properties, which in the case of additively manufactured structures are anisotropic and, under certain circumstances, inhomogeneous in nature. Furthermore, these characteristics are highly dependent on the fabrication settings. In this study, the anisotropic tensile properties of selective laser-melted stainless steel (1.4404, 316L) are investigated: the Young’s modulus ranged from 148 to 227 GPa, the ultimate tensile strength from 512 to 699 MPa, and the breaking elongation ranged, respectively, from 12% to 43%. The results were compared to related studies in order to classify the influence of the fabrication settings. Furthermore, the influence of the chosen raw material was addressed by comparing deviations on the directional dependencies reasoned from differing microstructural developments during manufacture. Stainless steel was found to possess its maximum strength at a 45° layer versus loading offset, which is precisely where AlSi10Mg was previously reported to be at its weakest.

On the Anisotropic Mechanical Properties of Selective Laser-Melted Stainless Steel.

Additive manufacturing of soft magnetic materials and components based on laser powder bed fusion (L-PBF) offers new opportunities for soft magnetic core materials in efficient energy converters. For more favorable material compositions like FeSi6.7 (strategy 1) with larger electrical resistivity and close-to-zero magnetostriction a maximum permeability of μmax = 31,000, minimum coercivity of Hc = 16 A/m and hysteresis losses of 0.7 W/kg at 1 T and 50 Hz have been realized. To further reduce eddy current losses significantly, novel topological structures like inner slits (strategy 2) and multilayered structures of alternating layers of electrically insulating material and soft magnetic material (strategy 3) are suggested. Feasibility, functionality and potential of the different strategies (and combinations thereof) are discussed based on first prototypes and supporting simulations. The results are compared to conventional electrical steel and SMC (soft magnetic composites).

Additive manufacturing of soft magnetic materials and components

Selective laser melting is gaining importance to manufacture reliable and highly complex parts. However, the surfaces of the selective laser melted parts exhibit for many applications an insufficient high roughness, thus require subsequent post processing steps. A relatively new way to reduce the surface roughness is the laser polishing technique. In the present paper, additively manufactured AlSi10Mg samples were polished with different laser intensities and laser modes. The investigations contain the potential of roughness reduction and enhancement of the surface appearances, which can be achieved by laser polishing of the as-built surfaces. An initial arithmetic mean roughness of 8.43 μm was remarkably reduced up to 98 %. The compositions of the polished surfaces were detected and the surface appearances were examined. Reasons and mechanisms were explained and depicted for the occurred shade formations on the polished surfaces. High laser intensity led to segregation of silicon and magnesium on the surface. A higher laser intensity enabled an increased melt depth within the conture layer of the selective laser melting structure. Through increasing melt depth, a porosity of max. 1.7 % was detected in the remolten area. Hardness investigations of the initial and laser remolten cross section revealed no significant reduction in hardness.

Metallurgical investigations of laser remelted additively manufactured AlSi10Mg parts

Neue Werkstoffe sind oft der entscheidende Treiber bei der Entwicklung innovativer Produkte, so auch im Automobilbau. Gerade bei den Schlusselkomponenten Energielieferant, Energiewandler und Leichtbaukonstruktionen lasst die Pulvermetallurgie signifikante Innovationspotenziale fur die Elektromobilitat erwarten. Im vorliegenden Artikel soll eine Ubersicht gegeben werden uber die fur die Elektromobilitat wichtigen Komponenten, bei denen die Pulvertechnologie eine Bedeutung spielen kann. An einigen Beispielen werden der Forschungsbedarf und die Zukunftspotenziale der Pulvertechnologie diskutiert.

Pulvertechnisch hergestellte Werkstoffe für die Elektromobilität — Teil 1: Batterien

Laser based additive manufacturing is a key technology for sustainable mobility and power engineering. It has undergone a dynamic development in recent years regarding process stabilization, reliability and standardization. However, in the current state laser based additive manufacturing still requires extensive R and D work in process understanding and investigation of material properties as well as developing new materials and advance the process possibilities. To overcome restrictions of commercially available AM machines with regard to necessary powder quantity and adaptable equipment such as sensors and e.g. heating devices two individual laser process chambers (LPCs), manual and partly automated, have been established. In addition to the low powder quantities needed to produce samples for process and material development the LPCs also offer the possibility to manufacture two materials in alternating layers to combine physical properties. A manual LPC is used to produce small scale samples from lab scale adjusted WC-Co powder types to further develop the material class for AM and to deepen understanding of phase formation. WC-12Co with additives is successfully manufactured to a high density and phase formation is investigated. The manual LPC is also used to proof the concept of layered AM structures from a combination of Fe and FeAl for magnetic applications. A further developed and automated version of the manual LPC is then used to produce larger layered samples for further analysis.

Individual material and process development in laser based additive manufacturing

Cemented carbide development for Additive Manufacturing (AM)

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